Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD OF ENGRAVING MACHINE READABLE INFORMATION ON METALLIC
WORKPIECES DURING MANUFACTURING AND RELATED TRACKING SYSTEMS
CROSS REFERENCE TO RELATED APPLICATIONS
This is a Continuation-In-Part application of and claims priority and benefit
to U.S.
Application Serial No. 17/681,549, filed February 25, 2022, which claims
priority and
benefits under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Serial
No.
63/154,124 filed on February 26, 2021, and this application claims priority
and benefits
under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Serial No.
63/245,623 filed
on September 17, 2021, which are each incorporated herein in their entirety by
reference.
FIELD
The present disclosure relates generally to systems, methods, and apparatus
for
marking a metallic workpiece, such as a container, an end closure, a roll-on
pilfer proof
(ROPP) closure, or other metal packaging, for tracking and tracing throughout
its lifecycle.
BACKGROUND
Metal packaging, such as metallic containers, offers distributors and
consumers
many benefits and is used to store a variety of products including beverages
and food
products. The body of a metallic container provides enhanced protection
properties for
beverages and other liquids, foodstuffs, and a variety of other products
including personal
care items such as deodorant, sunscreen, hair spray, and the like. The
surfaces of metallic
containers are also ideal for decorating with brand names, logos, designs,
product
information, and/or other preferred indicia for identifying, marketing, and
distinguishing the
metallic container and its contents from other products and competitors. Thus,
metallic
containers offer bottlers, distributors, and retailers an ability to stand out
at the point of sale.
Metallic containers are frequently produced by a draw and wall ironing (DWI)
process. Production lines generally start with an uncoiler that unrolls a coil
of an aluminum
sheet. Two or more coils of aluminum sheet may be used each day for a
production line.
The aluminum sheet is fed into a cupper which cuts circular blanks from the
aluminum sheet
and forms the blanks into cups.
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The cups are then transported by a conveyor to a bodymaker. The bodymaker
forms
the cups into container bodies. The production line may have two or more
bodymakers that
operate in parallel. Some production lines have seven or more bodymakers.
The container bodies are subsequently transported to downstream equipment
which
performs additional operations on the container bodies. The equipment
downstream from
the bodymakers may include trimmers, washers, ovens, decorators, internal
coaters, neckers,
flangers, and palletizers. Container bodies produced by two or more bodymakers
may be
combined on a single conveyor as the container bodies are transported to the
downstream
equipment.
Monitoring the health and performance of the equipment is critical for
efficient
operation of a container production line. When equipment on the production
line
malfunctions or operates out of specification, a large number of container
bodies that are
deficient may be produced in a very short period of time For example, some
production
lines produce 2,000 container bodies per minute. Accordingly, it is very
important to
quickly trace the cause of a deficient container body to equipment that caused
the deficiency.
The bodymakers may produce a mark on the dome of the container bodies.
Referring
now to Fig. 1, a picture of a prior art mark 6 formed on a dome 4 at a closed
end of a
container body 2 is provided. Some prior art bodymakers produce two numbers on
the
public side of the dome, similar to the "35" shown in Fig. 1. One mark 6A (the
number "3"
in this example) may refer to a production line of a production facility.
Another mark 6B
(in this example, the number "5") may identify the bodymaker in the production
line. The
mark (or marks) 6 produced by a bodymaker do not change; the same mark 6 is
formed by
the bodymaker on each container body it produces until the bodymaker is
disassembled and
the marking dies are changed. Accordingly, the bodymaker does not produce a
mark that is
unique for each container body.
The mark 6 is used to identify a bodymaker and a production line that produced
the
container body. The mark 6 is used for troubleshooting of the production line.
However,
because a production line typically has more than two bodymakers operating in
parallel, and
container bodies from multiple bodymakers are normally transported by one
conveyor to
downstream equipment (such as a washer), the mark 6 cannot be used to identify
other
equipment on the production line that performs subsequent operations on the
container
bodies. Further, the time or date the container body is produced or when other
operations
are performed are not recorded and cannot be traced by the mark 6.
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Other problems with the mark 6 formed by the bodymaker is that it cannot be
used
to track the container bodies after they leave the production facility and the
mark cannot be
used to encourage recycling. The mark 6 also cannot be used to trace the
container body
back to a particular coil of the aluminum sheet from which the cupper cut a
blank used to
form the particular container body. Thus, the mark 6 produced by a bodymaker
cannot be
used to identify the manufacturer of the coil of the aluminum sheet used to
produce a
container body. Accordingly, deficiencies in a container body that are caused
by a problem
with the aluminum sheet cannot be traced back to the manufacturer after the
container body
leaves the production line.
As will be appreciated by one of skill in the art, the tooling within the
bodymaker
that forms the mark 6 wears out over time. Wear and degradation of the tools
that form the
mark results in a lack of definition of the mark 6 formed on the container
bodies. The lack
of definition of a mark 6 formed by worn out tooling results in poor
readability. Some
inspection systems of production lines use cameras to read the marks 6 on
container bodies.
Marks 6 formed by a bodymaker with damaged or worn out marking dies may not
have
sufficient definition and clarity to be read by the cameras of the inspection
system resulting
in erroneous tracking and incorrect identification of a bodymaker responsible
for production
of a container body that is deficient.
Some equipment downline from the bodymakers may also produce additional marks
on the container bodies. For example, a date code may be applied as part of a
decoration.
Other equipment, such as an internal coater, may add an identification mark to
a container
body. These marks also have deficiencies, including deficiencies similar to
the mark 6
formed by the bodymaker. Specifically, the marks formed as part of a
decoration or by an
internal coater are not unique to each container body and may not include a
time stamp.
Accordingly, these marks also cannot be used to track an individual container
body and
cannot be used to trace the container body once it leaves a production
facility. Moreover,
the equipment or tooling used to form the marks downline from the bodymakers
may also
require maintenance and would not be necessary if a single piece of equipment
would form
a unique mark for each container body at or near the beginning of the
production line.
Tracking and tracing of container bodies is also important for recycling
programs.
Recycling of used metallic containers is important for a number of reasons.
Recycling has
been, and continues to be, one of the primary ways to reduce pollution,
contaminants, and
related negative environmental effects. Pollution is a particularly acute
issue for food and
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beverage packaging since consumers buy and consume food and beverages stored
in
disposable packaging on a frequent and periodic basis. Recycling of metal
packaging diverts
food and beverage containers as well as other consumer products away from
landfills and
oceans to manufacturing plants where the packaging is reused to create
additional packaging
or to make completely unrelated products. As a result, pollution and
contaminants in
landfills and oceans are reduced.
In addition, less raw material is extracted from the Earth when metal
packaging is
produced from recycled metal material which further reduces negative effects
on the
environment. Recycling used aluminum containers and using the recovered
aluminum to
form a new container body reduces the energy required to produce the new
container body
by 90% compared to a container body formed from virgin aluminum material.
Thus, it is
important to increase the rate of recycling of metal packaging.
Tracking and tracing container bodies at the end of life is also important
because
used metal packaging is very valuable. For example, used beverage cans are
about ten times
more valuable than glass, and about six times more valuable than clear PET.
The
homogenous design of metallic containers and use of a material, such as
aluminum, that is
endlessly recyclable through simple remelting, means that the recycling of
used metallic
containers is a profitable activity. Accordingly, accurate record keeping and
tracking of
metallic containers collected at a recycling center is important. However,
prior art marks 6
formed on container bodies are not unique and cannot be used to track or
identify individual
container bodies 2 of the prior art.
It would be beneficial to track a container body from a production line until
end of
life to monitor disposal and recycling of the container body. Recycling rates
vary greatly
globally and regionally. Collecting data on the lifecycle of container bodies
from production
to end of life collection is useful for analyzing recycling rates. Analyzing
data collected on
a container body as it moves from a production line, to a filler, to a point
of sale, and from
the point of sale to a consumer and then to a collection point at end of life
may identify
deficiencies in a distribution program or a recycling program. The information
may also
help identify successful recycling programs that could be implemented in other
areas. For
example, analyzing the lifecycle of a container body may be used to identify
shortcomings
in recycling (or collecting) infrastructure and deficiencies in collection
centers.
Unfortunately, the marks 6 currently formed on container bodies 2 provide a
very limited
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amount of information that gives little insight into the life cycle of an
individual container
body.
One way to increase recycling rates is through effective incentive programs.
Recycling is incentivized in a number of ways. For instance, a commercial
advertisement
campaign can be used to provide information to consumers and to persuade
consumers to
recycle. Some U.S. states and other countries have programs where a container
or other
product can be returned for money. For example, California has a recycling
program in
which consumers pay a deposit fee, for example, $0.05, when purchasing a
beverage
container. Beverage containers purchased in California can be returned to a
California
recycling center and receive a redemption of the $0.05 per container deposit
fee.
There are several issues with existing recycling programs, information, and
incentives. Because a container body does not have a unique mark that can be
used to
identify a location of purchase and to track the lifecycle of the container
body, it is possible
to cheat or defraud recycling programs such as the California program. For
example, people
in a first region that does not charge consumers a deposition fee may
transport used container
bodies to a recycling center in a second region (such as California) to
fraudulently recover
the deposit fee redemption.
Further, a container body could be taken (or stolen) from a recycling center
after the
deposit fee for the container body has been redeemed. The container body could
then be
returned to a deposit center and redeemed a second time.
Accordingly, record keeping, such as identification of container bodies that
are
returned to a recycling center and redeemed for a deposit is critical to
prevent fraud.
However, the marks 6 currently formed on container bodies 2 do not provide
sufficient
information to uniquely identify each container body. Providing a unique mark
to
individually identify each container body would provide a means to improve
record keeping
of individual container bodies and help reduce fraud associated with current
recycling
incentive programs.
A unique mark formed on each container body could be used to track recycling
rates
of each brand and each product in a container body as well as recycling rates
for (or in) a
region or portion of a region. For example, the unique mark for each container
body could
be stored in a record (such as in a database). When the container body is
filled, the record
could be updated with information about the product. If the container body is
turned in to a
collection point (such as a recycling center) at its end of life, the unique
mark may be
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scanned and the record in the database may be updated again. Analyzing this
data could
identify deficiencies in recycling rates in a region, for a brand, for a type
of product, or for
a type or style of container body. With this information, trends could be
identified and
targeted advertising could be used to incentivize recycling. If a container
body could be
tracked after production, brands could target recycling marketing if, for
instance, tracking
information indicates that consumers of beverage A in a first geographic
region are not
recycling at a rate comparable to consumers of beverage A in a second
geographic region.
Unfortunately, the current marks 6 formed on container bodies do not provide
enough
information to track container bodies in this manner.
Advertisement campaigns are expensive, and thus, are not persistent in the
minds of
consumers. Moreover, with so many different means and platforms for receiving
advertisements, a given consumer who does not monitor all means and platforms
may
simply miss an advertisement for a recycling program Recycling programs in the
US are
run by states, and thus, a given consumer may not be aware of a specific
recycling program
when traveling or moving between states. In addition, monetary incentives such
as a 50 per
container deposit refund may not sufficiently incentivize a consumer to travel
to a recycling
center to return a container. Thus, there is a need to provide incentives to
consumers to
encourage recycling and to enable manufacturers and retailers to track the
lifecycle of
recyclable products. Unfortunately, the mark 6 formed by prior art bodymakers
cannot be
used to track container bodies to end of life collection.
Accordingly, there is an unmet need for methods and apparatus of forming a
mark
that is unique on a metallic workpiece, such as a container body or other
metal packaging,
for tracking and tracing the metallic workpiece during production, during
distribution, and
to end of life collection without sacrificing production efficiency in a high-
speed
manufacturing process. There is also a need for a system of tracking and
tracing each
individual metallic workpiece through all phases of the manufacturing process
and for
identifying some or all pieces of equipment that perform an operation on the
container body
during the metallic workpiece. Moreover, there is a need for a system and
method of tracking
a metallic workpiece from the end of the manufacturing process to a consumer
and until the
metallic workpiece is collected at its end of life. Another needed piece of
information is a
time stamp collected at different locations and phases as an individual
metallic workpiece
moves through the manufacturing process, enters the distribution stream, is
purchased, and
then collected at end of life.
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SUMMARY
In one aspect of the present disclosure is a system and a method of providing
a mark
on a metallic workpiece, the mark being unique to each metallic workpiece. A
metallic
workpiece with a mark that is unique and according to the present disclosure
can be tracked
and traced through every step of a manufacturing process from coil to pallet
of a production
line that manufactures the metallic workpiece. In this manner, each piece of
equipment that
handles the metallic workpiece or that performs an operation on the metallic
workpiece can
be identified. Moreover, after the metallic workpiece leaves a production
facility, the mark
may be scanned as the metallic workpiece travels to a filler. Thereafter, the
mark may be
scanned as the metallic workpiece moves through a distribution system to a
point of sale, to
a consumer, and then to a point of collection, such as a recycling center,
when the metallic
workpiece reaches its end of life. In this manner, the metallic workpiece can
be tracked
from cradle to grave by scanning the mark
The mark, or marks, can be applied using various marking technologies at
different
points in the manufacturing process. Moreover, further technologies support
the marking
technologies including technologies for orienting and/or stabilizing a
metallic workpiece for
marking. Additionally, the manufacturing process may be altered to decrease
the rate of
movement of the metallic workpiece to provide marking equipment sufficient
time to form
the mark. For example, a single lane conveyor in a portion of the
manufacturing process
may be changed to include from two to twenty parallel lanes to decrease the
rate of
movement of a metallic workpiece relative to the marking equipment. As a
result, one or
more marks are applied to a metallic workpiece that serves as a container, a
container body,
an end closure, a tab, etc.
The mark may be formed on any part of a container, a can, a bottle, an end
shell or
end closure, a tapered cup, etc. For example, the mark may be formed on a
closed end of a
container such as an inwardly-extending dome, a cup base, a region of a
container that is
interior to a container standing surface, etc. This location may be
advantageous for a mark
since the closed end will typically remain intact even after the container is
crushed or
damaged.
Additionally, or alternatively, a mark may be formed on a body of a container
such
as a label portion or a neck portion. The label portion of a container is
generally the
cylindrical portion of a container where a label or decoration is placed. The
label portion is
highly visible which is useful for scanning a mark during the manufacturing
process and at
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subsequent locations. The neck portion of a container includes the radius and
angled necked
regions of, for instance, a can or bottle. This neck portion is also highly
visible which is
useful for scanning a mark.
The end shell that forms part of an end closure can also bear a mark, or
marks. In
particular, the mark can be placed on either (or both) the product side that
contacts the
contents of the container or the public side that an end user views and
contacts. In some
embodiments, the mark is applied to the product side of the end shell, and
then later in the
manufacturing process the mark is copied to the public side of the end shell.
Thus, the same
mark can be viewed and scanned without needing to reorient the end shell. In
other
embodiments, the end shell has different marks, one on the product side for
tracking and
tracing the end shell during manufacturing, and one on the public side for
tracking and
tracing the finished container after manufacturing.
A mark can also be applied to a tab of an end closure This location may be
advantageous for scanning a mark since a user readily interacts with and
operates the tab.
The mark can even be placed on an underside of a tab as discussed herein.
Finally, a mark may also be applied to a cap of a container such as a bottle.
The mark
can be applied to any portion of, for instance, a coated aluminum, unthreaded
cap with a
polymer seal disk. The mark can also be applied to pilfer-proof cap.
A variety of different marking technologies may apply the mark to a metallic
workpiece. For example, a continuous inkjet (CIJ) printer can apply a mark to
a metallic
workpiece with a pressurized flow of ink that is sprayed onto the metallic
workpiece as the
metallic workpiece moves during the manufacturing process or as the metallic
workpiece is
stationary, for instance, during a dwell period as described herein. In some
embodiments,
metallic workpieces are separated into multiple lanes to slow the production
speed. This
type of printing can apply marks up to 12x12 mm in size but can also apply
marks 6x6 mm
in size and smaller. In some embodiments, the ink is a toner ink that is
suitable for printing
various shapes as the toner is fast curing, has high adhesion, and is
resistant to abrasion with
no impact on mobility.
Drop on demand (DoD) inkjet printing is a type of printing where piezo or
thermal
modes of jetting ink are used to deposit ink onto a metallic workpiece to form
a mark with
resolutions up to 600 dots per inch (236 dots per cm). This type of printing
can produce a
mark with a height or size up to between 10-12 mm when a single print head is
used. An
array comprising two to twenty DoD print heads can produce a mark of up to 70
mm. In
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some embodiments, the mark can be between 50-80 mm. A solvent ink may be used
with
drop on demand inkjet printing on a non-porous metallic workpiece such as
aluminum. In
various embodiments, the DoD print head is positioned between 1-5 mm from the
metallic
workpiece, and a drying time of between 0.5-20 seconds is required.
In some embodiments, drop on demand inkjet printing may jet one of a solvent,
an
ultraviolet cure material, and/or a thermal cure material. In embodiments with
an ultraviolet
cure material, the ink is applied to a metallic workpiece, then the ink is
cured. The ink can
be cured without an exterior source within about one second. However, one or
more
radiation sources can emit radiation on the ink to speed the curing time.
These radiation
sources can emit the same or different wavelengths. In some embodiments, at
least one
radiation source emits ultraviolet radiation between approximately 10-400 nm
wavelengths,
or even between 200-400 nm wavelengths, and at least one further radiation
source is a
mercury lamp that emits radiation in spectrum of wavelengths that at least
partially includes
radiation within the spectrum of ultraviolet radiation. The light initiates
photochemicals in
the ink which causes crosslinking in a polymer matrix. In a further
embodiment, one or more
radiation sources are light-emitting diode (LED) ultraviolet (UV) lamps.
Electrostatic jetting is a type of drop on demand inkjet printing where an
array of
ejector electrodes is positioned inline within the printing head. Voltage is
varied to the
electrodes to control the ink accumulated on top of the electrodes, and thus,
control the
ejected drop volume. In various embodiments, this type of printing deposits
ink on a metallic
workpiece positioned up to about 1-10 mm from the electrodes.
A variety of laser technologies may also apply a mark to a metallic workpiece.
Laser
etching can be used to ablate, selectively oxidize, and/or remove an over
varnish and/or ink
on, for instance, a surface of a decorated container to expose the base
material. The selective
exposing of the base material produces a mark, and the removal of only a
varnish and/or ink
does not impact the structural integrity of the container. The exposed base
material can be
allowed to stain in subsequent washing and/or thermal operations to produce a
more visible
mark.
In some embodiments, a laser may ablate and vaporize a small portion of a
metallic
workpiece but not substantially impact the structural integrity of, for
example, the resulting
container. The vaporization changes, for example, a reflectivity of part of
the container to
produce a mark. In some embodiments, a laser used to form a mark on a metallic
cup may
ablate or vaporize more material because the metallic cup is not sealed and
does not retain
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a product under pressure. The removal of more material can produce a mark with
increased
contrast that is more easily scanned.
In yet a further embodiment, a laser is used to slowly heat the metallic
workpiece to
diffuse oxygen below the surface of the workpiece, which oxidizes a portion of
the
workpiece with a different color to produce a mark. As discussed herein, a
laser can also
activate a thermally and/or light sensitive ink on part of a metallic
workpiece. Portions of
the ink are activated to produce the mark without impacting the structurally
integrity of, for
example, the resulting container.
Digital printing can produce a unique mark on a metallic workpiece. In some
embodiments, different print heads all with the same color can increase
production speed
by coordinating and combining to print a given mark faster. In other
embodiments, one print
head produces one mark at a time, and a production line with multiple print
heads can
increase overall production speed In yet further embodiments, different print
heads with
different colors can produce a mark with different colors. The print heads may
deposit ink
directly onto a metallic workpiece or onto a printing plate, which then
contacts the metallic
workpiece.
Watermark technology can also be used to form a mark on a metallic workpiece
where the watermark has low visibility and does not interfere with other marks
or
decorations on, for instance, the resulting container. Specifically, in some
embodiments, a
plate of a decorator applies an ink to a container body to form a mark that is
imperceptible,
or nearly imperceptible to humans. The brightness and intensity of the color
or colors that
form the mark are adjusted to be imperceptible to humans, yet the mark is
easily read by
scanners and other sensors to detect track and trace the mark and container
body through
the manufacturing process and/or end user applications. Further, in some
embodiments,
spaces between two different colors are adjusted to form a mark As a result,
instead of
relying on, for instance, a black and white barcode in one location on a
finished container,
multiple marks can be applied all over the finished container without
interfering with the
decoration.
Finally, fingerprinting technology can use variations in the metallic
workpiece
and/or resulting container itself as a mark. A container has distinct
variations in appearance
outside of the decoration applied to metallic workpieces and/or containers in
a lot or
sequence. These variations can include patterns in the metal, ink, varnish,
etc. Thus, a
camera or other sensor can detect or take a picture of the metallic workpiece
and/or resulting
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container which is used to identify distinct variations to use as a
"fingerprint." A subsequent
sensor can detect this fingerprint to add data to a record of the container.
These marking
technologies are exemplary in nature, and embodiments of the present
disclosure encompass
a variety of marking technologies.
Next, various treatments may condition a metallic workpiece for these various
marking technologies. For instance, a metallic workpiece can be subjected to a
plasma or
coronal treatment that burns oil and/or impurities from the surface of the
metallic workpiece
and increases the surface energy of the metallic workpiece before, for
instance, a primer
application or ink application. In some embodiments, this treatment is
critical for controlling
the adhesion of a primer, an ink, or other material to a metallic workpiece.
The primer can
be white or clear in various embodiments, and the primer helps promote
adhesion of a
subsequent ink. Moreover, washing and/or oxidation of a metallic workpiece can
improve
the surface tension of the workpiece for the application of inks and can even
eliminate the
need for a primer. It will be appreciated that these treatments may be located
prior to a
decoration or ink application station of a production line and the metallic
workpiece is
typically a container body, however, these treatments can be located at any
point in a
production line of a manufacturing process and can be applied to any metallic
workpiece.
In addition, control systems can be used to synchronize marking technologies
with
existing components, stations, and equipment on a production line of a
manufacturing
process. Specifically, timing control is critical as metallic workpieces such
as container
bodies can pass through a station on a production line at a rate of thousands
per minute or
more. Thus, timing control can change a speed or output of various stations or
lines with,
for instance, encoder wheels, reading the speed from variable frequency drives
that power
the movement of equipment on the production line, and reading signals from
servo drives.
Moreover, the position of a metallic workpiece can be stabilized with a star
wheel, feed
screws, variable speed vacuum conveyance, etc. as described herein. Multiple
markers can
also increase the rate of marking a metallic workpiece to match production
line speeds.
The marking technologies can apply a mark to a metallic workpiece at various
locations in the manufacturing process. In some embodiments, a marker forms a
mark on a
continuous sheet of metallic material before blanks are cut or punched from
the continuous
sheet. For example, in some embodiments, the marker forms the mark before the
continuous
sheet is fed into a cupper or blanking operation. Specifically, the mark can
be formed as the
continuous sheet is stationary during a dwell period of the cupper or blanking
operation,
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such as between incremental movements of the continuous sheet. Advantageously,
the
continuous sheet has low lubrication and debris contamination at this point in
the
manufacturing process which leads to a higher quality mark.
The marker is operable to form a mark which is unique for each container body
produced by the production line. The mark is formed at each location of the
continuous sheet
where a blank will be cut. As will be appreciated by one of skill in the art,
the blank is
generally circular.
In some embodiments, the blank is cut by a cupper. The cupper may be on a
production line that manufactures container bodies.
Alternatively, the blank is cut from the coil by equipment other than a
cupper, such
as a blanker. For example, in some embodiments, a blank is cut from a coil by
a blanker at
a site where the coil is manufactured. The blanker may be at an aluminum
rolling mill or
other similar production facility that manufactures coils of metallic material
Thereafter the
blank is shipped to the production facility with a production line that
transforms the blank
into a container body.
Optionally, the marker can form the mark at two or more portions of the blank
location. In this manner, each container body may have the unique mark at two
or more
locations.
In some embodiments, the mark is formed at each blank location on only a first
side
of the continuous sheet of metallic material. The first side of the continuous
sheet may
subsequently define an exterior surface of the container body such that the
mark is
positioned on a portion of the exterior surface (or "public side") of the
container body.
Alternatively, the first side of the continuous sheet may form an interior
surface (or "product
side") of the container body.
In some embodiments, the marker may form the mark on a portion of a blank
location that will form a closed end of a container body. The mark may be
centered on the
closed end or offset from a center in some embodiments. Additionally, or
alternatively, the
marker can form the mark on a portion of a blank location that will form a
sidewall or
cylindrical portion of a container body. When a blank with the mark in the
blank location
is formed into a container body, the mark may be on the exterior surface or
the interior
surface of the container body. The marks on the continuous sheet can be
synchronized with
subsequent operations in the manufacturing process to ensure that the mark
appears
consistently in the same location and same orientation. For example, the marks
on the
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continuous sheet are synchronized with a shell press to ensure the mark
appears consistently
on an end closure. In some embodiments, a marker such as a laser can form
multiple marks,
or multiple lasers can form a single mark.
Optionally, a first marker is positioned to form a first mark on a first side
of a first
blank location of the continuous sheet. A second marker is positioned to form
the same first
mark on a second side of the first blank location of the continuous sheet. In
this manner, in
some embodiments, the first mark may be formed on both sides of the continuous
sheet of
the first blank location where a blank will be cut from the continuous sheet.
Accordingly, a
container body may have the first mark positioned on its exterior surface or
public side. The
same first mark can be repeated on an interior surface (or product side) of
the container body
to allow for readability and scanning of the mark at any point in the
manufacturing process
where either the product side or public side is exposed.
Optionally, the first mark formed on the first side of the first blank
location is
positioned approximately opposite to a position of the first mark formed on
the second side
of the first blank location. Alternatively, the first mark on the first side
is offset from the
first mark on the second side. In this manner, the first mark may be
positioned on a closed
end on a first surface of the container body and the first mark can be
positioned on a sidewall
on a second surface of the container body. In various embodiments, the first
mark is formed
on the sidewall after the container body is formed by an ironing process.
In some embodiments, a mark is only formed on a first side of the continuous
sheet.
In other embodiments, a mark is only formed on a second side of the continuous
sheet.
Optionally, a mark may be formed on both a first side and a second side of the
continuous sheet.
The mark formed by the marker is adapted to be read or scanned by a scanner.
The
mark may comprise any combination of letters, numbers, symbols, and machine
readable
codes arranged in any order or orientation and of any size. In some
embodiments, the mark
is an alphanumerical code, a bar code (or "1D code"), a 2D code (such as a
quick response
(QR) code or a data matrix (DM) code), and the like. For example, each mark
may be a
randomized alphanumerical code which is unique for each blank location and
accordingly
provides a unique identifier for each container body produced from each blank
location.
The mark formed by the marker includes a unique identifier for the container
body.
In addition, the mark may also include one or more of: (a) a production date;
(b) a
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production time; (c) a production location (or identifier of the production
facility); (d) a
production line identifier; (e) a batch number; (f) a shift identifier; (g)
material specifications
of the continuous sheet (such as the type of aluminum alloy or other material
in the
continuous sheet); (h) an identifier for the manufacturer of a coil from which
the continuous
sheet is unwound; (i) an identifier or serial number of the coil; (j) a
position of the mark on
the continuous sheet (such as an X, Y coordinate of a blank location where the
mark is
formed); (k) a mass of the container body; (1) a name or identifier for a
customer (such as a
filler) that ordered the container body; and (m) a randomized alphanumerical
code.
In some embodiments, the marker is positioned on a production line that
includes a
cupper. For example, the marker may be down line from an uncoiler and up line
of the
cupper. Specifically, a mark is applied to a continuous sheet as it feeds into
a cupper, and/or
a mark is applied to a cup at the outfeed conveyance of the cupper,
In other embodiments, the marker is not associated with the production line
that has
a cupper. For example, in some embodiments, the marker may form marks on a
continuous
sheet before a coil with the continuous sheet that includes the marks is
loaded into an
uncoiler associated with a production line that has a cupper. In these and
other embodiments,
the marker, or markers, forms a mark on the continuous sheet as the sheet is
moving at a
constant speed, and the marking process is separate from any dwell period.
However, it will
be appreciated that the marker can form a mark on the sheet as the sheet is
stationary during
a dwell period, moving, or a combination thereof. Next, the continuous sheet
is flat or nearly
flat at this point in the production line, and therefore, the mark or marks
applied to the sheet
have no distortion compared to forming a mark on a concave surface. As
discussed herein,
marking earlier in the manufacturing process allows for the collection of more
data, which
is important to track and trace any metallic workpieces and reduce spoilage,
reduce material
costs, etc.
Optionally, the marker is positioned in a production facility that has a
cupper, In
some embodiments, the production facility includes a marker positioned between
a first
uncoiler and a coiler (or recoiler). In this embodiment, the first uncoiler
uncoils a continuous
sheet of a metallic material from a first coil. The marker forms marks on the
continuous
sheet at each blank location where a blank will be cut from the continuous
sheet. The
recoiler then rolls the continuous sheet with the marks into a second coil.
The second coil
with the marks is subsequently loaded into a second uncoiler associated with a
production
line that includes the cupper.
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Additionally, or alternatively, the marker is not positioned in a production
facility
that includes a cupper. In this embodiment, marks are formed on a continuous
sheet of
metallic material before a coil with the marked continuous sheet is delivered
to the
production facility that includes the cupper. Accordingly, the continuous
sheet that includes
marks may be recoiled by a coiler after the marker has formed the marks. In at
least one
embodiment, the marker is positioned between an uncoiler and a coiler that
recoils a
continuous sheet that includes marks.
Optionally, blanks are cut from the coil at the blank locations which include
a mark
by a blanker. Thereafter, the blanks are delivered to the production facility
and transformed
into container bodies.
In some embodiments, the marker is at a location where a continuous sheet of
metallic material is manufactured and rolled into a coil. For example, the
marker may be
located in a metal production plant where the continuous sheet is manufactured
The marker
can form marks on the continuous sheet before the continuous sheet is rolled
into a coil. In
this manner, a coil with a plurality of unique marks may be delivered to a
production facility
with a cupper.
As noted above, a marker can mark a cup at the outfeed conveyance of the
cupper.
In some embodiments, a laser can etch a closed end of a cup with a mark. The
mark can be
on center or off center on the closed end, on either the product side or the
public side. The
outfeed conveyance may handle the cups in various orientations where the
marker such as
a laser can apply the mark. Multiple lasers can apply a single mark, a single
laser can apply
multiple marks, etc. The marker can apply the mark while the cups are moving,
stationary,
or both. Forming the mark at the outfeed conveyance of the cupper is
advantageous
compared to the infeed as no stabilization of a continuous sheet is needed,
and marking is
independent from the stroke cycle of the cupper. Further, by forming the mark
at the outfeed
conveyance, production data may be collected on all subsequent equipment and
operations
that perform operations on the cup. Moreover, because the cupper forms a
plurality of cups
across the width (or Y-dimension) of a sheet of aluminum, information about
variations in
cups formed across the width of the sheet may be identified and tracked.
Scanners, cameras, and/or sensors operable to read a mark on each container
body
may be associated with each piece of equipment of the production line. For
example, a
scanner may be associated with one or more of: a cupper, a bodymaker, a
trimmer, a washer,
a dry off oven, a basecoater, a basecoat oven, a conveyor, a decorator, a deco
oven, an
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internal coater, an internal bake oven, an ejector, a necker, a flanger, a
palletizer, and any
other equipment of the production line. In some embodiments, a scanner is
associated with
each conveyor (whether a single-line conveyor or a mass conveyor) that
transports a
container body from a first piece of equipment to a second piece of equipment
(or from a
first process to a second process) of the production line.
In some embodiments, a first scanner is positioned up line (or at an in-feed)
of each
piece of equipment. Additionally, or alternatively, a second scanner may be
positioned
down line (or at an out-feed) of each piece of equipment. Optionally, some
pieces of
equipment may have a scanner positioned at both an input and an exit of the
equipment.
In some embodiments, information from the scanner is transmitted to a control
system each time the mark of a container body is read. The scanner may
transmit at least a
unique identifier of the mark, a date and a time the mark was scanned, and a
location of the
scanner (such as, where the scanner is located within the production line, or
which piece of
equipment the scanner is associated with).
The control system includes a database with a record for each container body.
The
record may include information about the container body including the unique
identifier of
the mark. The control system is operable to update the record for each
container body each
time the mark is scanned by a scanner.
The production line optionally includes an inspection system. A scanner may be
associated with the inspection system. The inspection system may retrieve
information from
a record associated with a container body stored in the database after the
scanner reads the
mark on the container body. The inspection system may separate a container
body from the
production line based on an identification of a piece of equipment that
performed an
operation on the container body for a routine quality inspection. In this
manner, a first
container body processed by a first piece of equipment may be distinguished
from a second
container body processed by a second piece of equipment that performs the same
operation
or function as the first piece of equipment. Specifically, in some
embodiments, a record in
a database may store information for a container body that indicates each
piece of equipment
that performed an operation on (or handled) the container body.
For example, a record associated with a first container body may have a field
that
indicates the first container body was processed by a first bodymaker. A
record associated
with a second container body may have a field that indicates the second
container body was
processed by a second bodymaker. Accordingly, by scanning marks on the first
and second
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container bodies, the first container body may be separated from the
production line and
inspected to determine performance of the first bodymaker.
Additionally, if a container body is found to be deficient during inspection
and
ejected from the production line, the scanner can read the mark. The
inspection system may
then provide data (such as a reason for the rejection) to the control system
and the control
system may update a record in the database associated with the rejected
container body.
Because the mark facilitates identifying each piece of equipment that handled
or performed
an operation on the container body, it is possible to identify the equipment
that caused the
deficiency found by the inspection system. Accordingly, equipment that is out
of calibration
or in need of maintenance can be quickly identified.
Once a container body or other metallic workpiece is rejected from the
manufacturing process, the defective container body is optionally inspected by
additional
scanners, cameras, and/or sensors Data from the defective container body is
transmitted to
the database where information about the rejected container body is associated
with a mark
on the container body, and thus, associated with production information
related to the mark
and container body in a record. This additional collection of information can
help trace
particular defect issues with a container body instead of simply recording a
container body
as "defective" in general without further information. As a result, this
additional collection
of information aids in the reduction of spoilage, reduce material costs, etc.
Another aspect of the present disclosure is a system and method of tracking
and
tracing a metallic workpiece (such as a container body, a metallic cup, an end
closure, or a
tab) throughout its life cycle from production to collection at end of life.
The system and
method include forming a unique mark on a continuous sheet of material.
In some embodiments, the mark is subsequently cut from the continuous sheet by
a
cupper as part of a blank. The cupper forms the blank into a cup that is
subsequently formed
into a metallic workpiece.
Scanners or sensors positioned along a production line that produces the
metallic
workpiece scan the mark and track the progress of the metallic workpiece
through the
production line. This information includes an identity of each piece of
equipment, lane,
gun, etc. that handles the metallic workpiece or that performs and operation
on the metallic
workpiece. In addition, this information is collected in real time. Therefore,
any possible
defects are detected quickly and can be traced to a deficient process,
station, tool, etc. Even
if a defect is detected further downstream, including after the manufacturing
process, the
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collection of data described in the present disclosure allows the source, or
at least potential
sources, of the defect to be quickly identified. This benefit greatly reduces
spoilage and
reduces material waste and is optionally used to schedule preemptive
maintenance and
increase overall manufacturing efficiency.
Collecting and storing the information on equipment that handles or performs
an
operation on each metallic workpiece provides many benefits. For example, the
information
will provide insight into the quality of metallic workpieces produced by the
production line,
performance of equipment on the production line, indications that equipment on
the
production line requires maintenance, and spoilage rates for one or more of:
the production
line as a whole as well as individual pieces of equipment of the production
line. The
information collected as metallic workpieces are processed by the production
line may also
provide insight into a spoilage rate associated with a coil of metallic
material and/or a
spoilage rate associated with a manufacturer of a coil of a metallic sheet
The information collected may also be used to provide a report for each
production
line with information about the performance of equipment, spoilage rates,
upcoming
maintenance, and the like. The report could be based on performance over a
predetermined
period of time. For example, a report could be prepared for each production
line based on
data collected for one shift, one production run, one day, one week, one
month, one year, or
any other period of time. Moreover, finished containers are optionally sorted
after
manufacturing to scrap individual containers due to an individual defective
process, station,
tool, etc. rather than scraping an entire lot of containers when a defect in
one container is
discovered. This additional benefit of the present disclosure saves on
materials, costs, and
reduces harm to the environment.
In some embodiments, the production line ends with a palletizer that places
the
metallic workpiece on a pallet. The mark on the metallic workpiece allows the
metallic
workpiece to be associated with a pallet, such as a pallet of unfilled
metallic containers. The
location of the metallic workpiece can then be tracked to a filler. The filler
receives the
metallic workpiece (such as a container body and/or an end closure). Once the
container
body is filled and sealed with the end closure, the filled metallic container
may be scanned
and tracked to a pallet of filled metallic containers. The filled metallic
container can then
be tracked from the filler to a distributor, to a point of sale, to a
consumer, and to a collection
point (such as a recycler or a deposit redemption center) by scanners at each
location.
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A control system with a database can update a record for the metallic
workpiece
each time the mark is scanned. In this manner, the location of the metallic
workpiece can
be tracked throughout its lifecycle from the first operation performed in a
production line
until the mark is scanned at a collection center. With this information, a
consumer can be
rewarded for recycling the metallic workpiece after use. Further the
information can be
used to monitor recycle rates and performance of incentive programs designed
to encourage
recycling.
The information may also be used to provide alerts to fillers, points of sale,
and
consumers about the status of a product in a metallic workpiece. For example,
information
about a product sealed in a metallic workpiece may be stored in the record for
the metallic
workpiece. Accordingly, if a product needs to be recalled, such as a metallic
container filled
with a food product or a medicine, an alert may be provided to the filler,
point of sale, or
consumer identified as currently in possession of the metallic workpiece
Further, when a
product in a metallic workpiece reaches its expiration date, the control
system can send an
alert to the filler, point of sale, or consumer identified as currently in
possession of the
metallic workpiece.
In some embodiments, a mark is applied to a metallic workpiece at other points
in
the manufacturing process. The metallic workpiece may refer to workpieces in
different
manufacturing processes for containers, cans, container bodies, shells, end
closures, tapered
cups, tabs, etc. In one example, after a washing action in a manufacturing
process, container
bodies are dried and conveyed to another station in the production line.
During this
conveyance, the container bodies can flow from a single lane to multiple
lanes, or from
single file to mass conveyance, to slow the conveyance speed of the container
bodies. Then,
a marker (for example, a laser or inkjet printing technology such as pad
printing or
continuous inkjet spraying) can apply a mark to a closed end of a container
body (such as a
concave dome). When marking a concave dome, the distance between the marker
(such as
a laser) and the metallic workpiece varies. Thus, in some embodiments a laser
is
articulatable about multiple degrees of freedom. In an exemplary embodiment,
the laser
moves about three axes to maintain the focus of the laser on the concave dome
and prevent
poor marking. In a further exemplary embodiment, the laser is stationary, and
one or more
of a lens and a mirror associated with the laser head moves to maintain a
focus of the laser
on the concave dome and prevent poor marking.
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A rim coat machine may be positioned after washer oven discharge. At the
washer
over discharge, container bodies are in mass conveyance with the closed ends
(and their
domes) facing upward which allows a marker to apply a mark to this closed end.
A varnish
covered roller with a width as wide as the mass conveyor can roll a thin film
onto the
"standing surface" of can. Varnish provides a low friction standing surface to
the container
bodies to help with mobility throughout the manufacturing and filling line. As
discussed
herein, a marker such as a laser can selectively remove or ablate part of the
varnish to form
a unique mark in various embodiments. Additionally or alternatively, an inkjet
printer
applies a second mark to the closed end of a container body. Subsequently,
part of the ink
is ablated by, for instance, a laser to create a mark on the closed end.
In some embodiments, the container bodies are conveyed to a decorator where
the
container bodies already receive forms of decoration at speeds that allow, for
instance, the
application and curing of ink With respect to the decorator, it will be
appreciated that ink
or laser or other types of marking technologies can be used to apply a mark to
any portion
of a container body such as a label portion or closed end at the infeed,
within the decorator,
or outfeed locations. The container bodies may need to have their position
stabilized and/or
orientation controlled to ensure a consistent application of a mark, or marks.
Position and
orientation technologies are described in further detail herein.
In some embodiments, within the decorator while a container body is on the
mandrel
of the decorator, an ink-based or laser-produced mark can be applied to the
label portion of
the container body or even a closed end of the container body. A high speed
inkjet printer
can form a mark with no dwell time as fast as the container bodies move
through the
decorator. Moreover, a mark comprising ink can be first transferred to a
blanket or other
intermediate component, then the ink is transferred to the container body. It
will be
appreciated that the blanket can be cleaned or at least partially cleaned
between variable
applications to prevent or reduce a memory effect between multiple container
bodies where
residual ink is unintentionally applied to the next container body.
Next, a drop on demand inkjet printer may mark a label portion or other
portion of
a container body at an infeed or outfeed location of the decorator. The inkjet
printer may
rely on, for example, piezo or thermal control as discussed herein, and the
mark may be any
size, including up to 70 mm of vertical height or size along the label portion
of a container
body. Continuous inkjet printers are also contemplated for marks that are 6x6
mm or
smaller. As noted above, the container bodies are already conveyed at speeds
conducive for
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decoration, 2000 containers per minute in various embodiments, but the
container bodies
may require some treatment for the adherence of the ink. Moreover, the ink can
be any type
of ink such as an ultraviolet-based ink that cures with the use of ultraviolet
lamps. A laser
may also apply a mark to any part of the container body as described herein
using, for
instance, ablation of a material or coating, activation of a light or
thermally sensitive ink,
etc.
In addition, the container bodies may be inspected at any point after the
decorator,
including immediately after the decorator, to assess the quality of the
decorations. In some
embodiments, the container bodies may be inspected while being transported on
a pin chain.
Inspecting the container bodies while on a pin chain being transported away
from the
decorator and before the container bodies are positioned on a mass conveyor is
beneficial
because the quality of the decoration can still be associated with the
decorator. Further,
components of the decorator that contacted the container body (such as a
particular mandrel
or a particular printing plate) or that helped form the image (including a
particular printing
blanket) can be identified and associated with the container body and stored
in a record in
the database. Any substandard decorations are grounds to reject a container
body. At this
point, a marker may apply a mark to the container body. In some embodiments, a
laser
ablates a material or coating on a label portion of a container body to form a
mark, a laser
activates an ink on the body label portion to form a mark, and/or a continuous
inkjet printer
applies ink to a body label portion to form a mark.
A closed end or a dome of a container body can be an advantageous part of a
container to locate a mark since the closed end is largely protected from many
types of wear
and generally remains intact after crushing. While a container body is
positioned in a
rotational indexer or other part of a decorator, or even after a decorator, an
overvarnish
and/or a bottom coat can be applied to a container body, including the closed
end. At a dome
spraying location of the production line, a laser can ablation one or more
aspect of the closed
end to form a mark. Specifically, in one embodiment, a dome spraying system
can apply a
material to the dome, then a laser can ablate part of that material to form a
mark as raw
aluminum will potentially stain or oxidize during subsequently processing and
stand in
contrast to the coated portion of the dome. In some embodiments, the material
is a clear
varnish. In other embodiments, the material is an ink, tinted varnish, or
matte translucent
varnish to achieve a higher contrast with the laser formed mark on the closed
end. The higher
contrast means less time is necessary for a sensor to detect the mark in view
of any lighting
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or glare issues. In some embodiments, a matte material is advantageous for a
reduction in
overspray and delineation line issues where edges of a mark can bleed together
making the
mark illegible.
Ovens or curing devices associated with inks or materials such as ultraviolet-
activated inks can be used to help complete the marking process. In the
instance of an oven,
the increase in temperature from a heat source causes a chemical reaction in
the polymer
matrix that hardens the polymer and can also evaporate a solvent in the ink to
speed curing.
In an exemplary E-Beam curing process, the ink or coating is solidified with
electrons
emitted from multiple sources and wavelengths to initiate a cross-linking
process in various
monomers and/or polymers to cure the ink or coating.
In various embodiments, a spray nozzle can jet a material onto the dome to
stand in
contrast to a subsequently laser marked portion of the dome. The spray nozzle
may jet
material in a discrete shot with, for instance, a round spray pattern to form
a circle/dot In
other embodiments, a fan shaped nozzle can jet material in a discrete shot to
form a square
pattern. In yet further embodiments, the entire dome is coated with a
material. Then, part of
the material can be ablated with a laser to remove at least some ink and/or
expose part of
the container body material such as aluminum to form the mark. The jetted
material can be
ink, tinted varnish, matte translucent varnish, etc. In some embodiments,
hydraulic pressure
can be used to apply material to reduce overspray. In other embodiments, air-
atomized
material is applied to the closed end of the container body. Optionally, the
material can be
a solvent material or an ultraviolet-activated ink to avoid the use of a large
oven. These
marks can be formed on multiple metallic workpieces at once when the metallic
workpieces
are formed from an uncontrolled mass conveyance into a repeatable pattern. For
instance,
using gates, channels, or other similar components, an unorganized number of
metallic
workpieces is formed into an ordered pattern that can more readily and easily
receive marks
from markers.
In some embodiments, material can be simultaneously applied to multiple
container
bodies then selectively ablated by one or more lasers to form marks. Multiple
pad print
devices on a common rotating shaft of a translating platform can
simultaneously pad print
multiple container bodies on, for instance, closed ends or domes of the
container bodies.
Pad printing utilizes a pad that presses onto a print head to receive ink and
then presses
against a metallic workpiece such as the dome of a container body to transfer
the ink to the
metallic workpiece. The ink can include multiple colors and form complex
graphics, and
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the container bodies may move at a rate of 2000 containers per minute. The
container bodies
may be oriented with the closed end or dome facing upward during this form of
material
application, which is advantageous since any drips will move to a center of
the closed end.
In embodiments where the material is an ultraviolet-activated ink, the
material can be cured
in an oven on the production line that is used to cure a rim coat. In other
embodiments, the
material applied by the pad print devices is a laser or heat-activated ink
applied to a closed
end of a container body such as a dome. One or more lasers may subsequently
activate the
ink to form a mark that stands in contrast to the un-activated parts of the
ink. Again, this
high contrast means less time is required for a sensor to detect the mark in
view of any
lighting or glare issues.
A mark also can be applied to a container body at the inside spray coating
part of the
manufacturing process. A mark can be applied to, for instance, a closed end
such as a dome
of a container body at the infeed portion of the inside spray machine where
any trackwork
or conveyance is directing container bodies into the inside spray machine.
Specifically, for
example, a continuous inkjet printer can apply an ink or a laser can etch a
mark on the closed
end or any portion of the container body positioned in the infeed portion of
the inside spray
machine. In some embodiments, the container bodies are stabilized with a feed
screw or belt
to control the position, timing, and orientation of the container bodies as
described herein to
ensure a consistent mark position. The marker can be located at a waterfall
location from a
mezzanine level into the inside spray machine. Specifically, the container
bodies flow from
a station in the production line at the elevated mezzanine level and then are
gravity fed into
an inside spray machine positioned below or lower than the mezzanine level,
and a marker
can apply a mark to a container body as it moves, for instance, in a cage
system from the
mezzanine level to the inside spray machine. Further, a mark can be applied to
a container
body as the container body is positioned in a star wheel that moves the
container body
through the inside spray machine itself.
Additionally, or alternatively, a mark can be applied to a metallic workpiece
at a
necker machine or after a necker machine. Some necker machines reduce the
diameter of
an end of a container body such as an open end. This can reduce the amount of
material used
in the container body, reduce costs, and provide a geometry that allows
multiple containers
to be stacked, etc. A necker machine can also add a threaded surface to the
end of a container
body. The position and/or orientation of the container bodies may need to be
controlled to
provide a mark at a consistent location on the container body such as the
neck, the label
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portion of the body or the closed end. Position and orientation technologies
are described in
further detail herein. Moreover, the container bodies may be divided into
multiple lanes of
conveyance to reduce the speed of conveyance and ensure a complete marking
process in
the instance of, for example, two dimensional marking such as a QR code.
In some embodiments, a necker machine comprises a marker that is a continuous
inkjet printer or drop on demand inkjet printer, which jets ink using piezo or
thermal modes
of operation, that marks the neck, the label portion and/or closed end of a
container body as
the container body is positioned in an indexing turret or an indexing necker.
In other
embodiments, the marker is a laser that ablates part of a coating on the
container body as
the container body is positioned in an indexing turret or an indexing necker.
The exposed
metal can stand in contrast to the coated portion, and the exposed metal may
oxidize or
develop a stain during further processes for greater contrast with the coated
portion.
The marker is positioned in a relatively small space within the necker machine
without interfering with any operations of the necker machine. In some
embodiments, the
marker may replace tools of a station of the necker machine. Alternatively,
the marker may
be positioned between stations of the necker machine, or between two necker
machines that
operate in series, such that the marker marks the container body between
forming operations
and/or during indexing.
Within the production facility, a container body may also be marked near the
end of
the production line and before the container bodies are palletized for
transportation. Again,
the container bodies may be divided into multiple lanes of conveyance to
reduce the speed
of the container bodies moving through the production line. At this point in
the production
line, if a mark is applied to a closed end of the container body, the
conveying structure or
multiple lanes of conveyance may expose the closed end of the container body
for marking.
Exposure in this sense may mean a conveyance through a cage system where a
container
body is constrained in multiple directions by rails or rods but is otherwise
exposed for
marking. In some embodiments, the conveying structure may comprise a belt.
Orientation technology may be used to apply a mark in a consistent location on
the
container body, as described in greater detail herein. The marker can be a
drop on demand
inkjet printer with piezo or thermal control. The mark can be applied to a
label portion of a
container body and extend up to, for instance, 70 mm in a vertical direction
on the label
portion. Additionally, or alternatively, a continuous inkjet print head may
also apply a mark
to the container body at this point in the production line. In some
embodiments, a pre-
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treatment is applied to the container body for the ink to properly adhere.
Further, a laser can
ablate part of the ink or overcoating or even active part of the ink or
overcoating as described
herein. It will be appreciated that with this embodiment or any embodiment
described
herein, an overvarnish is optionally applied to a metallic workpiece to
protect a mark.
Ablating material such as lasering an ink or part of a metallic workpiece can
leave metal
exposed. This may be undesirable since exposed metal can oxidize or may not be
appropriate
to contact contents of a finished container due to safety concerns. Thus, an
overvarnish can
be applied to a marked portion of a metallic workpiece using, for instance, a
wheel, a spray
head, a drop on demand head, etc. Optionally, the overvarnish can be cured
thermally and/or
with ultraviolet light.
Marking technologies may also be located at a filler location. Generally, a
manufacturer produces a container body, a can, a bottle, an end closure, a
closure (such as
a roll-on pilfer proof closure), etc, then these components are shipped to a
general customer
such as a filler. The filler may rinse one or more of these components, add
contents to the
container body, and then seal the contents with an end closure, a ROPP
closure, or a cap to
create the finished container. The filler also operates equipment to test the
containers,
package the containers, and palletize the cans, ends, bottles, and closures. A
marker can add
a mark to various parts of the container at different locations at the filler.
For example, a
drop on demand inkjet printer can apply a mark to a metallic workpiece prior
to packaging,
then the packaged metallic workpieces are palletized.
End shells are manufactured into end closures then shipped to a filler. The
end
closure may have features such as a tab, a frangible score that defines a pour
opening, etc.
The shell of the end closure forms most of the end closure including the
central panel.
An end shell can begin at the manufacturer as a coil of a continuous sheet of
metal
like the container body. Thus, a mark can be applied to the continuous sheet
at a shell press
coil infeed the same as, or similar to, marking a continuous sheet that forms
container
bodies. For instance, the marker or marking device may be synchronized with a
shell press
that separates a portion of metal from the continuous sheet to ensure that a
mark is formed
on the same part of each end shell, and thus, same part of each end closure.
In some embodiments, the marker can form the mark on the continuous sheet
during
a forming action of the shell press. This is beneficial as the continuous
sheet may be
substantially stationary during the forming action.
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Additionally, or alternatively, the marker may form the mark between forming
actions of the shell press. For example, in some embodiments the marker is
positioned and
operable to form the mark on the continuous sheet when it is being fed into
the shell press
such that the continuous sheet is in motion while the mark is formed. As noted
in various
embodiments herein, the marker forms the mark during an indexing of the
continuous sheet,
or even upstream at a coil feed where the continuous sheet moves at a constant
speed and is
separated from an indexing motion at a shell press by a length of slack sheet
material.
A mark can be applied (in some embodiments) to a continuous sheet at the
infeed of
the shell press by an inkjet printer, such as a continuous inkjet printer.
Specifically, in at
least one embodiment, the mark is formed on a side of a continuous sheet that
forms the
product side of an end shell, and the mark can be formed by, for instance,
food grade ink
that will maintain the safe nature of the interior of a finished container and
satisfy the U.S.
Food and Drug Administration's regulations for direct food contact In addition
or
alternatively, a mark can be applied by a marker (a laser, an inkjet printer,
etc.) to a public
side of the end shell at or near a location that will ultimately serve as a
rivet or tab attachment
location. Marking the end shell at this location in the production line allows
for subsequent
detection through the manufacturing process which generates more data and
leads to better
and more efficient manufacturing. Marking on the public side will also
preserve the ability
for end user data collection. Forming the mark on the public side at or near
the location of
the rivet is beneficial because in embodiments in which the rivet is centered
on the end shell,
the orientation of the end shell when the mark is formed is not critical. With
the product
side mark and the public side mark associated with each other at a database,
the information
related to the manufacturing of the finished container is associated with any
subsequent end
user data collection.
Once an end shell is formed, the end shell is joined with a tab, among other
actions
at a conversion press, to form an end closure. An infeed conveyor conveys end
shells into
the conversion press. The infeed conveyor may comprise one or more rods or
rails that form
a cage. The cage feeds a continuous stack of end shells vertically downward to
a separating
device, or downstacker, for placement in the conversion press timing belt
and/or transfer
belt where an end shell can be marked. The transfer belt conveys individual
end shells in
belt pockets into the conversion press and through a series of tools that form
various end
features on the end shell. The transfer belt prevents rotation of the end
shell, allowing
progressive die features to correctly form the end shell and resulting end
closure with respect
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to the mark. Thus, a marker or marking device can mark a public side of the
end shell
alongside other tools, which ensures that the end shell is oriented properly
for forming a
mark or marks in a consistent position on the resulting end closure.
Consistent marking in
this context is advantageous to prevent a mark from being obscured, damaged,
or interrupted
by end features (such as the score or the tab), if desired, or interfering
with features of the
end closure such as a tear panel. Alternatively, in some embodiments, it may
be
advantageous to locate the mark underneath the tab to avoid interfering with
an overall
aesthetic appearance of the container, in which case, the tab can be
articulated to expose the
mark for subsequent scanning and detection.
After the end shell and tab are combined to form an end closure, the
conversion press
outfeed conveys the end closures away from the conversion press. Specifically,
the transfer
belt conveys the end closures away, and in some embodiments, up to four end
closures can
fit across the width of the transfer belt A light tester is positioned above
the transfer belt to
conduct a pin hole check, and a marker (such as an inkjet or laser system) can
also form a
mark on the public side of the end closure at this point on the transfer belt.
The mark can be
formed, for instance, on a tab or central panel or other portion of the end
closure. Next, a
vacuum belt is positioned above the end closures to hold the end closures as
the transfer belt
moves over a roller to return to the infeed of the conversion press. Once held
by the vacuum
belt, again, a marker (such as an inkjet or laser system) can form a mark on
the product side
of the end closure. Specifically in the instance of the laser marker, a camera
system can
identify various feature of the end closure, and then a laser can articulate
to apply a mark to
an area of the end closure that does not interfere with the identified
features of the end
closure. This camera and laser system can thus be used in lieu of orientation
systems.
Cages can also convey the end closures (or end shells) between stations of the
production line. In various embodiments, four to five rods or rails are
arranged to form a
tunnel that constrains the movement of the end closures in more than one
direction but then
permits movement in at least one direction to convey a continuous flow of
stacked end
closures. The rods or rails can be straight, radiused, follow an n-order
polynomial shape,
etc. The gaps between the rods allow access to the end closures, for example,
if an end
closure needs to be removed from the stack. The gaps also present an
opportunity for a
marker to apply a mark to the end closures. Auxiliary devices can push the
stack of end
closures through parts of the cage and/or count end closures, etc.
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A continuous stack of end shells or end closures is separated into individual
shells
or end closures by a downstacker which has multiple wheels arrayed around the
continuous
stack. The wheels have a helical shape such that as the wheels turn, the
wheels engage an
edge or a curl of an end shell or end closure to separate the end shell or end
closure from
the continuous stack. In some embodiments, three wheels are synchronized to
work at high
speeds. Downstackers may be positioned at a compound liner machine infeed, a
conversion
press infeed, and/or a seamer infeed. Furthermore, downstackers can be
positioned at a
manufacturer or at a filler to separate ends for marking. A marker such as a
laser can apply
a mark to an outer edge of a shell or end closure such as a chuckwall in a
continuous stack
or to any portion of an end shell or end closure once separated from the
continuous stack.
A compound liner machine applies a compound to end shells prior to the
conversion
press. An outfeed conveyor, such as a vacuum belt, can convey the end shells
at a high speed
as spaced by the release from the compound liner machine At this point, the
public side of
the end shell is facing upward and available for compound inspection and
marking. An air
rejection system can blow substandard end shells off of the conveyer and into
a scrap bin.
The outfeed conveyor can extend between 15-20 feet (4.57-6.10 meters) and
terminate in a
90 degree elbow rod cage that stacks end shells for subsequent conveyance.
A marker can apply a mark to the product side of the end shell positioned on
the
outfeed conveyor of the compound liner machine. In some embodiment, the marker
comprises an inkjet printer but may also include other marking technologies
discussed
herein. Alternatively, the marker at the outfeed conveyor of the compound
liner machine is
a continuous inkjet printer. The ink used to form the mark by the continuous
inkjet printer
can be food grade to maintain safety of the resulting container. Forming a
mark while the
end shell is positioned in the outfeed conveyor of the compound liner machine
is
advantageous as the ink can be subsequently cured in a liner oven.
A shell accumulation balancer collects end shells at different points in the
manufacturing process, including an A Balancer between a curler and a liner
machine and
a B Balancer between the liner machine and a conversion press. The
accumulation balancer
can include manual balancers where operators may physically remove end shells
from one
rod cage and add end shells to any of multiple outfeeds. The end shells can
also be held for
inspection to reject defective shells. At this point, the end shells are
positioned in open, half
cylinder troughs that are fed by and discharged to rod cages. Automatic
balancers have
lengths of end shells fed onto trays which are automatically moved to a
desired discharge
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rod cage to meet line control demands. Trays of end shells can also be removed
from
balancers by forklifts for temporary warehouse storage/buffering.
Within these manual and automatic balancers are opportunities to apply a mark
to
an end shell. End shells can be fed to marking loops where a marker can apply
a mark to
any part, public side or product side, of shells. For instance, end shells can
be fed to a
balancer, exit the balancer to a marking loop, reenter the balancer, and exit
the balancer to
a downstream process or even into an inventory holding rack for storage in a
warehouse and
future use.
In some embodiments, the marker uses an ink to form the mark while the end
shell
is in a marking loop. The marker may be a continuous inkjet printer or a drop
on demand
printer. Alternatively, the marker at the marking loop may comprise a laser.
After a balancer, a feeder can be positioned in the end closure production
line.
Specifically, a feeder can be an end closure accumulation and staging machine
for a
customer such as a filler. Unsleeved "sticks" of end closures are loaded in a
vertical
orientation into a carousel staging pocket. Many stacks of end closures can be
unsleeved
loaded into different pockets at once to make efficient use of operator time.
Pockets are
conveyed around the carousel to an unloading position, where the end closures
in the pocket
are released to the rod cage conveyance.
A marker can mark part of an end closure while the end closures are within the
rod
cage conveyance. A separate system may take the output from the conversion
press at a
faster speed and feed several different marking lanes/devices at a slower
speed. Marked end
closures can then be loaded back to the balancer/feeder in different positions
to then be
passed to the existing palletizer system.
In some embodiments, the marker uses an ink to form the mark while the end
shell
or end closure is positioned within a rod cage conveyance. The marker may be a
continuous
inkjet printer or a drop on demand printer. Alternatively, the marker which is
positioned to
form the mark on end closures or end shells within a rod cage conveyance may
comprise a
laser.
In various embodiments, a mark is located on a peripheral curl of an end
closure.
This portion of the end closure is a relatively thin portion extending around
an outer
circumference of the end closure on a public side of the end closure. In some
embodiments,
the mark is a one-dimensional code like a bar code where the mark appears as
alternating
lines and spaces extending around the outer circumference of the end closure.
Moreover,
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the mark is optionally repeated at several positions around the outer
circumference of the
end closure such that a scanner directed at one side of the end closure reads
at least one of
the marks. With a mark in this location, the mark can be read while end
closures are stacked
in, for example, a rod cage.
A marker, including any marker described herein such as a laser or a pad
printer,
forms this mark at any location in the manufacturing process, including the
beginning of the
manufacturing process. In various embodiments, a marker forms a mark at a
blank location
of a continuous sheet of metallic material prior to a press. This mark may
comprise
alternating lines and spaces in a circular shape at an outer edge of the
circular blank location
and appears as a partial, sun burst pattern. Once the blank is cut from the
sheet and formed
into, for instance, an end shell and then an end closure, the resulting mark
is located at an
exterior of the peripheral curl of the shell or end closure. Then, when the
end shells or end
closures are arranged in a stack, the mark can be read by a scanner to
generate a scan event,
which is transmitted to a database to update a record associated with the
mark, and thus, the
end shell or end closure.
In various embodiments, the mark on the peripheral curl allows the end shell
and/or
end closure to be tracked and traced through the manufacturing process and
even to a
customer such as a filler. However, once a filler seams the end closure to a
container body,
the mark on the peripheral curl may be partially or fully covered.
Accordingly, in various
embodiments, an additional mark is formed on another location on the public
side of the end
closure. For example, this additional mark can be formed at or near a center
of an end shell
that, in some embodiments, is the location of the rivet to which the pull tab
joins. The area
of the central panel of the end closure around the rivet typically does not
have features such
as scores. Thus, the mark can be formed on the end shell without concern of
the particular
orientation of the end shell as the mark does not interfere with any
subsequent features on
the end closure, and this additional mark allows for the tracking and tracing
of the end
closure and/or finished container if the mark on the peripheral curl is
covered.
The packing location of a production line at the filler also presents another
opportunity for marking. The containers may be divided into multiple lanes of
conveyance
to reduce the speed of the containers moving through the production line. At
this point in
the production line, if a mark is applied to a closed end or a container body
of the containers,
the conveying structure or multiple lanes of conveyance may expose the closed
end of the
container for marking. Exposure in this sense may mean a conveyance through a
cage
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system where a container body is constrained in multiple directions by rails
or rods but is
otherwise exposed for marking. Orientation technology may be used to apply a
mark in a
consistent location on the container, as described in greater detail herein.
The marker associated with the packing location may comprise a laser or use an
ink
to form a mark on the container. In some embodiments, the marker can be a drop
on demand
inkjet printer with piezo or thermal control. The mark can be applied to a
label portion of a
container and extend up to, for instance, 70 mm in a vertical direction on the
label portion.
Additionally, or alternatively, a print head of a continuous inkjet printer
may also
apply a mark to the container at this point (the packing location) in the
production line. In
some embodiments, a pre-treatment is applied to the container for the ink to
properly adhere
as described herein.
Further, in some embodiments, a laser associated with the packing location can
ablate part of the ink or overcoating (or even activate part of the ink or
overcoating) to form
a mark on the container body or the end closure. The packing location at the
filler provides
space to mount orientation cameras and lasers to optionally orient containers
and mark
containers. For example, the orientation cameras or lasers may be positioned
proximate to
existing systems such as pressure checker platforms after, for instance,
filling or
pasteurization.
Tabs are manufactured and then combined with an end shell to form a complete
end
closure at a conversion press. At the tab stock infeed for the conversion
press, a marker can
mark portions of the tab stock where individual tabs will be formed during the
dwell time
or period of the conversion press. The tab stock moves into the conversion
press
incrementally and the dwell period is defined by a period when the tab stock
is substantially
stationary. Even before a conversion press, a marker such as a laser can
ablate part of a
coating on the tab stock to form a mark. The mark can be, for instance, a
small two-
dimension code that is less that 2mm in size and positioned on a topside of
the tab, which
would face upward toward the end user once the finished container is produced.
It will be
appreciated that a mark can be formed on any part of the tab even including
the underside.
Moreover, in some embodiments, a portion of the tab proximate to the lifting
end includes
a flat, webbed panel instead of a fingerhole to provide more surface area to
bear a mark or
marks. In various embodiments, a mark is applied between the rivet island and
the nose end
of the tab.
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One aspect of the present disclosure is a tab with an increased size compared
to prior
art tabs. Increasing the size of the tab is beneficial because the larger tab
provides additional
space to form marks, or to form a larger mark. The larger tab thus provides
benefits which
outweigh the increased material costs and costs associated with changes to the
end closure
production line that are required to form and handle larger tabs.
As discussed herein, a metallic workpiece may be stabilized and/or oriented
for a
marking process to ensure marks are repeatably produced at a consistent
location on the
metallic workpiece. Stabilization and orientation control make the mark
legible for
subsequent scanning events and prevent the mark from interfering with other
features of the
finished container such as a tab or pour opening.
Accordingly, in some embodiments, the orientation of the metallic workpiece is
optionally controlled before or during a marking process. This prevents the
mark from
damaging features such as score lines, from being hidden, and/or from becoming
unreadable. Any metallic workpiece can have its orientation controlled
including, but not
limited to, an end shell, an end closure, and a container body. In some
embodiments, an end
shell is formed and marked, then the end shell is oriented to a predetermined
orientation
before entering the conversion press to ensure the mark is in the proper
location on the
resulting end closure. In various embodiments, an end closure is oriented to a
predetermined
orientation after the conversion press, and a mark is applied to the oriented
end closure.
Orientation systems of the present disclosure are configured to rotate the
metallic
workpiece about at least one axis. One exemplary orientation system comprises
at least one
belt of a conveyance. A metallic workpiece (such as a container body) is
conveyed in a first
direction and the longitudinal axis of the metallic workpiece extends along a
perpendicular,
second direction. A first belt is positioned on one side of the metallic
workpiece and a second
belt is positioned on an opposing side of the metallic workpiece. A camera or
other senser
at the beginning of the conveyance can detect the initial orientation of the
metallic
workpiece. Based on this information, a control system or other electronic
device can
determine the amount and direction of rotation required to place the metallic
workpiece in
a final orientation. Then, the control system directs the belts to rotate at
different speeds to
rotate the metallic workpiece about its longitudinal axis as the metallic
workpiece moves by
the belts, and the workpiece emerges from the belts of the orientation system
in the final
orientation for marking.
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Another exemplary orientation system is a servo system. A metallic workpiece
such
as a container body can be loaded into a plate or wheel. A camera or other
sensor can detect
the initial orientation of the metallic workpiece. Based on this information,
a control system
or other electronic device can determine the amount and direction of rotation
required to
place the metallic workpiece in a final orientation. Then, the control system
directs a servo
motor on the plate or wheel to rotate the container body to the final
orientation.
It will be appreciated that these orientation systems will work with any
marking
technology described herein. It will also be appreciated that the orientation
systems will
work with any metallic workpiece described herein at any station in the
production line of
any manufacturing process.
In some embodiments, the metallic workpiece is optionally stabilized during
the
marking process. Improper stabilization due to random movement such as
jostling can cause
a mismark due to a laser being out of focus or a print head at an improper
distance from a
metallic workpiece, which leads to a rejection of a metallic workpiece.
Various stabilization
systems are contemplated, and a stabilization system can stabilize a metallic
workpiece prior
to a marker or can be incorporated with a marker such that the stabilization
system is
engaging a metallic workpiece as a marker applies a mark to the metallic
workpiece.
In at least one embodiment, the stabilization system comprises a feed screw to
stabilize a metallic workpiece such as a container body. As a container body
is conveyed in
a first direction, the longitudinal axis of the container body is oriented in
a perpendicular,
second direction. Within the stabilization system, a feed screw is positioned
on one side of
the container body and its longitudinal axis. The feed screw has a thread that
rotate around
a rotation axis oriented in the first direction. The stabilization system also
comprises a wall
opposing the feed screw, and the wall extends in the first direction
substantially parallel to
the rotation axis. The wall is flat or substantially flat. In some
embodiments, the wall can
be a moving belt to prevent rotation of the container body. As a container
body enters the
stabilization system, the container body is positioned in a valley (or pocket)
formed between
crests of the thread and pressed laterally in yet a third direction that is
perpendicular to both
the first and second directions. This pressing motion causes the container
body to contact
the flat wall, which reduces movement such that a marker can apply a mark to
the container
body.
Another stabilization system of the present disclosure utilizes a star wheel.
Metallic
workpieces such as container bodies are conveyed in a first direction, and
longitudinal axes
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of the container bodies are oriented in a perpendicular, second direction. The
star wheel is
a generally cylindrical device that rotates around a rotation axis aligned
with the second
direction. The star wheel has a plurality of recesses in an outer
circumference that are
substantially the same shape and size as a container body. The star wheel is
at least partially
positioned in the flow of conveying container bodies. As a container body
approaches the
star wheel, the container body enters a recess on the star wheel. The star
wheel reduces
movement and rotates the container body where a marker can apply a mark to the
container
body. Then, the star wheel continues rotating around the rotation axis and
releases the
container body back into the flow of conveying container bodies.
A further stabilization system is a vacuum conveyance. Metallic workpieces
such as
container bodies are conveyed in a first direction, and longitudinal axes of
the container
bodies are oriented in a perpendicular, second direction. One wall in the
stabilization system
draws in a vacuum As the container bodies move over the vacuum wall, the
container bodies
are drawn to the wall and movement such as jostling in the container bodies is
reduced.
Then, a marker can apply a mark to the container bodies.
In some embodiments the vacuum conveyance comprises a mesh belt. The mesh
belt is configured to move the container bodies in the first direction. A
vacuum is formed
such that a predetermined portion of the container bodies is drawn against the
mesh belt. In
some embodiments, an open end of the container bodies is positioned against
and drawn to
the mesh belt. Alternatively, in other embodiments, a close end of the
container bodies is
positioned against and drawn to the mesh belt.
Yet another stabilization system is a grip system. Metallic workpieces such as
container bodies are conveyed in a first direction, and longitudinal axes of
the container
bodies are oriented in a perpendicular, second direction. In some embodiments,
protrusions
extend from one wall of the stabilization system to contact container bodies.
In other
embodiments, protrusions extend from opposing walls of the stabilization
system to contact
container bodies. Thus, as a container body enters the stabilization system,
one or more
protrusions contact the container body to stabilize the container body and
reduce movement
such that a marker can apply a mark to the container body.
In some embodiments, the walls comprise belts positioned on either side of the
longitudinal axis of a container body. A first one of the belts may rotate in
a first direction.
A second one of the belts may rotate in a second direction opposite to the
first direction.
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Pneumatic systems positioned downstream of the stabilization system can reject
any
container bodies with mismarks. It will be appreciated that these
stabilization systems will
work with any marking technology described herein, and the stabilization
system will work
with any metallic workpiece described herein at any station in the production
line in the
manufacturing process.
One aspect of the present disclosure is a method of marking a container body
for
tracking and tracing, comprising: (1) moving a continuous sheet of a metallic
material past
a marker; (2) forming a mark by the marker at a blank location on the
continuous sheet
where a blank will be cut from the continuous sheet, the mark being unique to
the blank
location; (3) moving the continuous sheet into a cupper in a production line;
(5) cutting the
blank with the mark from the continuous sheet by the cupper; (6) forming the
blank into a
cup by the cupper such that the mark is positioned on an exterior surface of a
closed end of
the cup; and (7) forming the cup into the container body by a bodymaker of the
production
line.
In some embodiments the marker forms the mark without contacting the
continuous
sheet.
Optionally, the marker includes a laser to form the mark.
In some embodiments, the laser forms the mark by etching or engraving the
continuous sheet.
In at least one embodiment, the mark is formed with an ink.
In some embodiments, the ink is an ultraviolet ink such that the mark is
visible when
exposed to an ultraviolet light.
In some embodiments, the mark is formed by exposing a coating on the
continuous
sheet to a light source. The coating may be a photo-reactive ink. Optionally,
the light source
is a laser. Accordingly, the mark may be formed by exposing selected portions
of the photo-
reactive ink to the laser.
Additionally, or alternatively, the marker may include an inkjet print head to
form
the mark.
The method may include one or more of the previous embodiments and, in some
embodiments, the marker contacts the continuous sheet when forming the mark.
Additionally, or alternatively, the mark is formed with a toner material.
In some embodiments, the marker includes an electrophotographic print unit to
form
the mark.
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Optionally, in one or more of the previous embodiments, the marker forms the
mark
during a dwell period during which the continuous sheet is not advanced into
the cupper
such that the continuous sheet is generally stationary.
In some embodiments, the marker is operable to form the mark while the
continuous
sheet is moving.
Accordingly, in some embodiments, the marker may form the mark while the
continuous sheet is stationary, while the continuous sheet is moving, or while
the continuous
sheet is both stationary and moving.
The method may include one or more of the previous embodiments and, in some
embodiments, the mark is a computer readable code.
In some embodiments, the mark comprises a series of indi ci a and spaces
arranged in
rows and columns.
The method optionally includes one or more of the previous embodiments and in
at
least one embodiment, the mark includes a unique identifier for the container
body.
In some embodiments, that mark further comprises one or more of: (i) a
randomized
alphanumerical code; (ii) a production date; (iii) a production time; (iv) a
production
location; (v) a production line identifier; (vi) a batch number; (vii) a shift
identifier; (viii)
material specifications of the metallic material of the continuous sheet; (ix)
an identifier for
the manufacturer of the coil; (x) an identifier or a serial number of the
coil; (xi) a position
of the mark on the continuous sheet (such as an X, Y coordinate a location on
the continuous
sheet where the mark is formed; (xii) a mass of the container body; and (xiii)
a name of the
filler that ordered the container body.
The method may include one or more of the previous embodiments and optionally
the mark is generated by a control system in communication with the marker.
In some embodiments the method further comprises receiving the mark from the
control system. The control system may communicate with the marker over a
network, such
as the internet. Optionally, the control system is located away from the
production line that
includes the marker.
Optionally, the method includes any one or more of the previous embodiments
and
may further comprise: (a) scanning the mark by a sensor; (b) transmitting data
from the
sensor to a control system; and (c) updating a record associated with the
container body.
The record may be stored in a database.
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In some embodiments, the record may be updated to include one or more of: (i)
a
date of the scan; (ii) a time of the scan; (iii) a location of the sensor; and
(iv) a rejection
identification code. The rejection identification code may identify a cause of
a rejection or
a location at which the container body was rejected. Accordingly, the
rejection
identification code may identify a reason for rejection of the container body,
such as tear-
off at a bodymaker, blow-off at a decorator, failure in a necker, and the
like.
The method may include any one or more of the previous embodiments, and
further
comprise the sensor being positioned on the production line.
In some embodiments the sensor is positioned at one or more of an infeed and
an
outfeed of a piece of equipment of the production line.
In some embodiments, the piece of equipment is the bodymaker.
Additionally, or alternatively, a sensor may be associated with an infeed or
an
outfeed of an internal coater of the production line
The method may include any one or more of the previous embodiments, and in
some
embodiments the sensor is at a point of sale.
In some embodiments, a sensor is at a collection point associated with a
recycling
center.
Another aspect of the present disclosure is a system for tracking and tracing
a
container body, comprising: (1) a marker operable to form a mark on a
continuous sheet of
a metallic material at a blank location where a blank will be cut from the
continuous sheet;
(2) an uncoiler to uncoil a coil comprising the continuous sheet of the
metallic material; (3)
a cupper to cut the blank from the continuous sheet at the blank location and
form the blank
into a metallic cup; (4) a conveyor to transport the metallic cup to a
bodymaker that forms
the metallic cup into a container body, the bodymaker having an identifier;
(5) a sensor to
scan the mark, the sensor positioned at an infeed or an outfeed of the
bodymaker; and (6) a
control system in communication with the marker and the sensor, the control
system
operable to: (a) generate the mark formed by the marker; and (b) update a
record in a
database for the container body to include the identifier of the bodymaker
after the sensor
scans the mark.
In some embodiments, the mark is a computer readable code.
For example, the mark may be a data matrix code, a bar code, a quick response
(QR)
code, and the like.
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Additionally, or alternatively, the mark comprises a series of markings and
blanks
arranged in any manner or sequence. For example, the mark may comprise a
series of
indicia, such as a dot, a square, a circle, a symbol, a line, a letter or any
other marking.
Optionally, the mark may comprise spaces between one or more of the indicia.
In some
embodiments, the mark includes indicia and spaces arranged in rows and
columns.
The system may include one or more of the previous embodiments and optionally
the mark includes a unique identifier for the container body.
In some embodiments, the mark includes an ink or a toner.
In some embodiments, the ink is an ultraviolet ink such that the mark is
visible when
exposed to an ultraviolet light.
In some embodiments, the mark is formed by exposing a coating on the
continuous
sheet to a light source. The coating may be a photo-reactive ink. Optionally,
the light source
is a laser. Accordingly, the mark may be formed by exposing selected portions
of the photo-
reactive ink to the laser.
Additionally, or alternatively, the mark is engraved and/or etched in the
continuous
sheet.
The system may include any one or more of the previous embodiments, and the
mark
may further comprise one or more of: (i) a production date; (ii) a production
time; (iii) a
production location; (iv) a production line identifier; (v) a batch number;
(vi) a shift
identifier; (vii) material specifications of the metallic material of the
continuous sheet; (viii)
an identifier for a manufacturer of the coil; (ix) an identifier or serial
number of the coil; (x)
a position of the mark on the continuous sheet; (xi) a mass of the container
body; (xii) a
name of a filler that ordered the container body; and (xiii) a randomized
alphanumerical
code.
In some embodiments, the marker comprises a laser to form the mark.
The system may include one or more of the previous embodiments, and optionally
the marker comprises an inkjet print head to form the mark.
Additionally, or alternatively, the marker may comprise an electrophotographic
print
unit to form the mark
Optionally, the marker forms the mark during a dwell period during which the
continuous sheet is not advanced into the cupper such that the continuous
sheet is generally
stationary.
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In some embodiments, the marker is operable to form the mark while the
continuous
sheet is moving.
Accordingly, in some embodiments, the marker may form the mark while the
continuous sheet is stationary, while the continuous sheet is moving, or while
the continuous
sheet is both stationary and moving.
The system may include any one or more of the previous embodiments, and
optionally the system further comprises: (a) a decorator downline from the
bodymaker, the
decorator having a unique name or identifier; and (b) a second sensor to scan
the mark, the
second sensor positioned at an infeed or an outfeed of the bodymaker.
In some embodiments, the control system is further operable to update the
record in
the database for the container body to include the unique name of the
bodymaker after the
second sensor scans the mark.
Optionally, the control system includes a date and time of the scan of the
mark by
the second sensor in the record in the database.
In some embodiments, the control system is further operable to update the
record in
the database for the container body when a sensor associated with a point of
sale scans the
mark.
Still another aspect of the present disclosure is a metallic container having
a mark
for tracking and tracing the metallic container, comprising: (1) a body with a
closed end, a
sidewall extending upward from the closed end, and an opening located at an
upper end of
the body; and (2) the mark positioned on the closed end, the mark including a
unique
identifier for the metallic container which is distinct from every other
metallic container.
In some embodiments, the mark is a computer readable code.
For example, the mark may be a data matrix code, a bar code, a quick response
(QR)
code, and the like.
Additionally, or alternatively, the mark comprises a series of markings and
blanks
(or spaces) arranged in any manner or sequence. For example, the mark may
comprise a
series of indicia, such as a dot, a square, a circle, a symbol, a line, a
letter or any other
marking. Optionally, the mark may comprise spaces between one or more of the
indicia. In
some embodiments, the mark includes indicia and spaces arranged in rows and
columns.
The metallic container may comprise one or more of the previous embodiments,
and
optionally the mark (and/or a record in a database that is associated with the
mark) further
comprises one or more of: (i) a production date; (ii) a production time; (iii)
a production
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location; (iv) a production line identifier; (v) a batch number; (vi) a shift
identifier; (vii)
material specifications of a metallic material of a continuous sheet from
which the metallic
container was formed (such as chemical composition of the metallic material);
(viii) an
identifier for a manufacturer of a coil comprising the continuous sheet of
metallic material;
(ix) an identifier or a serial number of the coil; (x) a date of manufacture
of the coil; (xi) a
manufacture location of the coil; (xii) a position of the mark on the
continuous sheet; (xiv)
a mass of the metallic container; (xv) a name of the filler that ordered the
metallic container;
(xvi) a randomized alphanumerical code; and (xvi) other production data pulled
from
existing systems and databases associated with the production line.
In some embodiments, the mark is formed by a laser.
In some embodiments, the laser forms the mark by etching or engraving a
metallic
material which is formed into the metallic container.
Optionally, the mark is engraved in the closed end
The metallic container may include any one or more of the previous
embodiments,
and optionally the mark is formed with an ink.
In some embodiments, the ink is an ultraviolet ink such that the mark is
visible when
exposed to an ultraviolet light.
In some embodiments, the mark is formed by exposing a coating to a light
source.
The coating may be a photo-reactive ink. Optionally, the light source is a
laser.
Accordingly, the mark may be formed by exposing selected portions of the photo-
reactive
ink to the laser.
Additionally, or alternatively, the mark may be formed with a toner material.
In some embodiments, the mark is stored in a record in a database. The record
may
include two or more of: (i) an identifier for a bodymaker that formed the
metallic container;
(ii) an identifier for a decorator that formed a decoration on the sidewall;
(iii) an identifier
for an internal coater that sprayed a coating into a hollow interior of the
body; (iv) an
identifier for a necker that formed a neck on the metallic container; and (v)
an identifier for
a cupper that formed a cup that was subsequently formed into the metallic
container.
Optionally, the record further comprises one or more of: (a) an identifier for
a
manufacturer of a coil comprising the continuous sheet of metallic material;
(b) an identifier
for a palletizer that placed the metallic container into a pallet; (c) an
identifier for a shipper
that transported the metallic container to a filler; (d) an identifier for a
point of sale that sold
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the metallic container; and (e) an identifier for a collection point that
received the metallic
container.
In some embodiments, the record may also include one or more of: (a) a mass of
the metallic container; (b) a name of the filler that ordered the metallic
container; (c) a
randomized alphanumerical code; (d) a date the metallic container left the
production
facility; (e) an identification of a filler; (f) an identify of a product with
which the metallic
container was filled; and (g) an expiration date of the product
Optionally the record may be manually updated. For example, a user may enter
data
into a record of a database that is associated with a container body. The user
may enter
production data, such as a date and a time that equipment of a production line
was adjusted
or information about a material applied to container bodies by equipment of
the production
line. In this manner, information about types of coatings, inks, or
decorations applied to an
interior surface or an exterior surface of a container body may be entered in
a record by a
user.
Additionally, or alternatively, the record may further comprise other
production data
pulled from existing systems and databases associated with a production line
that produced
the metallic container. The other production data may include data such as,
but not limited
to: (a) a temperature of an oven that dried the metallic container; (b) a
temperature of an
oven that cured an ink or coating on the metallic container; (c) a time stamp
identifying
when the metallic container entered each piece of equipment on the production
line; (d) a
time stamp identifying when the metallic container exited each piece of
equipment on the
production line; (e) an identification of a coating on an exterior surface of
the metallic
container; (f) an identification of a coating on an interior surface of the
metallic container;
(g) an identification of an ink used in a decoration on the exterior surface;
(h) a PH of a fluid
used to wash the container body; (i) a weight or volume of a coating applied
to the interior
surface; and (j) a weight or volume of a coating applied to the exterior
surface.
The metallic container may include one or more of the previous embodiments,
and
optionally the metallic container is formed of an aluminum material.
In some embodiments, the metallic material of the continuous sheet is a steel
or tin
coated steel.
In some embodiments, the metallic container is a recyclable tapered cup.
Alternatively, in another embodiment, the metallic container is a bottle.
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In at least one embodiment, the metallic container has a flange to receive an
end
closure.
Optionally, the metallic container is a food can.
In some embodiments the metallic container is a two-piece container with a
cylindrical body having one open end sealed by one end closure. Optionally,
the mark may
be formed on one or more of the end closure and the cylindrical body. In some
embodiments, the mark is formed only on the cylindrical body of a two-piece
container.
In other embodiments, the metallic container is a three-piece container that
has a
cylindrical body with two open ends, each open end being sealed by an end
closure. In this
embodiment, the mark may be formed on one or more of a first end closure, a
second end
closure, and a cylindrical body extending between the first and second end
closures. In
some embodiments, a mark is formed only on a cylindrical body of a three-piece
container.
Another aspect of the present disclosure is to provide a coil of an aluminum
material,
comprising: (1) a sheet of the aluminum material rolled to define the coil,
the sheet having
a length and comprising: (a) a first long edge; and (b) a second long edge
spaced from the
first long edge by a width of the sheet, the second long edge approximately
parallel to the
first long edge; and (2) a plurality of unique marks formed on the sheet, each
of the unique
marks being a computer readable code and positioned within a blank location,
where (i)
each blank location is a circle with a center and a predetermined diameter;
(ii) a first column
of at least five blank locations is oriented with their centers defining a
first line
approximately perpendicular to the first and second edges; and (iii) a second
column of at
least five blank locations is oriented with their centers defining a second
line approximately
parallel to the first line.
In some embodiment, each of the unique marks includes an ink or a toner.
Additionally, or alternatively, the coil may include unique marks that are
engraved
in the continuous sheet.
In some embodiments, each of the unique marks is formed by a laser.
The coil may include any one or more of the previous embodiments, and
optionally
each of the unique marks is substantially centered within a blank location.
In some embodiments, each of the plurality of unique marks is formed on a
first side
of the sheet.
Optionally, each of the plurality of unique marks is repeated on a second side
of the
sheet. In this manner, a first blank location includes a first mark of the
plurality of unique
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marks on the first side of the sheet and the first blank location includes the
first mark on the
second side of the sheet.
The coil may include any one or more of the previous embodiments, and
optionally
the first mark on the first side of the sheet is positioned substantially
opposite to the first
mark on the second side of the sheet.
Another aspect is to provide a system to produce a mark on a continuous sheet
of a
metallic material, comprising: (1) a marker to form marks on the continuous
sheet at blank
locations where blanks will be cut from the continuous sheet, each mark being
a unique
computer readable code positioned within a blank location; and (2) a coiler to
roll the
continuous sheet with the marks onto a coil.
Optionally, the marks include an ink or a toner.
In some embodiments, the marks are engraved in the continuous sheet
Additionally, or alternatively, the marker comprises a laser to form the marks
In some embodiments, the marker comprises an inkjet print head to form the
marks.
In at least one embodiment, the marker comprises an electrophotographic print
unit
to form the marks.
The system may include one or more of the previous embodiments and optionally
the marks are generated by a control system in communication with the marker.
The system may include one or more of the previous embodiments and optionally
the marker forms the marks on a first side of the continuous sheet.
In some embodiments, the marker forms the marks on both the first side and a
second
side of the continuous sheet such that a first unique mark is formed on a
first side at a first
blank location and the first unique mark is formed on a second side of the
first blank
location.
Optionally, the marker is operable to form the first unique mark at a first
position on
the first side that is approximately opposite to a second position of the
first unique mark on
the second side.
The system may include one or more of the previous embodiments and in some
embodiments each mark is a unique identifier of a blank location
Optionally, the blank location is subsequently formed into a container body.
The system may include one or more of the previous embodiments and optionally
each blank location is generally circular and has a center.
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In some embodiments, the marker forms the marks such that each mark is
approximately centered in a blank location.
The system may include one or more of the previous embodiments, and optionally
the system further comprises an uncoiler positioned upstream from the marker,
the uncoiler
operable to unroll the continuous sheet from an original coil.
The system may include one or more of the previous embodiments and optionally
the metallic material is an aluminum and the marker is operable to form the
marks on the
aluminum metallic material.
Still another aspect of the present disclosure is a method of tracking and
tracing a
container body, comprising: (1) creating a unique identifier; (2) storing the
unique identifier
in a record of a database; (3) providing the unique identifier to a marker,
wherein the marker
forms a mark that is positioned on the container body, wherein the mark is
associated with
the unique identifier; (4) scanning the mark by a first sensor in a production
facility; (5)
updating the record associated with the unique identifier with information
received from the
first sensor; (6) scanning the mark by a second sensor after the container
body is transported
from the production facility; and (7) updating the record associated with the
unique
identifier with information received from the second sensor.
Optionally the first sensor is associated with a cupper, a bodymaker, a
decorator, an
internal coater, a necker, a flanger, a sorter, or a palletizer of the
production facility.
In some embodiments, the second sensor is associated with a filler, a
distributor, a
point of sale, a consumer, or a collection point.
Optionally, the second sensor is at the point of sale and the record is
updated to
include information about a sale of the container body and a deposit collected
during the
sale.
In some embodiments, the second sensor is at the collection point and the
record is
updated to include information about redemption of a deposit collected when
the container
body was sold.
The method may include one or more of the previous embodiments, and optionally
further comprises modifying the record to include one or more of (i) a
production date of
the container body, (ii) a production time of the container body, (iii) a
production location
of the container body; (iv) a production line identifier; (v) a batch number,
(vi) a shift
identifier; (vii) material specifications of metallic material of a sheet from
which the
container body was formed; (viii) an identifier for a manufacturer of a coil
comprising the
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sheet; (ix) an identifier or a serial number of the coil; (x) a position of
the mark on the sheet;
(xi) a mass of the container body; (xii) a name of the filler that ordered the
container body;
and (xiii) a randomized alphanumerical code.
The method may further comprise modifying the record each time the mark is
scanned to include one or more of: a date of the scan; a time of the scan; and
a location of a
sensor making the scan.
In some embodiments, the mark is a computer readable code.
Additionally, or alternatively, the method may further comprise updating the
record
to include one or more of: (a) an identifier for a bodymaker that formed the
container body;
(b) an identifier for a decorator that formed a decoration on the container
body; (c) an
identifier for an internal coater that sprayed a coating into a hollow
interior of the container
body; and (d) an identifier for a necker that formed a neck on the container
body.
In some embodiments the method further comprises updating the record to
include
one or more of: (a) an identifier for a manufacturer of a coil from which the
container body
was formed; (b) an identifier for a palletizer that placed the container body
into a pallet; (c)
an identifier for a shipper that transported the container body to a filler;
(d) an identifier for
a point of sale that sold the container body; and (e) an identifier for a
collection point that
received the container body.
Another aspect of the present disclosure is a method of recycling a container
body,
comprising: (1) receiving the container body at a collection point; (2)
scanning a mark on
the container body with a sensor; (3) identifying a record in a database, the
record being
associated with the mark; (4) checking the record to determine if a deposit
was collected for
the container body when the container body was purchased; and (5) revising the
record to
indicate that the deposit was redeemed.
Still another aspect of the present disclosure is a method of forming an end
closure
adapted to be interconnected to an open end of a metallic container. The
method comprises:
(1) forming an end shell from a sheet of aluminum material, the end shell
comprising a first
side, a second side, and a circular perimeter; (2) feeding the end shell into
a conversion
press; (3) forming, by the conversion press, a rivet on the end shell; (4)
interconnecting, by
the conversion press, a tab to the rivet to transform the end shell into the
end closure, the
tab positioned on the second side of the end closure, wherein the first side
of the end shell
has a first mark formed before the tab is interconnected to the rivet.
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Optionally, the method may further comprise forming a second mark on the
second
side of the end closure.
The method may optionally comprise creating a record in a database, the record
comprising information about the first mark, the optional second mark, and the
end closure.
Optionally, the method further comprises: (a) scanning the first mark with a
first
sensor after forming the rivet; and (b) updating the record with a time of the
scan by the first
sensor.
Additionally, or alternatively, the method may include one or more of the
previous
embodiments and further comprises: (c) scanning the first mark with a second
sensor before
attaching the tab to the rivet; and (d) updating the record with a time of the
scan by the
second sensor.
In some embodiments, the method comprises: (e) scanning the second mark with a
third sensor after the end closure is discharged from the conversion press;
and (f) updating
the record with a time of the scan by the third sensor.
The method may include any one or more of the previous embodiments and
optionally the first mark is identical to the second mark. Alternatively, in
other
embodiments, the first mark is different from the second mark. The method may
optionally
comprise updating a record associated with the first mark in a database to
include a field
with information about the second mark. In this manner, the end closure may be
tracked by
scanning either the first mark or the second mark.
The method may include any one or more of the previous embodiments and
optionally a marker forms one or more of the first mark and the second mark
with an ink.
Additionally, or alternatively, a marker forms one or more of the first mark
and the second
mark with a laser.
In some embodiments, the marker that forms the first mark on the first side is
a
printer that deposits a food grade ink. The printer is optionally a continuous
inkjet printer
or a drop on demand inkjet printer.
In some embodiments the method includes one or more of the previous
embodiments
and further comprises forming a score on the second side of the end shell, the
score defining
a tear panel.
Optionally, the method comprises forming the second mark on the tear panel.
Additionally, or alternatively, the second mark may be formed at or near the
rivet.
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In one or more embodiments, the second mark is formed before the tab is
interconnected to the rivet. Alternatively, the second mark is formed after
the tab is
interconnected to the rivet.
The method may include any of the previous embodiments and optionally, after
the
tab is interconnected to the rivet, the tab covers at least a portion of the
second mark.
In some embodiments, forming the second mark further comprises: (i)
determining
an orientation of the tear panel; (ii) rotating the end closure about a
central axis to a
predetermined orientation such that the central axis is perpendicular to the
second side; and
(iii) forming the second mark in a predetermined location of the second side.
The method may include any one or more of the previous embodiments and further
comprise forming the first mark before the rivet is formed.
In some embodiments, the first mark is formed before the end shell is fed into
the
conversion press
Additionally, or alternatively, the first mark may be formed before the end
shell is
formed by a shell press.
The method may include one or more of the previous embodiments, and optionally
include forming the first mark on the sheet of aluminum material.
In some embodiments, one of the first mark and the second mark is formed when
the end shell is in a rod cage conveyor.
Yet another aspect of the present disclosure is to provide an end closure
adapted to
be seamed to an open end of a metallic container, comprising: (1) a peripheral
curl; (2) a
chuck wall extending downwardly from the peripheral curl; (3) a countersink
interconnected
to a lower end of the chuck wall; (4) a central panel interconnected to the
countersink; (5) a
tear panel defined by a score in the central panel; (6) a tab operably
interconnected to a
public side of the central panel; (7) a product side opposite to the public
side; and (8) a first
mark on the product side..
Optionally, the end closure further comprises a second mark selectively
visible from
the public side.
The first mark is optionally identical to the second mark.
Alternatively, the first mark is different from the second mark.
In some embodiments, one or more of the first mark and the second mark is
formed
by an ink.
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Additionally, or alternatively, one or more of the first mark and the second
mark is
formed by a laser.
In some embodiments, the first mark is formed of a food grade ink.
Additionally, or
alternatively, the first mark is optionally formed by a continuous inkjet
printer or a drop on
demand inkjet printer.
The end closure may include one or more of the previous embodiments and
further
comprise the second mark formed on the tear panel.
In at least one embodiment, the second mark is covered at least partially by
the tab.
In some embodiments, the second mark is formed on a first surface of the tab
facing
the public side of the central panel such that the second mark is visible
after the tab is pivoted
relative to the central panel
The second mark may optionally be formed on a second surface of the tab facing
away from the public side of the central panel
The end closure may include one or more of the previous embodiments, and the
tab
may optionally comprise: (a) a nose end to engage the tear panel; (b) a tail
end opposite to
the nose end that is configured to be manipulated by a user to force the nose
end against the
tear panel; and (c) a medial portion between the nose end and the tail end
that is operably
interconnected to the central panel.
In some embodiments, the second mark is formed on the tail end of the tab.
The tab may optionally have a closed web of aluminum material in the tail end.
In
some embodiments, the second mark is formed on the closed web.
Additionally, or alternatively, the second mark is formed proximate to the
nose end
of the tab.
In one or more of the previous embodiments, the second mark is positioned
between
the nose end and a point at which the tab is operably interconnected to the
central panel.
One aspect of the present disclosure is to provide an end closure adapted to
be
seamed to an open end of a metallic container for tracking and tracing the end
closure,
comprising a product side and an opposing public side of the end closure; a
chuck wall
extending downwardly from a peripheral curl, wherein a countersink is
interconnected to a
lower end of the chuck wall, and a central panel is interconnected to the
countersink, a tear
panel defined by a score in the central panel; a tab operably interconnected
the central panel;
and a mark on the public side of the end closure at the peripheral curl.
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The end closure of the present disclosure may include the previous embodiment
and
optionally an additional mark on the public side of the central panel. In some
embodiments,
the additional mark is partially covered by the tab.
Another aspect of the present disclosure is to provide a method of marking a
continuous sheet of a metallic material for tracking and tracing an end
closure during a
manufacturing process and during the subsequent distribution of the end
closure, comprising
moving the sheet proximate to a marker; forming, by the marker, a mark at an
outer edge of
a blank location of the sheet, wherein the mark includes a unique identifier;
cutting a blank
from the sheet such that the mark is located on a public side of the blank;
forming the blank
into an end shell having a chuck wall extending downwardly from a peripheral
curl, wherein
a countersink is interconnected to a lower end of the chuck wall, and a
central panel is
interconnected to the countersink, wherein the mark is located on the
peripheral curl;
forming the end shell into the end closure; scanning, by a sensor, the mark on
the end closure
to generate a scan event associated with the mark, and transmitting, via a
network, the scan
event to a database where the scan event is used to track and trace the end
closure
One aspect of the present disclosure is to provide a method of marking an end
closure
during a manufacturing process for tracking and tracing the end closure,
comprising cutting
a blank from a continuous sheet of metallic material; forming an end shell
from the blank,
wherein a first mark, formed by a first marker, is located on a product side
of the end shell,
and the end shell has a public side opposing the product side; scanning, by a
first sensor, the
first mark to generate a first scan event associated with the first mark;
conveying the end
shell to a conversion press; forming, by a second marker, a second mark on the
public side
of the end shell; forming, by the conversion press, at least one feature on
the public side of
the end shell to form the end closure; and scanning, by a second sensor, the
second mark to
generate a second scan event associated with the second mark for tracking and
tracing the
end closure
In some embodiments, the first mark is formed by the first marker on a product
side
of the continuous sheet prior to cutting the blank from the continuous sheet.
The method of the present disclosure may include one or more of the previous
embodiments and optionally the first marker is a printer that deposits a food
grade ink on
the product side of the continuous sheet to form the first mark. In some
embodiments, the
printer is an inkjet printer, such as a continuous inkjet printer or a drop on
demand inkjet
printer.
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Optionally, the second marker is a laser that ablates at least a portion of a
coating or
a material of the public side of the end shell to form the second mark.
In some embodiments, the second marker is a printer that uses ink to form the
second
mark. Optionally, the second marker comprises an inkjet printer, such as a
continuous inkjet
printer or a drop on demand inkjet printer.
The method of the present disclosure may include one or more of the previous
embodiments and optionally the second mark is formed by the second marker at
an infeed
of the conversion press.
Additionally or alternatively, the method of the present disclosure may
comprise
forming, by the first marker, a plurality of first marks at blank locations on
a product side
of the continuous sheet; mapping, in a database, the plurality of first marks
to the blank
locations; cutting a plurality of blanks from the continuous sheet; scanning,
by the first
sensor, the plurality of first marks to generate a plurality of first scan
events; and
transmitting, via a network, the plurality of first scan events to the
database where the
plurality of first scan events is associated with the plurality of first marks
and blank locations
to collect data on the manufacturing process and to determine a deficiency in
the
manufacturing process.
The method of the present disclosure may include one or more of the previous
embodiments and optionally further comprise holding, by a transfer belt, the
end shell in a
constant orientation during the forming of the second mark and the forming of
the at least
one feature.
In some embodiments, the second mark is associated with the first mark in a
record
of a database.
The method of the present disclosure may include one or more of the previous
embodiments and optionally further comprise recording, in a record of a
database, the first
mark and associated end shell; transmitting the first scan event to the
database to update the
record with the first scan event, wherein subsequent scan events associated
with the first
mark are used to determine a deficiency in the manufacturing process;
recording, in the
record of the database, the second mark; and transmitting the second scan
event to the
database to update the record with the second scan event.
The method of the present disclosure may include one or more of the previous
embodiments and optionally further comprise scanning, by a sensor of a mobile
device, the
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second mark to generate a mobile scan event to associate the mobile device
with the end
closure.
It is another aspect of the present disclosure to provide an end closure
adapted to be
seamed to an open end of a metallic container for tracking and tracing the end
closure,
comprising a product side and an opposing public side of the end closure; a
chuck wall
extending downwardly from a peripheral curl, wherein a countersink is
interconnected to a
lower end of the chuck wall, and a central panel is interconnected to the
countersink; a tear
panel defined by a score in the central panel; a tab operably interconnected
the central panel;
and a first mark on the product side of the end closure, and wherein the first
mark is formed
of a food grade ink wherein the first mark is adapted to be scanned for
tracking and tracing
the end closure.
In some embodiments, the end closure further comprises a second mark on the
public
side of the end closure, wherein the second mark is formed by an ablated
material on the
public side of the end closure, and the second mark is adapted to be scanned
for tracking
and tracing the end closure.
In some embodiments, a unique identifier of the first mark is distinct from a
unique
identifier of the second mark.
The end closure of the present disclosure may include one or more of the
previous
embodiments and optionally the second mark is formed on at least one of the
peripheral
curl, the tear panel, a tail of the tab, a nose of the tab, the central panel
at least partially under
the tail of the tab, a surface of the tab facing the central panel, a surface
of the tab facing
away from the central panel, and the chuck wall.
The end closure of the present disclosure may include one or more of the
previous
embodiments and optionally the second mark is at least one of: formed on the
tear panel,
and at least partially covered by the tab.
The end closure of the present disclosure may include one or more of the
previous
embodiments and optionally the second mark is on a tail end of the tab.
In some embodiments, the second mark is on a surface of the tab facing the
central
panel of the end closure
Alternatively or additionally, the second mark is on a surface of the tab
facing away
from the central panel of the end closure.
It is an aspect of the present disclosure to provide a method of marking a
continuous
sheet of a metallic material for tracking and tracing metallic workpieces
during a
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manufacturing process and during the subsequent distribution of metallic
containers,
comprising moving the continuous sheet proximate to a marker; forming, by the
marker, a
plurality of marks at blank locations of the continuous sheet, wherein each
mark of the
plurality of marks includes a unique identifier; cutting blanks from the
continuous sheet
such that each blank has a mark from the plurality of marks; forming the
blanks into the
metallic workpieces; scanning, by a sensor, the marks on the metallic
workpieces to generate
a scan event associated with each mark; and transmitting, via a network, the
scan events to
a database where the scan events are used to track and trace the metallic
workpieces.
In some embodiments, the marks are formed at the blank locations at (i) an
infeed
of a press during a dwell period of the continuous sheet; (ii) the infeed of
the press between
dwells periods of the continuous sheet; or (iii) a location upstream of the
infeed of the press
where a continuous feed of the continuous sheet is separated from the dwell
period by a
slack portion of the continuous sheet
In various embodiments, the marker comprises at least one of a laser and a
printer.
In some embodiments, the metallic workpieces are one of a cup, a tab, an end
shell,
and an end closure.
The method of the present disclosure may further comprise cutting, by a
cupper, the
blanks from the blank locations, wherein the metallic workpieces are cups, and
wherein the
cupper forms the blanks into the cups with one of the marks located on a
closed end of each
one of the cups.
Alternatively, the method of the present disclosure may further comprise
cutting, by
a conversion press, the blanks from the blank locations, wherein the metallic
workpieces are
tabs, and wherein the conversion press forms the blanks into the tabs with one
of the marks
located on each one of the tabs.
Alternatively, the method of the present disclosure may further comprise
cutting, by
a shell press, the blanks from the blank locations, wherein the metallic
workpieces are end
shells, and wherein the shell press forms the blanks into the end shells with
one of the marks
located on each one of the end shells.
The method of the present disclosure may further comprise scanning, by a
second
sensor, the marks on the metallic workpieces to generate a second scan event
associated
with each mark; transmitting, via the network, the second scan events to the
database;
determining that one of the metallic workpieces is defective; and identifying
a cause of a
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deficiency in the manufacturing process based on the scan events related to
the defective
workpiece.
The method of the present disclosure may include one or more of the previous
embodiments and optionally each mark of the plurality of marks is located
proximate to an
outer edge of the respective blank location, and the metallic workpieces are
end shells such
that each mark of the plurality of marks is position on a peripheral curl of
the respective end
shell.
In some embodiments, the method further comprises scanning, by the sensor, the
marks to generate the scan event occurs as the plurality of end shells is
arranged in a stack
such that the mark on the peripheral curl of each end shell of the plurality
of end shells is
visible.
In various embodiments, the annular shape of each mark comprises alternating
lines
and spaces that form at least one barcode on the peripheral curl of each end
shell of the
plurality of end shells.
In some embodiments, the annular shape of each mark is on a public side of the
respective end shell.
It is another aspect of the present disclosure to provide a method of marking
a
metallic workpiece for tracking and tracing the metallic workpiece during a
manufacturing
process and during the subsequent distribution of a metallic container,
comprising detecting,
by a sensor, a first orientation of the metallic workpiece used to produce the
metallic
container; reorienting the metallic workpiece from the first orientation to a
second
orientation; stabilizing the metallic workpiece as the metallic workpiece is
moved proximate
to a marker; forming, by the marker, a mark on the stabilized metallic
workpiece, wherein
the mark includes a unique identifier; and scanning, by a sensor, the mark to
generate a scan
event associated with the mark for tracking and tracing the metallic
workpiece.
In various embodiments, the metallic workpiece is one of a tab, a container
body, an
end shell, an end closure, or a tapered cup.
In some embodiments, the marker comprises at least one of a laser and an
inkjet
printer.
The method of the present disclosure may include one or more of the previous
embodiments and optionally further comprise providing a first belt contacting
a first side of
the metallic workpiece, and providing a second belt contacting a second side
of the metallic
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workpiece; and rotating the first belt at a first speed and the second belt at
a second speed,
based on the first orientation, to rotate the metallic workpiece to the second
orientation.
Additionally or alternatively, the method of the present disclosure may
include one
or more of the previous embodiments and optionally further comprise providing
a rotating
plate with at least one servo; positioning the metallic workpiece on the at
least one servo of
the rotating plate; and rotating, by the at least one servo, the metallic
workpiece from the
first orientation to the second orientation.
The method of the present disclosure may include one or more of the previous
embodiments and optionally further comprise providing a stabilization system
having a feed
screw, wherein the feed screw rotates about an axis that is parallel with a
direction of
movement of the metallic workpiece; and contacting, by a thread of the feed
screw, the
metallic workpiece to move the metallic workpiece in a direction perpendicular
to the
movement direction such that the metallic workpiece contacts a surface to
stabilize the
metallic workpiece.
Additionally or alternatively, the method of the present disclosure may
include one
or more of the previous embodiments and optionally further comprise providing
a
stabilization system having a vacuum portion that moves air in a direction
perpendicular to
a direction of movement of the metallic workpiece; and drawing the metallic
workpiece
against the vacuum portion to stabilize the metallic workpiece.
In some embodiments, the marker comprises a continuous inkjet printer at an
end of
a production line prior to the metallic workpiece being packaged, palletized,
and shipped to
a second location.
In various embodiments, the marker comprises a continuous inkjet printer at an
infeed of an inside spray machine, and wherein the method further comprises
spraying a
coating on an interior surface of the metallic workpiece.
Still another aspect of the present disclosure is a metallic container,
comprising. a
body comprising: a closed end; a sidewall extending upward from the closed
end; a neck
located at an upper end of the sidewall; and a first mark on an exterior
surface of the body,
the first mark adapted to be scanned for tracking and tracing the body; and an
end closure
connected to the neck of the body by a seam, comprising: a chuck wall
extending
downwardly from the seam; a countersink interconnected to a lower end of the
chuck wall;
a central panel interconnected to the countersink; a tear panel defined by a
score in the
central panel; a tab operably interconnected the central panel; and a second
mark on a public
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side of the end closure, wherein the second mark is adapted to be scanned for
tracking and
tracing the end closure.
In some embodiments the first mark is formed by an ink.
Alternatively, the first mark is formed by an ablated material on the exterior
surface
of the body.
Optionally, the second mark is formed by an ink.
Alternatively, the second mark is formed by an ablated material on the public
side
of the end closure.
The metallic container may comprise one or more of the previous embodiments,
and
optionally a unique identifier of the first mark is distinct from a unique
identifier of the
second mark
In one or more embodiments, a database comprises a record associated with the
metallic container. A first field of the record includes a first identifier
associated with the
first mark. A second field of the record includes a second identifier
associated with the
second mark.
Optionally, the record comprises a first production identifier to identify a
first
production line that produced the container body.
Additionally, or alternatively, the record may comprise a second production
identifier of a second production line that produced the container body. In at
least one
embodiment, the first production line is at a first geographic location and
the second
production line is at a second geographic location spaced at least 1 km from
the first
geographic location.
In some embodiments, the record comprises an identifier of a filler that
filled the
metallic container and seamed the end closure to the container body.
The metallic container may include any one or more of the previous
embodiments,
and the second mark is optionally formed on at least one of the peripheral
curl, the tear
panel, a tail of the tab, a nose of the tab, a portion of the central panel at
least partially under
the tail of the tab, a surface of the tab facing the central panel, a surface
of the tab facing
away from the central panel, and the chuck wall
In at least one embodiment, the first mark is formed on the closed end of the
body.
Optionally, the closed end of the body comprises a dome. The first mark may be
approximately centered on the dome.
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The Summary is neither intended nor should it be construed as being
representative
of the full extent and scope of the present disclosure. The present disclosure
is set forth in
various levels of detail in the Summary as well as in the attached drawings
and the Detailed
Description and no limitation as to the scope of the present disclosure is
intended by either
the inclusion or non-inclusion of elements, components, etc. in this Summary.
Additional
aspects of the present disclosure will become more clear from the Detailed
Description,
particularly when taken together with the drawings.
The systems, methods, and apparatus of the present disclosure may be used to
apply
marks to workpieces and packaging formed of any material. More specifically,
the systems,
methods and apparatus of the present disclosure may be used to mark, track,
and trace
workpieces, packaging, and container bodies formed of paper and other fibrous
materials,
plastic, glass, metals, and other materials known to those of skill in the
art.
The terms "metal" or "metallic" as used hereinto refer to any metallic
material that
may be used to form a container, including without limitation aluminum, steel,
tin, tin coated
steel, copper, and any combination thereof.
The terms "sensor,- "camera-, and "scanner" may be used interchangeably herein
and generally refer to a device that detects a physical property of an object,
in this instance
a mark or other feature of a metallic workpiece.
Although generally referred to herein as a "container body" or a "metallic
container," it should be appreciated that the methods and apparatus described
herein may be
used in the production of metallic workpieces and metal packaging of any size,
shape, or
type which are used for any purpose. In some embodiments, the metallic
workpieces include
without limitation a metallic beverage bottle, a metallic beverage container,
an aluminum
bottle, a two-piece container, a two-piece can, a can, an aerosol container, a
three-piece
container (for example, a food can), or a metal cup (such as a tapered cup).
As used herein,
a "container body" can be formed into any type of container or vessel for a
product The
product may be a liquid or a solid. In some embodiments, the product may be a
beverage
or a food. The produce may also be a personal care item such as deodorant,
sunscreen, hair
spray, and the like. In some embodiments, the product may be from a plant.
A container body generally includes a closed endwall, a sidewall, and an open
end.
In some embodiments the endwall includes a dome. When present, the dome is
positioned
inward of a standing surface or "stand ring" formed on the closed end wall.
Alternatively,
the endwall may be generally planar. The sidewall may be generally
cylindrical.
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Alternatively, the sidewall is tapered such that the open end has a larger
diameter than the
closed endwall. In some embodiments, container body includes a neck between
the sidewall
and the open end.
References made herein to "end closures," or "container end closures" should
not
necessarily be construed as limiting the present invention to a particular
size, shape, or type
of end closure. It will be recognized by one skilled in the art that the
systems and methods
of the present disclosure may be used to form a mark on an end closure of any
variety, size,
or type, including end closures with one or more pour or vent openings or
other areas or
features. An end closure may comprise one or more of, but is not limited to: a
peripheral
curl, a chuck wall extending downwardly from the peripheral curl, a
countersink
interconnected to a lower end of the chuck wall, a central panel
interconnected to the
countersink, a tear panel in the central panel, and a tab operably
interconnected to an exterior
surface of the central panel In some embodiments, the tab is interconnected to
the central
panel by a rivet. As used herein, an end shell refers to an incomplete end
closure such as at
a point of production before the rivet is interconnected to the central panel.
The public side
of an end closure refers to the side that the public interacts with. The
product side of the
end closure refers to the side that will be contact with product when the end
closure is
interconnected to a container body.
The terms "sheet" and "continuous sheet" may refer to a piece of material that
has a
length greater than 100 feet (30.5 meters). The sheet may also be referred to
as continuous
web of material. The sheet is rolled to form a coil, and a coil is unrolled to
provide a sheet.
The systems and methods of the present disclosure may be used with a container
body formed by any method known to one of skill in the art. For example, a
container body
may be formed by a draw and ironing process or by an impact extrusion process.
Alternatively, a container body can be formed by a blow molding process or by
injection
molding.
The phrases "at least one," "one or more," and "and/or," as used herein, are
open-
ended expressions that are both conjunctive and disjunctive in operation. For
example, each
of the expressions "at least one of A, B and C," "at least one of A, B, or C,"
"one or more
of A, B, and C," "one or more of A, B, or C," and "A, B, and/or C" means A
alone, B alone,
C alone, A and B together, A and C together, B and C together, or A, B and C
together.
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The term "a" or "an" entity, as used herein, refers to one or more of that
entity. As
such, the terms "a- (or "an"), "one or more" and "at least one" can be used
interchangeably
herein.
Unless otherwise indicated, all numbers expressing quantities, dimensions,
conditions, ratios, ranges, and so forth used in the specification and claims
are to be
understood as being modified in all instances by the term -about" or -
approximately".
Accordingly, unless otherwise indicated, all numbers expressing quantities,
dimensions,
conditions, ratios, angles, ranges, and so forth used in the specification and
claims may be
increased or decreased by approximately 5% to achieve satisfactory results.
Additionally,
where the meaning of the terms "about" or "approximately" as used herein would
not
otherwise be apparent to one of ordinary skill in the art, the terms "about"
and
"approximately" should be interpreted as meaning within plus or minus 10% of
the stated
value
Unless otherwise indicated, the term "substantially" indicates a different of
from 0%
to 5% of the stated value is acceptable.
All ranges described herein may be reduced to any sub-range or portion of the
range,
or to any value within the range without deviating from the invention. For
example, the
range "5 to 55" includes, but is not limited to, the sub-ranges -5 to 20" as
well as "17 to 54."
The use of "including," "comprising," or "having" and variations thereof
herein is
meant to encompass the items listed thereafter and equivalents thereof as well
as additional
items. Accordingly, the terms "including," "comprising," or "having" and
variations thereof
can be used interchangeably herein.
It shall be understood that the term "means" as used herein shall be given its
broadest
possible interpretation in accordance with 35 U.S.C., Section 112(f).
Accordingly, a claim
incorporating the term "means" shall cover all structures, materials, or acts
set forth herein,
and all of the equivalents thereof. Further, the structures, materials, or
acts and the
equivalents thereof shall include all those described in the Summary, Brief
Description of
the Drawings, Detailed Description, Abstract, and Claims themselves.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of
the
specification, illustrate embodiments of the disclosed system and together
with the general
description of the disclosure given above and the detailed description of the
drawings given
below, serve to explain the principles of the disclosed system(s) and
device(s).
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Fig. 1 illustrates a closed endwall of a container body showing a prior art
mark made
by a bodymaker during production of the container body;
Fig. 2A is a schematic illustration of a production line according to
embodiments of
the present disclosure;
Fig. 2B is a schematic illustration of a sorting system according to the
present
disclosure;
Fig. 3A is a bottom plan view of a portion of the production line of Fig. 2A;
Fig. 3B is a top plan view of an orientation system comprising a belt
according to
the present disclosure;
Fig. 3C is a top plan view of another orientation system comprising a
rotatable plate
according to the present disclosure;
Fig. 3D is a top plan view of a stabilization system comprising a feed screw
according to the present disclosure;
Fig. 3E is a side elevation view of the stabilization system in Fig. 3D,
Fig. 3F is a top plan view of another stabilization system comprising a star
wheel
according to the present disclosure;
Fig. 3G is a side elevation view of a vacuum stabilization system according to
the
present disclosure;
Fig. 3H is a top plan view of another stabilization system according to a
present
disclosure;
Fig. 31 is a side elevation view of the stabilization system of Fig. 3H;
Fig. 3J is a flowchart for marking a product side and a public side of an end
closure
according to a present disclosure;
Fig. 3K is a bottom plan view of an end closure formed by the process shown in
Fig.
3J;
Fig. 3L is a top plan view of the end closure in Fig. 3K;
Fig. 3M is a flowchart for marking a metallic workpiece prior to a cupper
according
to a present disclosure;
Fig. 3N is a flowchart for marking a container body prior to an inside spray
machine
according to a present disclosure;
Fig. 30 is a flowchart for marking a tab prior to a conversion press according
to a
present disclosure;
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Fig. 3P is a flowchart for marking a container body prior to a palletizer
according to
a present disclosure;
Fig. 4A illustrates a mark formed on a closed end of a container body
according to
embodiments of the present disclosure;
Fig. 4B is an enlarged illustration of the mark of Fig. 4A;
Fig. 5 is a schematic illustration of a system to track and trace a container
body;
Fig. 6 is a block diagram of a control system according to embodiments of the
present disclosure; and
Fig. 7 is a block diagram of an embodiment of a data structure for storing
data about
a container body.
The drawings are not necessarily (but may be) to scale. In certain instances,
details
that are not necessary for an understanding of the disclosure or that render
other details
difficult to perceive may have been omitted It should be understood, of
course, that the
disclosure is not necessarily limited to the embodiments illustrated herein.
As will be
appreciated, other embodiments are possible using, alone or in combination,
one or more of
the features set forth above or described below. For example, it is
contemplated that various
features and devices shown and/or described with respect to one embodiment may
be
combined with or substituted for features or devices of other embodiments
regardless of
whether or not such a combination or substitution is specifically shown or
described herein.
The following is a listing of components according to various embodiments of
the
present disclosure, and as shown in the drawings:
Number Component
2 Container body
4 Closed end or dome of container body
6 Mark
10 Production line
12 Uncoiler
14 Sheet
16 Arrow showing direction of movement
18 Portion of sheet
20 Blank location where a cup will be formed
22 Cupper
24 Marker
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26 Mark
28 Indicia
30 Space
32 Conveyor
34 Sensor
36 Bodymaker
38 Washer
40 Dry-off Oven
42 Basecoater
44 Basecoat oven
46 Decorator
48 Deco Oven
50 Internal coater
52 Internal Bake Oven
54 Die necker
56 Flanger
57 Inspection station
58 Sorter
59 Palletizer
60 Storage
61 De-palletizer
62 Filler
64 Point of Sale
66 Consumer
68 Collection Point
70 X-axis (corresponding to a length of a sheet)
72 Y-axis (corresponding to a width of a sheet)
100 Control system
102 Bus
104 CPU
106 Input devices
108 Output devices
110 Storage devices
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112 Computer readable storage media reader
114 Communication system
116 Working memory
118 Processing acceleration unit
120 Database
122 Network
124 Remote storage device/database
126 Operating system
128 Other code
130 Data structure
132 First data object
134 Second data object
136 Ellipses
138 Ellipses
140 Record
142 Identifier
144 Production date
146 Production time
148 Production location
150 Production line identifier
152 Cupper identifier
154 Other equipment
200 Orientation System
202 Container Body
204a, 204b Initial, Final Orientations
205 Reference Line
206 Sensor
208 Electronic Device
210a, 210b Belts
212 Orientation System
214 Infeed
216 Sensor
218 Electronic Device
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220 Plate
221 Rotation Direction
222 Servo
'4 Outfeed
226 Stabilization System
228 Cage
230 Container
232 First Direction
234 Second Direction
236 Feed Screw
238 Marker
240 Inspection System
242 Ejector System
244 Gap
246 Third Direction
248 Stabilization System
250 Container
252 Star Wheel
254 Marker
256 Scanner
258 Pneumatic System
260 Stabilization System
262 Container
264 Vacuum Conveyance System
266 Marker
268 Scanner
270 Pneumatic System
272 Stabilization System
274 Cage
276 Container
278 First Direction
280 Second Direction
282a, 282b Side Grip
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284 Marker
286 Scanner
288 Pneumatic System
290 Process
292 Form First Mark
294 Cut Blank
296 Scan First Mark
298 Feed Transfer Belt
300 Form Second Mark
302 Form Feature
304 Scan Second Mark
306 End Closure
308a, 308b Mark
310 Peripheral Curl
312 Chuck Wall
314 Countersink
316 Central Panel
318 Score
320 Rivet
322 Tab
324a-c Mark
326 Process
328 Form Mark
330 Feed Cupper
332 Cut Blank
334 Form Cup
336 Process
338 Form Mark
340 Feed Inside Spray Machine
342 Process
344 Form Mark
346 Feed Conversion Press
348 Cut Blank
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350 Form Tab
352 Process
354 Form Mark
356 Palletize
DETAILED DESCRIPTION
Referring now to Fig. 2A, a schematic illustration of a production line 10
according
to embodiments of the present disclosure is generally illustrated. The
production line
produces container bodies by a draw and wall ironing (DWI) process.
The production line has an uncoiler 12 that unwinds a coil of a continuous
sheet 14
of a metal material. The metal material may be an aluminum alloy or any other
metallic
material (such as a steel or a tin coated steel) used to form container
bodies. The continuous
sheet has a length extending in a X-direction and a width (in a Y-direction)
between a first
long edge and an opposite second long edge. As will be appreciated by one of
skill in the
art, the length of the continuous sheet 14 is substantially longer than its
width.
The uncoiler 12 feeds the sheet 14 in a direction indicated by the arrow 16
into a
cupper 22. The cupper cuts circular blanks from the sheet 14 and forms the
blanks into cups.
The sheet 14 is fed or drawn into the cupper 22 incrementally after each
stroke of the cupper.
Accordingly, there is a dwell period between each stroke of the cupper during
which the
sheet 14 is generally stationary. Some cuppers operate at up to 250 strokes
per minute and
may form 12 to 16 cups per stroke. A typical cupper forms eight cups in one or
more rows
across the width of the sheet during each cycle.
Although only one cupper is illustrated in Fig. 2A, some production lines 10
have
two or more cuppers. Accordingly, during a single production run, the
production line may
have container bodies created from sheets 14 of two or more coils of metallic
material.
Similarly, although only one uncoiler 12 is illustrated, the production line
10 may have any
number of uncoilers.
In some embodiments, the production line does not have any uncoilers or
cuppers.
In these embodiments, blanks with marks are introduced into the production
line and formed
into a container body by a bodymaker.
In some embodiments, the coil loaded in the uncoiler 12 includes a plurality
of
unique marks 26 formed on the sheet 14. The marks are formed at a plurality of
blank
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locations 20 (illustrated in Fig. 3A) where blanks for cups will be cut by a
cupper 22.
Specifically, the marks 26 may be formed before the coil is loaded into the
uncoiler.
In some embodiments, the marks are formed by a marker in a production facility
that
includes the production line 10. However, in some embodiments, the marks are
formed on
the sheet 14 before the coil is delivered to the production facility.
Alternatively, in some embodiments, a marker 24 according to embodiments of
the
present disclosure is positioned in the production line 10 between the
uncoiler 12 and the
cupper 22. In embodiments, the marker 24 is positioned up-line of an infeed of
the cupper
22.
The marker 24 is operable to form a mark on at least one side of the sheet 14
before
it is fed into the cupper. In some embodiments, the marks 26 are formed on a
side of the
sheet that will form an exterior surface (or "public side") of the container
bodies.
Alternatively, the marks 26 are formed on a side of the sheet that will form
an interior
surface (or "product side") of the container bodies 2.
Optionally, the marker 24 can form the mark 26 at two or more portions of each
blank location 20. In this manner, each container body 2 may have the unique
mark 26 at
two or more locations.
In some embodiments, the marker 24 forms marks on only a first side of the
sheet.
Alternatively, in other embodiments, the marker 24 forms marks on only a
second side of
the sheet. In still other embodiments, the marker 24 forms marks on both the
first and second
sides of the sheet.
The marker 24 is configured to form a mark 26 at each blank location 20 where
the
cupper 22 will form a cup. More specifically, and referring now to Fig. 3A,
the marker 24
is configured to form a mark 26 in each location 20 of the sheet 14 that will
be formed into
a cup by the cupper 22. In various embodiments, a plurality of markers 16 form
marks 26
at multiple locations 20 of the sheet 14 to maintain a production speed of the
sheet 14. For
example, sixteen markers 16 can be arrayed across a width (or Y-dimension 72)
of the sheet
to simultaneously, or nearly simultaneously, mark sixteen blank locations 20,
in this
instance, 3a-3p. Thus, in a given marking sequence, each marker 26 will apply
a mark with
a unique identifier to one location 20 of the sheet 14. It will be appreciated
that sixteen
markers 24 is only exemplary in nature. In some embodiments where both of a
product side
and a public side of a sheet are simultaneously marked, thirty two markers 24
are used, and
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generally, embodiments of the present disclosure encompass any number of
markers 24 in
any configuration to form marks 26 on the sheet.
In some embodiments, the marker 24 is configured to form the mark 26 on any
portion of a blank location 20 that will subsequently define the closed bottom
end of a
metallic container. In some embodiments, the marker 24 will form the mark on a
portion of
the blank location that is offset from a center of the closed bottom end.
Additionally, or
alternatively, the marker may for the mark 26 at approximately a center of
each blank
location 20. Positioning the marks in approximately a center of each cup
location 20
beneficially ensures the marks will be approximately centered on the closed
bottom ends of
metallic containers formed by the production line 10.
Locating the mark 26 on a closed bottom end of a container body is
advantageous
for several reasons. First, in some container bodies, the closed bottom end
includes a dome
that is recessed inwardly. A mark 26 positioned on the bottom dome is
generally protected
from abrading or wearing forces that may render the mark incapable of being
read by a
sensor. In addition, when metallic containers are crushed to a smaller size,
they are
frequently crushed along a length of the container body, leaving the closed
bottom end intact
and substantially unchanged.
Forming the mark 26 such that it is approximately centered on a blank location
20
is also beneficial because during cupping by the cupper 22 (and in an ironing
process
performed by a bodymaker 36) the closed end 4 of the container body 2
experiences little
deformation. Accordingly, a mark 26 formed at a position of the blank location
20 that is
subsequently formed into the closed end means that the mark experience little
(or no)
deformation and degradation by operations performed by the cupper 22 or the
bodymaker
36.
Another benefit of locating the mark 26 of the present disclosure on the
closed
bottom end is that the closed bottom end is not typically decorated. In
contrast, the
cylindrical sidewall of a container body is frequently decorated with inks or
coved by a
label. Accordingly, by positioning the mark on the closed bottom end, the mark
is not
covered by decoration and labels and does not detract from decorations formed
on the
cylindrical sidewall.
Moreover, a mark 26 positioned on the closed bottom end is easier to detect
with a
sensor 34 as a container body is transported on a conveyor 32. For example, as
will be
appreciated by one of skill in the art, some conveyors 32 of the production
line transport a
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plurality of container bodies tightly packed together with either the closed
bottom ends or
the open ends facing the conveyor. Accordingly, a sensor positioned above or
below the
conveyor can scan the mark on the closed bottom end of a container body.
In contrast, the cylindrical sidewalls of the container bodies may be
contacting the
cylindrical sidewalls of several other container bodies. Accordingly, a mark
formed on the
cylindrical sidewall of a container body is frequently obstructed by other
container bodies
and blocked from view of a sensor.
In some embodiments, the marker 24 may form the mark 26 on a portion of a
blank
location 20 that will form a closed end 4 of a container body 2. Additionally,
or
alternatively, the marker 24 can form the mark 26 on a portion of a blank 20
location that
will form a sidewall or cylindrical portion of a container body 2. The mark 26
may be
formed on a side of the sheet that will subsequently define an exterior
surface (the "public
side") or an interior surface (the "public side") of the container body
Optionally, a first marker 24 is positioned to form a first mark 26 on a first
side of a
first blank location 20 of the continuous sheet 14. A second marker 24 is
positioned to form
the same first mark 26 on a second side of the first blank location 20 of the
continuous sheet.
In this manner, in some embodiments, the first mark 26 may be formed on both
sides of the
continuous sheet of the first blank location 20 where a blank will be cut from
the continuous
sheet. Accordingly, a container body 2 may have the first mark 26 positioned
on its exterior
surface. The same first mark 26 can be repeated on an interior surface of the
container body
2.
Optionally, the first mark formed on the first side of the first blank
location 20 is
positioned approximately opposite to a position of the first mark formed on
the second side
of the first blank location. Alternatively, the first mark on the first side
is offset from the
first mark on the second side. In this manner, the first mark may be
positioned on a closed
end on a first surface of the container body and the first mark can be
positioned on a sidewall
on a second surface of the container body.
In some embodiments, the marker 24 forms the marks for each cup location 20
during each cycle of the cupper 22. Optionally, the marker 24 forms the marks
26 while the
sheet 14 is stationary. For example, the marker 24 may form the marks during a
dwell
period during which the continuous sheet 14 is not advanced into the cupper
22.
Accordingly, in some embodiments, the continuous sheet is generally stationary
when the
marks 26 are formed.
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In some embodiments, the marker 24 is operable to form the marks 26 while the
continuous sheet 14 is moving. For example, the marker 24 may be configured to
move
with the continuous sheet. In some embodiments, the marker can be pointed or
steered such
that the mark is formed as the continuous sheet is moving.
Additionally, or alternatively, in some embodiments the marker includes a
laser that
can be pointed to form a mark 26 while the sheet is moving. In some
embodiments, the
marker 24 includes a mirror or lens to steer a beam from the laser against the
sheet 14 as the
sheet moves.
Accordingly, in some embodiments, the marker 24 may form the mark 26 while the
continuous sheet 14 is stationary, while the continuous sheet 14 is moving, or
while the
continuous sheet is both stationary and moving.
Referring now to Fig. 3A, in one embodiment, all the marks 26A formed in a
first
portion 18A of the sheet are formed substantially simultaneously by the marker
Similarly,
the marks 26B in the second portion 18B are formed substantially
simultaneously. A third
portion 18C of the sheet is generally illustrated as being aligned with the
marker 24 for
forming marks 26C.
The marks 26 are unique for each cup location 20 that will be cut from the
sheet 14
by the cupper 22. In some embodiments, a control system 100 is in
communication with
the marker 24. The control system 100 may generate the marks that the marker
forms on
the sheet.
In some embodiments, each mark 26 comprises a unique code that identifies one
container body 2. The mark may be a unique series of numbers. In some
embodiments that
mark is an alpha numeric code.
Optionally, each mark 26 may include one or more of: (a) a unique identifier
for the
container body; (b) a production date; (c) a production time; (d) a production
location; (e) a
production line identifier; (f) a batch number; (g) a shift identifier; (h)
material
specifications of the sheet (such as the type of aluminum alloy or other
material in the sheet);
(i) an identifier for the manufacturer of a coil from which the sheet is
unwound; (j) an
identifier or serial number of the coil; (k) a position of the mark on the
sheet (such as an X,
Y coordinate of the position of the mark); (1) a mass of the container body;
and (m) a name
of the filler or other customer that ordered the container body.
The marks 26 may comprise any combination of indicia, letters, numbers,
symbols,
spaces (or blank areas), and machine readable codes arranged in any order or
orientation
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and of any size. In some embodiments, the marks 26 are data matrix codes, bar
codes, quick
response (QR) codes, and the like.
Referring now to Figs. 3B and 3C, examples of orientation systems are
provided.
Fig. 3B shows an orientation system 200 that comprises at least one belt, and
Fig. 3C shows
an orientation system 212 that comprises a rotating plate and servo. These
orientation
systems change the orientation of a metallic workpiece prior to marking to
ensure that a
mark is applied to the desired location on the metallic workpiece such that
the mark does
not interfere with other features on the metallic workpiece, or features that
will be formed
on the metallic workpiece. While the orientation systems in these figures show
container
bodies being oriented about a longitudinal axis for marking, it will be
appreciated that
orientation systems can reorient any metallic workpiece described herein in
any direction.
Fig. 3B is a top plan view of an orientation system 200 that changes an
orientation
of a container body 202 from a first orientation 204a to a second orientation
204b prior to
marking the container body 202, which ensures that marks are consistently
applied to the
same location on container bodies. This change in orientation 204a, 204b is
shown by a
reference line 205. Orientation in this embodiment means the orientation of a
container body
about a longitudinal or vertical axis. As container bodies 202 approach the
orientation
system 200, the container bodies 202 can be conveyed via a belt system, a cage
system, etc.
where the container bodies 202 are in random orientations. Yet, the container
bodies 202
need to be in a particular orientation prior to marking.
In some embodiments, a camera 206 or other sensor detects a first orientation
204a
of a container body 202 prior to the container body 202 contacting a pair of
belts 210a, 210b
of the orientation system 200. The camera 206 relays image data to an
electronic device 208
(such as the control system 100) that determines the first orientation 204a of
the container
body 202. Specifically, the image of the incoming container body 202 is
compared to a
reference image to determine the first orientation 204a. For example, if the
container body
202 has a mark or decoration on an outer surface, then the electronic device
208 compares
the mark or decoration to one or more reference images to determine if the
container body
202 is 5 degrees, 43 degrees, 163 degrees, etc. out of alignment from the
proper, second
orientation 204b for marking. Alternatively or in addition, a mark or
decoration inside of
the container body 202 is used to determine the orientation of the container
body 202.
Once the first orientation 204a is determined, the electronic device 208
directs two
belts 210a, 210b to change the orientation of the container body 202 from the
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orientation 204a to a second orientation 204b. The belts 210a, 210b are
positioned on either
side of the container body 202, and the surface of each belt 210a, 210b that
contacts an outer
surface of the container body 202 generally moves in the same direction as the
flow of
container bodies 202. However, the belts 210a, 210b each vary their respective
rotation
speed to reorient a container body 202. For example, if the first orientation
204a of the
container body 202 must be reoriented by 15 degrees in a clockwise direction
to meet the
second orientation 204b, then the first belt 210a rotates faster than the
second belt 210b, on
a relative basis, to rotate the container body 202 as the container body 202
passes by the
belts 210a, 210b. When, incidentally, the first orientation 204a of the
container body 202 is
equal to the second orientation 204a, then the belts 210a, 210b idle allowing
the container
body 202 to pass by. In other words, the belts 210a, 210b rotate at the same
speed to ensure
that the container body 202 exits the belts 210a, 210b at the proper, second
orientation 204b.
Fig 3C shows another orientation system 212 where a servo changes the
orientation
of a container body. The orientation system 212 has an infeed 214 to take in
container bodies
that have random or undesirable orientations and has an outfeed 224 to convey
container
bodies with a uniform or desirable orientation. Like the orientation system
200 in Fig. 3B,
the orientation system 212 in Fig. 3C has a camera 216 and an electronic
device 218 (such
as the control system 100) that determine the first or initial orientation of
a container body
as the container body passes through the infeed 214. The container body is
then conveyed
on, for example, a plate 220 or turntable that has at least one servo 222. The
container body
is held in place by a vacuum system on the servo 222. The vacuum system draws
air through
at least one opening to draw a container body against the servo 222. As the
plate 220 moves
in a rotational direction 221, the electronic device 218 directs the servo 222
to reorient the
container body from the first orientation to a second orientation. The servo
222 can be any
electromagnetic servomechanism device that converts electricity or electrical
signals into
physical motion, in this case, rotational motion. After rotating to the
proper, second
orientation, the vacuum system releases the container body, which exits the
plate 220 and
servo 222 and is conveyed away from the orientation system 212 at the outfeed
224. While
a plate 220 is shown in Fig. 3C, other devices like a star wheel can be used
to locate servos
or other devices for reorienting container bodies.
Referring now to Figs. 3D-3I, examples of stabilization systems are provided.
Figs.
3D and 3E show a stabilization system 226 that comprises a feed screw, Fig. 3F
shows a
stabilization system 248 that comprises a star wheel, Fig. 3G shows a
stabilization system
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260 that comprises a vacuum conveyance system, and Figs. 3H and 31 show a
stabilization
system 272 with a side gripper system. The stabilization systems hold a
metallic workpiece
to reduce random movement such as jostling while the marker applies a mark to
the metallic
workpiece. The reduction in random movement results in a clearer and more
legible mark
that is more easily scanned in subsequent actions. While the stabilization
systems in these
figures show container bodies being stabilized for marking, it will be
appreciated that
stabilization systems can stabilize any metallic workpiece described herein.
Figs. 3D and 3E show a stabilization system 226 that stabilizes a container
body 230
to reduce random movement like jostling as a marker 238 applies a mark to the
container
body 230. The stabilization system 226 in this embodiment utilizes a feed
screw 236 to
receive and stabilize container bodies 230. Specifically, the container bodies
230 move in,
for instance, a cage system 228 in a first direction 232. The longitudinal
axes of the container
bodies are oriented in a second direction 234 that is perpendicular to the
first direction 232
The feed screw 236 in this embodiment has a threaded outer surface, and the
feed screw 236
rotates about an axis oriented in the first direction 232. As a container body
230 enters the
feed screw 236, the container body 230 is positioned between adjacent peaks or
ridges of
the threaded outer surface, the feed screw 236 at least partially displaces
the container body
230 in a third direction 246 that is perpendicular to both the first and
second directions 232,
234. The displacement braces the container body 230 against a wall or part of
the cage
system 228 to stabilize the container body 230 such that a marker 238 can
apply a clear
mark to the container body 230.
The wall 228 may be generally planar. The wall extends in the first direction
232
substantially parallel to the rotation axis of the feed screw. Optionally, the
feed screw 236
may brace the container body 230 against a belt that moves at the same rate as
the feed
screw 236 to prevent the container body 230 from rotating as the container
body 230 is
stabilized.
After the mark is formed and the marked container body is discharged from the
feed
screw 236, a scanner 240 detects or takes a picture of the mark to determine
if the mark
meets predetermined standards. If not, an ejector 242 selectively rejects the
container body
230 with the substandard mark out of a gap 244 in the cage system 228. In some
embodiments the ejector 242 has an actuator that pushes rejected container
bodies through
the gap. Alternatively, the ejector 242 may comprise a pneumatic system that
blows rejected
container bodies through the gap.
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Fig. 3F shows a stabilization system 248 that comprises a star wheel 252.
Container
bodies 250 flow in a conveyor (for example, a cage system) to a star wheel 252
that at least
partially extends into the cage system to receive the container bodies 250.
Once a container
body 250 is positioned in a recess in the star wheel 252, any random movement
is eliminated
or at least significantly reduced. As the star wheel 252 rotates the container
body 250, a
marker applies a mark to the container body 250. Then a scanner 256 reads the
mark to
determine if the mark meets predetermined standards. Like the embodiment
described in
Figs. 3D and 3E, an ejector 258 (such as a pneumatic system) selectively
rejects a container
body 250 with a substandard mark.
Fig. 3G shows a stabilization system 260 that comprises a vacuum conveyance
system 264. Air is drawn through at least one aperture in the vacuum
conveyance system
264 so that container bodies 262 passing through, for example, a cage system
are drawn to
the vacuum conveyance system 264 In some embodiments, air is drawn through a
mesh
belt as described herein. This reduces random movement such as jostling of the
container
bodies 262 and allows a marker 266 to apply a clear and legible mark on the
container body
262. In addition, a scanner 268 reads and assesses the mark, and a pneumatic
system 270
selectively rejects a container body 262 with a substandard mark. Fig. 3G
generally
illustrates the containers 262 oriented with their cylindrical sidewalls
proximate to the
vacuum conveyance system 264. However, in other embodiments, the stabilization
system
260 is configured to process containers with either a closed end or an open
end oriented
proximate to the vacuum conveyance system.
Figs. 3H and 31 show a stabilization system 272 that grips container bodies
276 to
reduce movement such as jostling. Container bodies 276 are conveyed in a cage
system 274
in a first direction 278, and the longitudinal axes of the container bodies
276 are oriented in
a second direction 280 that is perpendicular to the first direction 278. As
the container bodies
276 move into the stabilization system 272, protrusions 282a, 282b approach
and contact
the container bodies 276 from opposing sides to reduce movement. In some
embodiments,
the protrusions 282a, 282b contact a container body 276 at a lower location
near the closed
end as this part of the container body 276 is more rigid. This stabilization
system 272 has
the additional benefit of stabilizing container bodies individually where one
pair of
protrusions 282a, 282b contacts one container body 276. Thus, the protrusions
282a, 282b
may contact a container body 276 in a different manner depending on the amount
of
movement of the container body 276. For instance, if a container body 276 has
a large
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amount of movement, the protrusions 282a, 282b may contact the container body
276 at a
slower speed to reduce the likelihood of damaging the container body 276.
Then, a marker
284 applies a mark to the container body 276. The individual nature of the
stabilization also
improves the timing with respect to the marker 284 as the container body 276
is always
exactly positioned between two protrusions 282a, 282b. As in other
stabilization systems, a
scanner 286 assesses the marks, and an ejector 288 selectively rejects a
container body 276
with a substandard mark.
Referring now to Figs. 3J and 3M-3P, examples of flowcharts for various
marking
systems and processes are provided. While these figures show an order of
actions performed
during a process, it will be appreciated that these actions can be performed
in any order.
Moreover, it will be appreciated that the marking action can be performed at
any location in
a production line of a manufacturing process from the coil to the finished
product, as
described herein, or even at subsequent locations and/or processes Fig_ 3J
shows a flowchart
290 for marking a product side and a public side of an end shell, and an
example of such an
end shell is shown in Figs. 3K and 3L. A mark on the product side of the end
shell allows
the end shell to be tracked and traced during the manufacturing process. The
mark can be
scanned at different points in a production line, and then the resulting data
is compiled in
one or more records at a database to determine any deficiencies in the sheet
material,
machines in the production line, etc.
To begin, unique first marks are formed 292 at known, blank locations on a
product
side of a metallic sheet. Accordingly, a record of a first mark and its
location can be created
in a database without the need to scan the first mark. This record can be
created before,
during, or after the actual formation of the first mark on the metallic sheet.
Thus, the marks
are mapped to the known, blank locations on the metallic sheet in the
database.
The marker is an inkjet printer that applies a food grade ink to the sheet to
form the
first marks. In some embodiments, the marker is a continuous inkjet printer,
or a drop on
demand inkjet printer. It is not obvious to mark the product side of a
metallic workpiece as
this side of the metallic workpiece defines the interior of the resulting
container that contacts
contents consumed by humans, and disruptions to the product side can
negatively impact
the contents. For example, a marker that disrupts a protective liner or
coating on the product
side can render the liner or coating ineffective. Similarly, a marker that
disrupts the metallic
material can cause oxidation or other processes that render the contents unfit
for human
consumption. However, an inkjet printer can deposit a food grade ink that does
not degrade
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the liner or coating or otherwise render the contents of the container unsafe
for human
consumption. While an inkjet printer is shown and described, it will be
appreciated that the
marker can be any type of marker described herein.
Blanks are then cut 294 from the sheet and formed into end shells by a shell
press.
Each end shell has a unique first mark on a product side. Next, the first mark
of each end
shell, or at least some of the end shells, is scanned 296 at a subsequent
point in the
production line to generate a scan event. This scan event is transmitted to a
database 120,
124 via a network where the record associated with the first mark is updated
to include the
scan event. Subsequent scan events of the first marks are also transmitted to
the database
and stored in records where compiled data can be used for a subsequent
analysis. For
example, if blanks from one side across or along the width in the Y-dimension
72 of the
metallic sheet result in substandard end shells, there may be an issue with a
coiling process,
an uncoiling process, an indexing process, etc Similarly, if all blanks from a
particular
metallic sheet result in substandard end shells, there may be an issue with
the quality of the
material used to make the metallic sheet. At a shell press, unacceptably
shallow features
such as a panel or countersink are traced to a deficient component of the
shell press like, for
example, a pneumatic system for operating components of the shell press.
Likewise, poor
trimming on an outer edge of an end closure is traced to a deficient component
in the
production line.
At balancers, for instance A Balancers or B Balancers, end shells are arranged
in
stacks and the end shell at one end of the stack is exposed such that a mark
on this end shell
is read by a scanner. All end shells between this exposed end shell and the
exposed end shell
of the previous and/or subsequent scan are therefore known to the database.
For instance,
the end shells can be loaded into a stack in the same sequence that the end
shells were
marked. In another example, a scanner detects the marks on the end shells as
the end shells
are loaded into a stack, and therefore, the end shells between consecutive
scans are known
to the database. The entire stack of end shells can be dispositioned for a
warehouse,
positioned on a tray, loaded into a downstream process such as a conversion
press, etc., and
the database tracks and traces each end shell at these locations. For example,
each
conversion press in a production line may have four lanes, and a score tool
may be
improperly shimmed or machined which creates defective end closures that will
not open.
With a subsequent scanning and cataloging of end closures and marks in one or
more records
at the database, the defective tool is quickly identified and fixed.
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At a filler, a customer optionally associates a mark on an end closure or
container
body with a particular seam head that filled a container. Therefore, data like
carbonation
level, product temperature, etc. is captured and associated with the mark. In
addition, at a
seamer, cameras inspect the shape of the sealant on the end closure that
presses against an
end of a container body to form the finished container. These cameras also
detect one or
more marks on the end closure or container body and associate, for instance, a
lower amount
of sealant with one or more end closures. An exemplary production line can
have six liner
machines with each liner machine having six guns that deposit the sealant on
the end
closures. Based on data collected in one or more records at a database, low
sealant weights
are tracked and traced to a liner machine and a particular gun, which is then
fixed. Similar
associations are optionally made at a pasteurizer with pasteurization and/or
retort conditions
and at a packager at the filler. These situations and analyses are exemplary
in nature, and
embodiments of the present disclosure encompass further uses and analyses of
data from
the marks and scan events.
After forming the first mark on the product side of the end shell, a second
mark is
formed on a public side of the end shell. The first mark is used for tracking
and tracing
during a manufacturing process, and the second mark is used for tracking and
tracing a
finished container after the manufacturing process such as at a filler, a
distributor, a retainer,
and/or an end user. As described herein, a user may scan the second mark with
a camera of
a mobile device to associate the second mark and a container with the mobile
device to, for
instance, incentive and track recycling of the container. These marks may not
be exclusively
used for these purposes. For instance, the second mark can be used for
tracking and tracing
during a manufacturing process too. The location of the first mark on the
product side of the
end shell can be useful as a mark on this location is less likely to interfere
with forming
actions applied to the public side of the end shell during the manufacturing
process.
Moreover, at some points during the manufacturing process such as during a
conveyance
the product side may be the only side readily visible, and thus, the first
mark can be scanned
to generate a scan event without a costly and complex operation to flip or
reorient the end
shell.
In some embodiments, the second mark is formed at a conversion press,
including
at the infeed of the conversion press. First, the end shell is fed 298 into a
recess of a transfer
belt of the conversion press. The transfer belt is made from a pliable
material, and therefore,
the end shell is held in the recess and kept in a constant orientation through
the conversion
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press. This aspect of the transfer belt can also advantageously avoid the need
for orientation
and stabilization systems since the end shell is held in a constant
orientation and stably. The
transfer belt moves periodically because a dwell period is associated with the
conversion
press as the various tools of the conversion press interact with the end
shell. In some
embodiments, the dwell period is between 0.03 and 0.08 seconds. A marker such
as a laser
or an inkjet printer can be positioned at the infeed location of the
conversion press where
the laser forms 300 the second mark during the dwell period on a predetermined
area of the
public side of the end shell. The laser partially ablates material on the
public side of the end
shell to form the second mark, and the material can be a coating, a varnish,
or even part of
the end shell itself However, it will be appreciated that the marker can be
any type of marker
described herein.
Optionally, the marker can be positioned at a tooling location inside the
conversion
press In some embodiments, the marker is positioned between a first tooling
location and a
second tooling location inside the conversion press. Conversion presses have a
sequence of
tooling actions that convert the end shell into a complete end closure. In one
process, the
laser ablates material on the end shell. Then, a rivet is formed on the end
shell, a score is
formed, a deboss is formed, and the tab is staked to the rivet of the end
shell. This process
is exemplary and may include fewer or more actions in any order. In
particular, the laser
may ablate material before the forming actions as the end shell is cleaner at
the start of the
conversion press, but it will be appreciated that the laser or any marker can
be positioned at
any point in the conversion press. In some embodiments, the marker is between
a first
forming station and a second forming station of the conversion press.
The features formed by the conversion press on the end shell are located
outside of
the predetermined area with the second mark such that the second mark does not
affect the
features and vice versa. Again, the constant orientation of the end shell in
the transfer belt
means that the tools, including the marker, can form marks and features
without the marks
and features interfering with each other. Then, the second mark is
subsequently scanned 304
in a production facility and/or beyond the production facility to facilitate
track and trace
systems with an end user to encourage, for instance, recycling, as described
herein.
The first and second marks can be identical in some embodiments. Thus, the
database 120, 124 that stores scan events immediately associates end user scan
events of the
second mark with production scan events of the first mark in a record at a
database 120,
124. In other embodiments, the first and second marks are distinct, and the
second mark is
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applied to a metallic workpiece later than the first mark. In some
embodiments, the first
mark is known to the database as the second mark is formed on a metallic
workpiece.
Therefore, the first and second marks are associated in a record at the
database 120, 124. In
other embodiments, the first mark is detected by a scanner to associate the
first and second
marks in a record at the database 120, 124. For example, a vacuum belt
contacts and holds
a public side of the end closure at the outfeed of the conversion press to
convey the end
closure, which exposes the first mark on the product side of the end closure.
Thus, the second
mark is applied to the public side of the end closure in the conversion press,
then a camera
detects the first mark on the end shell at the outfeed, and the first and
second marks are
associated with each other in a record at the database. Optionally, the first
and second marks
may not be associated with each other.
The second mark is formed on any portion of the public side of the end shell.
In
some embodiments, the second mark is formed on a tear panel portion of the
central panel
of the end closure. This second mark can be at least partially covered or
obscured by the tab
until the tab is actuated to deflect the tear panel. In various embodiments,
the second mark
is applied to a part of the tab itself This may include the side of the tab
facing the central
panel or the side of the tab facing away from the central panel. The second
mark can be
applied to a tail end or a nose end of the tab. Further still, the second mark
can be applied to
a webbed portion at the tail end of the tab that replaces a fingerhole in the
tab.
The benefits of forming a mark on both the product side and the public side
are
substantial and outweigh the additional costs associated with providing and
maintaining two
separate markers to mark each side. More specifically, providing a first mark
on the product
side is beneficial because the mark can be formed early in the end closure
production process
and then scanned before, during, or after subsequent operations to collect
data on the
production process and the equipment and tooling that performs the subsequent
operations.
Forming the second mark on the public side is beneficial because it permits
the end closure
and a container body it seals to be tracked. In this manner, the life of the
end closure may
be tracked from the beginning of the production process to end of life
disposal of the end
closure.
Figs. 3K and 3L show a bottom plan view and a top plan view, respectively, of
an
end closure 306 formed from an end shell. Fig. 3K shows some exemplary first
marks 308a,
308b at various locations on the end closure 306. The first mark can be formed
at one or
more of these locations, or other locations. The first mark is formed on the
product side of
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an end shell, or on a sheet or workpiece that is formed into the end shell,
and in some
embodiments, the first mark is formed by a continuous inkjet printer with a
food grade ink.
Other marking techniques can interfere with a film or coating on the product
side of the end
closure 306 or otherwise interfere with the part of the end closure that
contacts the contents
of the resulting container. The first mark 308a can be located in the center
of the end closure
306 for easy readability, or for example, the first mark 308b can be located
off center to
avoid interfering with a feature such as a rivet or a process at a station in
the production line
such as the conversion press. While a continuous inkjet printer is described
herein, it will
be appreciated that the marker that produces the first mark 308a, 308b can be
any marker
described herein.
Fig. 3L shows a public side of the end closure 306, which has a peripheral
curl 310,
a chuck wall 312, a countersink 314, and a central panel 316. A score line 318
defines a tear
panel which is selectively opened to access the contents of the resulting
container A public
side of the rivet 320 is shown with a tab 322 operably interconnected thereto.
A user lifts a
tail end of the tab 322 to drive a nose end of the tab 322 into the tear
panel, which severs
the score line 318. Various second marks 324a, 324b, 324c are depicted in
several,
exemplary locations. The second mark can be formed at one or more of these
locations, or
other locations. In some embodiments, a laser forms the second mark by
partially ablating
material, which is faster and/or more efficient than some other marker
technologies.
However, it will be appreciated that any marker described herein can form the
second mark.
While first and second marks are described as located on the product side and
public
side, respectively, of an end closure, it will be appreciated that the present
disclosure
encompasses a variety of embodiments and combinations of marks and metallic
workpieces.
For instance, in some embodiments, a first mark is applied to a first
workpiece and a second
mark is applied to a second workpiece where the first and second workpieces
are adapted to
be joined together to form, at least in part, a finished container. For
example, in some
embodiments, a first mark is applied to a first metallic workpiece that is
formed into a
container body. The first mark can be applied to a product side or public side
of the metallic
workpiece, and the first mark is used to track and trace the metallic
workpiece during the
manufacturing process, and even at subsequent processes and locations. The
second mark
is applied to a public side of a second metallic workpiece that is formed into
an end closure.
This second mark can be used to track and trace the second metallic workpiece
during the
manufacturing process. Since the second mark is on a public side of the end
closure, the
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second mark can be used to track and trace the finished container through end
user
applications.
At, for instance, a seamer, the first and second marks on the first and second
metallic
workpieces can be associated with each other. This can be accomplished by one
or more
scanners that read the first and second marks and transmit one or more scan
events to a
database. These scan events associated with the first and second marks update
one or more
existing records on the database that relate to the first and second marks. In
some
embodiments, the first metallic workpiece has a mark on a public side, which
is used for
track and tracing through end user applications, and the second metallic
workpiece has a
mark on a product side which is used for tracking and tracing through at least
the end of the
manufacturing process. In various embodiments, a given metallic workpiece has
multiple
marks, some on a public side, some on a product side. Then, other metallic
workpieces have
a single mark for tracking and tracing through the end of the manufacturing
process Thus,
in an exemplary embodiment, the end closure has a first mark on a product side
and a second
mark on a public side, the tab has a mark, and the container body has a mark.
These
embodiments are exemplary in nature, and the present disclosure encompasses
various
combinations of marks on different sides of the metallic workpieces that form
the finished
container.
Fig. 3M shows a process 326 for applying a mark to a sheet from which a cup
and
container body are formed. As described above with respect to Fig. 3J, a
marker forms 328
a plurality of marks on a sheet of metallic material such as aluminum. In this
embodiment,
the marks are formed on a public side of the sheet at known, blank locations.
In some
embodiments, the marker is a laser that ablates part of the material of the
sheet, but it will
be appreciated that the marker can be any type of marker described herein. The
sheet is
incrementally fed 330 into a cupper that cuts 332 the blanks from the blank
locations of the
sheet. Dwell periods during which the sheet is substantially stationary are
defined between
each incremental movement of the sheet. The cupper cuts the blanks during a
dwell period,
and the laser can mark the sheet during the dwell period. Each resulting blank
has a mark
on a public side of the blank. Then, the blanks are formed 334 into a cup by
the cupper, and
the cups are formed into container bodies. The mark is located on a closed end
of the cup
and container body that serves as the dome of the resulting container because,
as described
herein, a mark on the dome avoids damage compared to other areas of the
container.
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Fig. 3N shows a process 336 where a metallic workpiece such as a container
body
is marked 338 with, for example, a continuous inkjet printer. However, it will
be appreciated
that the marker can be any type of marker described herein. The mark is formed
on a closed
end of the container body such as a dome, but it will be appreciated that the
mark can be
formed on any portion of the container body or metallic workpiece. Then, the
container
body is fed 340 into an inside spray machine where a coating is applied to an
interior surface
of the container body.
Fig. 30 shows a process 342 where, again, a mark is formed 344 onto a sheet of
metallic material such as aluminum. The marker is a laser that ablates part of
the material
of the sheet, in particular a coating of the sheet, but it will be appreciated
that the marker
can be any type of marker described herein. In this embodiment, the sheet with
marks is fed
346 into a conversion press where the conversion press cuts 348 blanks from
the sheet, and
each blank has a mark Then, the blanks are formed 350 into tabs As discussed
herein, the
mark can be located on any portion of the completed tab.
Fig. 3P shows a process 352 where a metallic workpiece such as a container
body is
marked 354 with, for example, a continuous inkjet printer. However, it will be
appreciated
that the marker can be any type of marker described herein. The mark is formed
on the body
label portion of a container body, but it will be appreciated that the mark
can be formed on
any portion of the container body or metallic workpiece. Then, the marked
container body
is combined with at least one other container body at a palletizer 356 for
shipping.
Referring now to Figs. 4A, 4B, examples of a mark 26 formed according to
embodiments of the present disclosure are generally illustrated. As shown in
Fig. 4B, a
mark 26 may comprise a series of indicia 28 and spaces 30. In the example of
Fig. 4B, the
indicia 28 are generally round -clots", or shapes that are generally circular.
In some
embodiments, the indicia and spaces are organized in rows and columns.
However, marks
26 of other forms may be created by the marker 24 of the present disclosure.
The marker may use any suitable method known to those of skill in the art to
form
the mark 26 on the sheet. For example, the marker 24 may use an ink to form
the mark 26.
In some embodiments, the marker includes a digital print head, such as an
inkjet print head,
to form the mark 26. In some embodiments, the ink is an ultraviolet ink such
that the mark
is visible when exposed to an ultraviolet light.
Additionally, or alternatively, the marker may use an electrophotographic
print
system to form the mark. Accordingly, the mark 26 may be formed with a toner
material.
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In some embodiments, the mark 26 is formed by exposing a coating on the
continuous sheet 14 to a light source. The coating may be a photo-reactive
ink. Optionally,
the light source is a laser. Accordingly, the mark may be formed by exposing
selected
portions of the photo-reactive ink to the laser.
Optionally, the marker 24 is operable to form the mark 26 without contacting
the
sheet 14. In some embodiments, the marker 24 contacts the sheet 14 to form the
mark 26.
In some embodiments, the marker forms the mark 26 by etching or engraving the
continuous sheet 14.
In some embodiments, the marker 24 includes at least one laser to mark at
least one
side of the sheet 14 before it is fed into the cupper 22. The marker 24 can
have any number
of lasers to form the marks 26. Optionally, the marker 24 has one laser to
form marks 26
on one side of the sheet.
The marker 24 may have any known optical elements to one or more of steer,
direct,
focus, and move a beam from a laser. For example, the maker may have one or
more
mirrors, lenses, refractive elements, reflective elements, and beam splitters
to form marks
26.
Optionally, the marker may include one laser configured to form two or more
marks
approximately simultaneously. For example, the marker may include the one
laser and
optical elements to split a beam from the laser into two or more beams.
Further, the marker
may have optical elements to direct the two or more beams to form two or more
different
marks that are each unique on the sheet.
In some embodiments, the marker includes at least one laser to form a mark 26
in
each blank location 20 for each cup that will be formed during a stroke of the
cupper. For
example, in a production line 10 with a cupper 22 that forms 16 cups per
stroke (such as
generally illustrated in Fig. 3A), the marker may have 16 lasers to form 16
unique marks for
each blank location 20 where a cup will be formed
In some embodiments, the marker 24 includes a mirror and/or other optical
elements
to steer a beam from a laser. Optionally, each laser of the marker 24 may have
at least one
mirror or other optical element to steer its beam. Additionally, or
alternatively, an actuator
may be associated with a laser of the marker 24 to steer or point a beam from
the laser.
The marker 24 is operable to form the marks 26 on the continuous sheet during
each
cycle of the continuous sheet into the cupper 22. In some embodiments, the
marker 24 can
form the marks at up to 400 cycles per minute. In some embodiments, the marker
24 can
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form a mark 26 in between about 0.001 seconds to about 0.5 seconds.
Additionally, or
alternatively, the marker 24 may form each mark in from about 0.01 second to
about 0.4
seconds. Optionally, the marker 24 can form a mark in approximately 0.16
seconds. In other
embodiments, the marker forms the marks in less than about 0.3 seconds.
Any suitable laser known to those of skill in the art may be used with the
marker 24
of the present disclosure. In embodiments the marker 24 may have one or more
Nd:YAG
lasers (also known as neodymium-doped yttrium aluminum garnet lasers). In
various
embodiments, the laser is a 10.6 or 9.3 [tm CO2 laser or a neodymium-doped
yttrium
aluminum garnet (Nd:Y3A15012) laser.
In further embodiments, the laser is a fiber laser where the active gain
medium is an
optical fiber doped with rare-earth elements such as erbium, ytterbium,
neodymium,
dysprosium, praseodymium, thulium and/or holmium.
In some embodiments, the laser has a wavelength of approximately 1 064 p.m
Additionally, or alternatively, the laser may have an output of from about 40
Watts to about
140 Watts of applied power, with about 80% of such power being delivered to a
target area
of the sheet 14.
In some embodiments, the laser provides a pulsed or intermittent form of laser
light.
For example, the laser optionally provides pulses at from approximately 3,000
Hz to
approximately 65,000 Hz. Preferably the output laser light pulses are
relatively stable in the
sense that there is relatively little variation in power from one pulse to the
next.
In some embodiments, the laser has sufficient power to alter the metallic
material of
the continuous sheet 14. More specifically, the marker 24 includes any laser
with sufficient
power to visibly alter the continuous sheet 14 to form a mark 26. In some
embodiment, the
laser of the marker oxidizes the material of the continuous sheet. The laser
may vaporize or
ablate the material of the continuous sheet 14 sufficiently to produce a
visible spot or mark
indicia 28, such as a "dot," circle, or other mark. For example, the laser may
partially melt
the material of the sheet 14. Alternatively, the laser may vaporize or alter a
coating on the
sheet 14.
In some embodiments, the laser has sufficient power to form a mark 26 recessed
into
the continuous sheet 14 by a predetermined amount. Specifically, in some
embodiments,
the laser of the marker 24 can form a mark 26 with a depth of up to
approximately 0.002
inches (0.00508 cm).
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The control system 100 may store information about the mark 26 for each
container
body in a database. The information may include data about the location of
each mark
formed on the sheet 14. For example, the coordinates of each mark 26 formed on
the sheet
14 can be stored by the control system 100 in a memory, such as in record 140
of a database
120, 124. Any suitable system for describing the location of the marks may be
used. In
some embodiments, the position of each mark may be described by a position
along a length
of the sheet (corresponding to an X-axis or X-dimension 70) and a width of the
sheet
(corresponding to a Y-axis or Y-dimension 72). In this manner, data about the
uniformity
of the sheet 14 along its length and across its width may be collected as
container bodies are
formed by the production line. This data may provide useful information about
the supplier
of the sheet, variations in the composition of the sheet, and variations in
the thickness of the
sheet 14. The record associated with the mark may also include a field to
store a chemical
makeup of the metallic material of a coil from which the container body was
formed, a
production date of the coil, and a location of the manufacturing facility that
produced the
coil.
Moreover, collecting the position of each mark formed on the sheet facilitates
identifying which die set of the cupper made each cup. In this manner, the
performance of
each die set of the cupper can be monitored and compared to other die sets of
the cupper.
Referring again to Fig. 2A, in some embodiments, after the marker 24 forms the
marks 26 on the sheet 14 and the cupper 22 creates the cups, the cups are
transported by a
conveyor 32 to a bodymaker 36. The production line 10 may have two or more
bodymakers
36. Some production lines have seven or more bodymakers
Optionally, a sensor 34A is positioned at an infeed to each of the bodymakers
36.
The infeed beneficially arranges the container bodies in a single file
exposing the marks 26
to scanning by a sensor. Additionally, or alternatively, a sensor 34A may be
positioned on
an outfeed end of the bodymakers 36.
In some embodiments, a first sensor is positioned up line (or at an in-feed)
of each
piece of equipment that handles or performs an operation on the container
body.
Additionally, or alternatively, a second sensor may be positioned down line
(or at an out-
feed) of each piece of equipment. Optionally, some pieces of equipment may
have a sensor
positioned at both up line and down line of the equipment.
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Each sensor 34 is operable to read the mark on each cup fed into a bodymaker
36.
Any suitable sensor known to those of skill in the art may be used with the
production line
of the present disclosure.
The production line 10 may have any number of sensors 34 to scan marks at any
5 location of a container body. Moreover, the production line may have two
or more types of
sensors, or sensors with different capabilities.
For example, some sensors 34 may be positioned and configured to read a mark
26
on an exterior surface of a container body 2. Accordingly, in some embodiments
sensors
34 positioned at an infeed or an out feed of a bodymaker 36, a basecoater 42,
a decorator
10 46, an internal coater 50, a necking station 54, a flanger 56 and other
locations where
container bodies are transported in a single line may have a sensor adapted to
read a mark
on the exterior surface of the container bodies.
At least one sensor may be positioned and configured to read a mark on an
interior
surface of a container body. In this manner, container bodies transported on a
mass
conveyor may have their marks read by suitable sensor. For example, sensors
operable to
scan marks on interior surfaces of container bodies may be positioned to scan
marks on
container bodies transported into, through, or out of a dry-off oven 40, a
basecoat oven 44
or an internal bake oven 52.
The sensor 34 may be an optical sensor. In some embodiments, the sensor 34 is
a
camera. Optionally, an emitter of electromatic waves (such as a light) may be
associated
with a sensor. In some embodiments, the sensor 34 includes a laser or projects
a beam
similar to a barcode reader.
In other embodiments, the sensor 34 is an infrared sensor which can detect the
contrast in emissivity between the metal material of a container body and a
mark 26.
Specifically, the mark 26 will change the metal material of the sheet, and
thus change the
emissivity compared to the emissivity of the metal material without the mark
such that an
IR sensor can detect the contrast in emissivity. In this manner, the IR sensor
34 can read the
mark 26 on the container body.
The sensor 34 is in communication with the control system 100 and can transmit
the
mark 26 of each cup fed into a bodymaker 36 to the control system. The sensor
34 may also
transmit a timestamp associated with the scanning of each mark 26 detected by
the sensor.
In this manner, the progress of a cup through the production line 10 is
recorded as well as
the route of the cup (i.e., which bodymaker 36 or other piece of equipment in
the production
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line performed an operation on the cup) through the production line is
monitored. The
information collected by the sensors 34 is useful to monitor the performance
of each
bodymaker. The timestamp may also be used to compare the performance of one
branch of
the conveyor 32 (or route of the production line) to another branch or route.
Optionally, a sensor 34 may be associated with a single-line conveyor 32 that
transports container bodies in one row or lane. In some embodiments, container
bodies are
transported by the single-line conveyor with their closed ends facing away
from the single-
line conveyor. One example of a single-line conveyor is a pin-chain downstream
from a
decorator 46.
Additionally, or alternatively, a sensor 34 can be associated with a mass
conveyor
that transports container bodies in multiple rows or lanes. Some mass
conveyors transport
the container bodies with their closed ends facing away from the mass
conveyor. Other
mass conveyors transport the container bodies with their closed ends facing
toward the mass
conveyor. Examples of mass conveyors include the conveyors 32 that transport
container
bodies through a washer 38, through a dry-off oven 40, and through an internal
bake oven
52. Forming a mark 26 on a portion of a sheet that will define an interior
surface of a
container body may be beneficial for scanning by a sensor when the container
body is
positioned on a mass conveyor.
In some embodiments, a sensor 34 is associated with each conveyor 32 that
transports a container body between each piece of equipment and between each
process of
the production line 10.
Bodymakers 36 use a punch on a ram to push the cups formed by the cupper 22
through a series of tooling dies that redraw and iron the cups into container
bodies. In some
production lines, such as for the production of beverage containers and
beverage bottles, the
bodymakers 36 form a dome on the closed ends of the container bodies. In some
embodiments, the bodymakers 36 do not form a dome, for example, when the
container
body will be formed into a tapered cup. Regardless, in some embodiments, the
mark 26 will
be positioned on an exterior surface of the closed end 4 and substantially
centered on the
closed end as generally illustrated in Fig. 4A.
The open ends of the container bodies are cut to a uniform height by trimmers.
In
some embodiments, a trimmer is associated with each bodymaker 36.
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Container bodies from several bodymakers are then transported by a single
conveyor
32 to a washer 38. A first oven 40, known as a "dry-off oven", then dries the
container
bodies.
Optionally, some container bodies are transported to a basecoater 42 which
applies
an exterior basecoat. The basecoat is sometimes required to provide a base
color before
subsequent decorations or coatings are applied.
Optionally, a sensor 34B is positioned at an infeed to the basecoater 42.
Alternatively, the sensor may be positioned at an outfeed of the basecoater.
The sensor is
operable to read the mark on each cup fed into the basecoater 42 and record a
timestamp for
when each mark is read. The sensor 34 is the same as or similar to the sensor
34A proximate
to the bodymaker.
The container bodies are then conveyed through a second oven 44 or "basecoat
oven" where the basecoat is cured The production line 10 may have two or more
basecoat
ovens. If so, a sensor 34 may be positioned upstream of each basecoat oven to
read the
marks 26 of the container bodies fed into each basecoat oven 44.
A sensor 34C is also positioned to scan the marks 26 of container bodies
transported
by a conveyor 32 past the basecoater 42.
The container bodies are then transported by one or more conveyors 32 to
decorators
46. A metallic container production line may have two or more decorators 46.
The exterior
sidewalls of the container bodies are decorated with up to six colors of ink
by the decorators.
The decorators may optionally include an overvamish unit. The overvamish unit
can apply a film of lacquer over the entire decoration to protect it. In some
embodiments,
bottom coaters associated with the decorators 46 may optionally apply a
coating of lacquer
to the rim around the bottom of the container bodies.
In some embodiments, a sensor 34D is positioned upline of each decorator 46.
Additionally, or alternatively, a sensor may be positioned at an outfeed of
each decorator.
In this manner, the identity of each container body (based on its mark 26) fed
into the
decorator 46 can be collected. The sensor 34D is the same as or similar to the
sensor 34A
proximate to the bodymaker,
The inks and lacquer coatings of the container bodies are cured by a third
oven 48
known as a "deco oven-. The deco oven 48 is also known as a "pin oven- because
container
bodies are typically transported through the oven on a chain with pins. The
pins are placed
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into the open ends of the container bodies to transport them without touching
the exterior
surfaces of the container bodies.
Some production lines have one deco oven. Alternatively, a deco oven 48 is
associated with each decorator 46. A sensor 34E of the present disclosure may
be positioned
at an infeed or an outfeed of each deco oven 48.
After the decoration and other exterior coatings are cured, the container
bodies may
return to a single conveyor 32. The container bodies are transported to one or
more internal
coaters 50 to receive an internal coating, such as a lacquer, to protect
product integrity.
A sensor 34F may be associated with each internal coater 50. The sensor 34F
may
be the same as or similar to other sensors 34 described herein. Moreover, the
sensors 34F
may be positioned up-line or down-line of the internal coaters 50.
The internal coating is subsequently cured as the container bodies pass
through a
fourth oven 52 known as an "internal coater oven" or "internal bake oven"
(IBO) The
container bodies may be positioned on a single conveyor 32 for transport
through the
internal bake oven 52.
Optionally, a sensor 34G is positioned up-line of the internal bake oven 52 as
generally illustrated in Fig. 2A. The sensor 34G may be the same as or similar
to other
sensors described herein and is operable to read the mark 26 of each container
body on the
conveyor 32.
In some embodiments, the open ends of the container bodies receive a thin coat
of a
lubricant from a waxer in preparation for necking. However, when the
production line is
producing tapered cups, no necking operation is performed on the container
bodies.
When a neck will be formed on the container bodies, a series of die neckers 54
(or
-necking stations") include tooling to sequentially reshape open ends of the
container bodies
and reduce the initial diameter down to a predetermined diameter. Although
only one die
necker 54 is illustrated in Fig. 2A, the production line may have six or more
die neckers
arranged in series that progressively reduce the diameter of necks of the
container bodies.
In some production lines, fourteen or more necking stations are used to form
necks of
beverage containers. Production lines for metallic bottle may include thirty
or more necking
stations 54.
The production line of the present disclosure may optionally include two or
more
sets of necking stations 54 arranged in parallel. Accordingly, a sensor 34H
such as described
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herein may be associated with each of the two or more sets of necking stations
54 to read
the mark of each container body processed by each set of neckers.
After necking, in some embodiments a conveyor 32 transports the container
bodies
to one or more flangers 56. The open ends of the container bodies are rolled
back by the
flanger 56 to form a lip or flange. The flange is used to attach an end
closure after the
container body is filled with a product. A sensor 341 may be associated with
the flanger.
The sensor 341 may be positioned upstream or downstream of the flanger. If the
production
line has more than one flanger 56 arranged in parallel, a sensor may be
associated with each
flanger.
The container bodies are tested and inspected at inspection stations 57 at one
or more
locations of the production line 10. Optionally, although only two inspection
stations 57 are
illustrated in Fig. 2A, the production line 10 may include an inspection
station 57 up line or
down line of each piece of equipment that handles or performs an operation on
the container
body. In some embodiments, an inspection station 57 is positioned at a
location downstream
from the flanger 56.
The inspection stations 57 check container bodies for defects, damage or
contamination. A variety of sensors known to those of skill in the art may be
associated with
the inspection stations. The sensors may include optical or visual systems
(such as a
camera). The camera may be a high definition camera, such as a camera with a
sensor with
greater than 5 megapixels. In some embodiments, the visual system may include
a high
speed or high "frame-rate" camera. One or more lights may be associated with
the sensor
to provide contrast.
The inspection stations may also include equipment to test the container
bodies for
damage and holes. In some embodiments, the inspect station may include a light
tester to
identify holes in a container body. The inspection station may also apply a
vacuum or
pressure to the container body.
In some embodiments a sensor 34K to detect a mark 26 is associated with each
inspection location. In this manner, the mark 26 for each container body that
is found to be
deficient and ejected from the production line 10 may be recorded by the
sensor 34K.
Information collected by the sensor 34K may be useful for determining the
cause of a
deficiency and for tracing the deficiency to a piece of equipment in the
production line or a
material deficiency of the sheet 14 from which the container body is formed.
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The inspection station 57 may be in communication with the control system 100
and
one or more databases 120/124. The inspection station 57 may retrieve
information from a
record 140 associated with a container body 2 stored in a database 120/124
after the sensor
34K reads the mark 26 on the container body.
The inspection station 57 may identify a container body for inspection based
on
information from the record 140. For example, the inspection station 57 may
receive an
instruction to identify a container body that was processed by a particular
bodymaker (such
as bodymaker 36C) during a predetermined period, such as once per hour (or
during some
other predefined interval). Accordingly, in this example, each hour the
inspection station
57 may identify (and separate from the production line) a container body
processed by the
bodymaker 36C Specifically, the inspection station 57 may scan marks 26 on
container
bodies, retrieve records 140 associated with the marks from a database
120/124, identify a
record with a field indicating a container body was processed by bodymaker
36C, and then
separate the container body from the production line. The container body may
then be
inspected to evaluate performance of the bodymaker 36C.
Similarly, in some embodiments, the inspection station 57 can identify
container
bodies processed by any piece of equipment 22, 32, 36, 38, 40, 42, 44, 46, 48,
50, 52, 54, or
56. Accordingly, an inspection station 57 may receive an instruction to
identify a container
body processed by a second internal coater 50B. However, as will be
appreciated by one of
skill in the art, downstream from the internal coaters 50A, 50B, 50C the
container bodies
are combined on a mass conveyor 32 and transported through an internal bake
oven 52.
Accordingly, the inspection station 57 may be positioned downline of the
internal bake oven
52 and identify a container body processed by internal coater 50B after the
container body
exits the internal bake oven 52 based on the mark 26 formed on the container
body. The
inspection station may then separate a sample container body from the
production line for a
routine quality inspection of the operation of the internal coater 50B In this
manner, the
inspection station 57 can identify and select a container body processed by
any piece of
equipment for routine or on-demand inspection to determine performance of the
piece of
equipment.
In some embodiments, a production line 10 may include a sorter 58A operable to
direct container bodies to different routes or locations (such as onto one of
two or more
conveyors 32A, 32B). The sorter 58A may be located at any position of the
production line.
In some embodiments, the sorter 58A is positioned downstream of the cupper 22
and
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upstream of any other equipment of the production line. The production line
may have two
or more sorters. At least one sorter is optionally positioned upstream of a
palletizer 59.
The sorter may direct container bodies to different routes 32A, 32B based on a
quality parameter. For example, a container body that meets a manufacturing
parameter
could be directed to a first route or conveyor 32A. In contrast, a container
body that does
not meet a manufacturing parameter may be directed to a second route 32B. In
some
embodiments, the sorter 58A may be associated with an inspection system 57. In
this
embodiment, the second route may be to an ejector.
The sorter may include a sensor 34K to read marks on the container bodies.
Accordingly, each container body processed by the sorter 58A may be identified
when its
mark 26 is scanned by the sensor 34K. In this manner, a route selected by the
sorter 58A
for each container body may be stored in a database 120/124 in a record 140
associated with
the container body when its mark 26 is scanned
In some embodiments, the sorter 58A may sort the container bodies based on
information retrieved from the record 140 associated with the container body
2. For
example, the sorter may direct a container body to a route based on equipment
that processed
the container body or performed an operation on it. Additionally, the sorter
58A could select
a route for the container body based on a manufacturer of the sheet 14, a
serial number or
other identifier of the coil of the sheet, or a composition of the metallic
material of the sheet.
The optional sorter 58A may also be used to separate container bodies
decorated by
a first decorator 46A of the production line from container bodies decorated
by a second
decorator 46B of the production line. In this manner, the first decorator may
form a first
decoration and the second decorator may form a second decoration different
from the first
decoration. Thereafter, the container bodies 2 with the first decoration may
be separated
from the container bodies with the second decoration based on information
retrieved from
records 140 associated with unique marks 26 formed on each container body 2.
Sorting container bodies 2 based on a decorator 46 that formed a decoration on
a
container body is beneficial because it facilitates producing small production
runs of
container bodies with unique decorations. As one of skill in the art will
appreciate, in order
to print a different image or decoration on a plurality of container bodies, a
new set of
printing plates must be installed on the plate cylinder of the decorator 46
resulting in
downtime and decreased efficiency of a prior art production line. Because only
one image
can be printed without changing the printing plates, it is economically
challenging to
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produce small batches of decorated container bodies with different images.
However, by
using a sorter 58A that can identify each container body 2 by scanning its
mark 26, the sorter
58A may retrieve a record 140 for the container body 2 from a database to
determine which
decorator 46 handled the container body. The record may also identify which
decoration is
on the container body and a client that ordered the decoration.
The production line 10 may have a first decorator 46A that has a first set of
printing
plates to produce a first decoration on the container bodies. A second
decorator 46B may
be configured with a second set of printing plates to produce a second
decoration on other
container bodies. The second decorator may be running a small batch of
container bodies
for a particular distributor or filler.
With the tracking and tracing facilitated by the unique marks 26 of the
present
disclosure, both decorators 46A, 46B may be run simultaneously without
stopping the
production line 10 When a predetermined number of container bodies are
decorated with
the second decoration by the second decorator 46B, it can be stopped and a new
set of
printing plates installed on the second decorator 46B. The second decorator
46B may then
be equipped with a first set of printing plates to decorate container bodies
with the first
decoration (or a third set of printing plates may be installed and the second
decorator 46B
can form a third decoration on container bodies). While the second decorator
46B is
stopped, the first decorator 46A can continue decorating container bodies.
The container bodies with the first and second decorations may (and likely
will) be
mingled together on a mass conveyor (for example, for transport through the
internal bake
oven 52 or for transport to the necker stations 54). However, the sorter 58A
can separate
container bodies 2 with the first decoration from container bodies with the
second decoration
after scanning their marks 26 and retrieving information from records 140 in a
database.
Once separated, the container bodies may be sent to one of two or more
conveyors 32A,
32B and to different palletizers 59A, 59B.
A conveyor 32A, 32B transports the container bodies to a palletizer 59A, 59B
where
they are placed in pallets. Another sensor 34J may be associated with the
palletizer.
Accordingly, the mark 26 on each container body loaded into a pallet can be
read and
associated with the pallet. Pallets of empty container bodies may then be
placed in storage
60. The container bodies may subsequently be shipped to a filler 62.
Occasionally, container bodies 2 on a pallet may need to be resorted or
inspected.
For example, production equipment may be found to be malfunctioning after
processing a
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plurality of container bodies. The container bodies that were handled by the
faulty
equipment may need to be identified, inspected, and/or discarded. In a prior
art production
line, container bodies already in pallets in storage 60 may only be sorted
manually. As can
be appreciated by one of skill in the art, this is a time consuming and
expensive process.
The unique mark 26 formed on each container body 2 according to embodiments of
the present disclosure facilitates a more efficient method of resorting
container bodies. In
some embodiments, the production line includes a de-palletizer 61 as generally
illustrated
in Fig. 2A. Pallets of container bodies 2 that includes the marks 26 described
herein can be
transported from storage 60 to the de-palletizer 61. Specifically, a pallet
may have a
container body 2 with a mark 26 that must be separated from other container
bodies in the
pallet. For example, a record 140 in a database that is associated with the
mark 26 may have
a field that indicates the container body 2 was processed by a piece of
equipment (or
received a coating) that was subsequently found to be deficient Accordingly,
the container
body 2 must be found and inspected.
A pallet with the container body 2 may be located in storage and transported
to a de-
palletizer 61. After being removed from the pallet, the container bodies 2 can
be transported
back to the optional sorter 58A by a conveyor 32. The sorter 58A may then use
a sensor
34K to scan a mark 26 on each container body 2 and retrieve a record 140 for
each container
body from a database 120/124 using the unique mark 26. The sorter 58A may then
separate
container bodies handled by a particular piece of equipment based on data
within the record.
Additionally, or alternatively, a production facility may include a stand-
alone sorter
58B as generally illustrated in Fig. 2B. The sorter 58B may be located in the
production
facility but separate from the production line 10. In some embodiments, the
sorter 58B is
located at a storage site (or warehouse), a filler 62, a distributor, or some
location separate
from the production line. Regardless, the sorter 58B may have the same or
similar features
and capabilities as described in conjunction with sorter 58A illustrated in
Fig. 2A.
More specifically, the sorter 58B may be positioned downstream from a de-
palletizer
61. Accordingly, a pallet with container bodies 2 including marks 26 may be
removed from
storage 60 and transported to the de-palletizer. Thereafter, the container
bodies 2 may be
transported to the sorter 58B. In some embodiments, a conveyor 32 is
positioned to transport
the container bodies from the depalletizer to the sorter 58B.
The sorter optionally includes a sensor 34K operable to read marks on the
container
bodies. The sorter 58B may then retrieve information from a record 140 of a
database by
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communicating with control system 100. In this manner, the sorter 58B can
identify
container bodies based on their unique marks 26 and separate them based on one
or more
fields in the record 140. Thereafter the sorter 58B can direct each container
body to one or
more routes to direct each container body to one of two or more palletizers
59. From the
palletizers, pallets of the sorted container bodies may be returned to storage
60 or some other
location.
Using sorters 58A and/or 58B, individual container bodies processed by
specific
pieces of equipment can be located. For example, an internal coater 50C may be
producing
faulty internal coatings. A sorter 58A/58B may receive container bodies from
the de-
palletizer 61 and identify those that received an internal coating from
internal coater 50C.
The sorter 58A/58B can then route those container bodies to an inspection
station, to a
holding area, or to a palletizer for salvage or reuse. Container bodies that
were not processed
by internal coater 50C (for example container bodies processed by internal
coolers 50A,
50B) can also be identified by their marks 26 and routed to a conveyor 32A,
32B for
transport back to a palletizer 59A, 59B.
Forming a mark 26 for each container body on the sheet 14 upline from the
cupper
22 provides many benefits. By positioning sensors 34 at various points on the
production
line the progress of individual container bodies through the manufacturing
process can be
tracked. Information such as a manufacturer of a coil of the sheet 14 of metal
material can
then be tied to (or associated with) each container body produced. In this
manner, failure
or rejection of a container body due to a deficiency of the metal material can
be tracked back
to manufacturer of the coil.
In addition, the mark 26 facilitates the collection of data related to the
production of
each container body with greater detail, accuracy, and quality compared to the
data
generated by prior art marks produced by a bodymaker or other tools of a prior
art
production line. For example, the time it takes for each container body to
progress through
each stage and operation of the production line can be tracked and analyzed.
Specifically,
the mark 26 enables the identity of each piece of equipment that performed an
operation on
each container body and the time the operation was performed to be collected
and stored in
a record 140 of a data structure (such as a database 120, 124 of the control
system 100). In
this manner, information such as the wellness and spoilage associated with
each piece of
equipment in the production line 10 can be collected for analysis. The
performance of
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individual pieces of equipment can be analyzed and compared to other similar
equipment
on the same production line (or on other production lines).
Marks 26 of the present disclosure may also be formed on metallic workpieces,
such
as container bodies, produced by an impact extrusion (IE) process. Impact
extrusion is a
process utilized to make container bodies and other articles with unique
shapes. The
container bodies produced by an IE process are typically made from a softened
metal slug
comprised of steel, magnesium, copper, aluminum, tin, and lead and other
alloys. An
extruded tube (which will be formed into a container body) is formed from a
slug of metallic
material. The slug is positioned in an extruder that has a confining die and a
punch. The
slug is contacted by the punch and the force from the punch deforms the metal
slug around
an outer diameter of the punch and the inner diameter of the confining die to
form the
extruded tube.
After the initial shape is formed, the extruded tube is removed from the punch
with
a counter-punch ejector, and other necking and shaping tools are used to form
the extruded
tube into a container body with preferred shape. The 1E production line for
container bodies
includes equipment that performs many operations similar to those described in
conjunction
with Fig. 2A. For example, an LE production line may include ironing stations
and a domer
position downstream from the extruder. A washer and a dry-off oven may be
downstream
from the domer. The IE production line can include a basecoater and a basecoat
oven.
Interior coatings may be applied to the container body by internal coaters and
the coating
cured by an internal bake oven. One or more decorators may apply decorations
to exterior
surfaces of the container bodies which are cured by one or more deco-ovens. A
neck can
be formed on the container body by necking stations. The IE production line
may also
include embossing stations, a wall ironing station, trimers, a curler, and a
mouth mill
assembly. In some embodiments a thread forming station is included in the IE
production
line.
Inspection stations 57 may be positioned at a plurality of locations along the
IE
production line. The IE production line may also include a sorter 58 and a de-
palletizer 61
as described herein. When the container body is finished, it may be positioned
on a pallet
by a palletizer 59.
A marker 24 of embodiments of the present disclosure may be positioned
downstream from extruder to form a mark 26 on each container body produced by
the IE
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production line. In some embodiments, the marker is positioned at or near an
exit of the
extruder.
In other embodiments, the marker 24 is positioned between the extruder and the
next
piece of equipment that will perform an operation on the container body of the
IE production
line. For example, the marker 24 may be positioned upstream from an ironer, a
domer, or a
washer.
The IE production line of the present disclosure also includes sensors 34 as
described
herein. The sensors 34 may be positioned at a plurality of locations on the IE
production
line. In some embodiments, a sensor 34 is associated with each piece of
equipment of the
IE production line that performs an operation on a container body.
Accordingly, as
described in conjunction with the production line 10, a container body 2
produced by the IE
production line will include a mark 26 that may be scanned before or after
each operation
that is performed on the container body.
Marking a metallic workpiece in a variety of manufacturing processes and
production lines is contemplated. For instance, marking a container body, a
bottle, a
shell/end, a tab, and/or a tapered cup is contemplated. The tables below
summarize various
manufacturing processes. A marker can be placed at different stations with
attendant
systems such as orientation and/or stabilization systems as described herein.
Further, a
marker may be associated with equipment of each station, positioned upstream
of each
station, or positioned downstream of each station. An exemplary manufacturing
process is
found in "How Ball Makes Beverage
Ends,"
https://www. scribd.com/document/516691496/How-Ball-Makes-Beverage-Ends
[retrieved
August 10, 2022], which is incorporated herein in its entirety by reference.
Another
exemplary manufacturing process is found in "Inside a Ball Beverage Can
Plant,"
https://igora.ch/files/ball-metalbeverageprocess.pdf [retrieved August 10,
2022], which is
incorporated herein in its entirety by reference.
Table 1. A list of actions and/or stations for producing a container body at a
manufacturer location.
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Potential coil preprint
Receive coil
Uncoil
Lube
Cupper
Bodymaker / Draw/Iron/Iron/Iron/Dome Forming
Trim
Washer
Washer Dry Off
Decorator infeed
Decorate
Overvarnish
Bottom Coat
Pin Oven / Coating Cure
Inside Spray Infeed
Inside Spray
Inside Spray Outfeed
Inside Spray Curing
Necking
Flanging
Light Tester
Palletizer
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Table 2. A list of actions and/or stations for producing a container at a
filler location.
Depalletize
Rinse (ionized air or DI water)
Date Code
Fill
Double Seam
Fill Level Detection (X or Gamma Ray)
Invert to promote defect leaking
Thermal Process
Warmer (dew point), or
Cooling Tunnel (Hotfill), or
Pasteurizer, or
Retort
Reinvert can (upright)
Pressure Check
Fill Level Detection (X or Gamma Ray)
Dryer
Secondary Pack:
Carton, or
Hi-cone, or
Shrink wrap, or
Tray w/ Shrink Wrap, or
Case
Additional Pack:
Case, or
Tray
Palletize
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Table 3. A list of actions and/or stations for producing a bottle at a
manufacturer
location.
Potential coil preprint
Receive coil
Uncoil
Lube
Cupper
Bodymaker / Draw/Iron/Iron/Iron/Dome Forming
Trim
Washer
Washer Dry Off
Decorator infeed
Decorate
Overvarnish
Bottom Coat
Pin Oven / Coating Cure
Inside Spray Infeed
Inside Spray
Inside Spray Outfeed
Inside Spray Curing
Neck
Trim
Thread
Throttle
Curl
Inspect / Light Tester
Palletizer
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Table 4. A list of actions and/or stations for producing a bottle at a filler
location.
Depalletize
Date Code
Rinse (ionized air or DI water)
Fill
Cap
Thread Camera Inspection
Fill Level Detection (X or Gamma Ray)
Thermal Process
Warmer (dew point), or
Cooling Tunnel (Hotfill), or
Pasteurizer, or
Retort (Batch Process)
Pressure Check
Fill Level Detection (X or Gamma Ray)
Dryer
Secondary Pack:
Carton, or
Hi-cone, or
Shrink wrap, or
Tray w/ Shrink Wrap, or
Case
Additional Pack:
Case, or
Tray
Palletize
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Table 5. A list of actions and/or stations for producing an end closure at a
manufacturer location.
Potential coil preprint before coil coating
Coil Coating with option to print codes integral to that
process
Potential coil preprint after coil coating
Receive coil
Uncoil
Shell Press
Curl
Compound liner
Accumulation (B al an c e r)
Conversion press infeed
Conversion press
Conversion press outfeed
Inspection
Bagging
Palletizing
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Table 6. A list of actions and/or stations for producing an end closure at a
filler
location.
Manual Depalletize
Remove paper sleeve
Manual (Common)
Automatic (Rare)
Load end stacks to rod cage conveyance
Manual into angled V-Trough
Manual into automatic carousel feed (feeder)
Automatic (Rare)
Downstacker separation into seamer
Double Seam and continue with container process
Table 7. A list of actions and/or stations for producing a tab at a
manufacturer
location.
Potential coil preprint before coil coating
Coil Coating with option to print codes integral to that
process
Potential coil preprint after coil coating
Receive coil
Uncoil
Conversion Press Infeed
Conversion Press
Referring now to Fig. 5, the mark 26 on each container body 2 also facilitates
tracking each container body to a filler 62, point of sale 64, consumer 66,
and to a collection
point 68 at the end of life of the container body. For example, when a pallet
of container
bodies is delivered to the filler 62, the unique mark 26 of each container
body 2 on the pallet
may be associated with the filler.
A record 140 for the mark stored in a database 120/124 may be updated with
information about the filler. Moreover, when the container body is filled with
a product, a
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timestamp may be added to the record 140 of the mark 26 in the database. In
addition,
information about the product in the container body (such as a type of
product, an expiration
date, and other data) may be added to the record.
When the filled container body is shipped to a point of sale 64, additional
entries can
be added to the record 140 for the mark. For example, an identifier for the
point of sale, a
date of delivery, and the like can be added to the record.
Thereafter, the record 140 for the mark can be supplemented when the filled
container body is purchased by a consumer 66. In some embodiments, a sensor
34M at the
point of sale will scan the mark 26. The sensor may be a barcode reader
associated with a
checkout system at the point of sale.
Information about the date and time of the sale may be added to the record 140
in
the database. In some embodiments, an identifier for the consumer 66 (such as
a name, a
customer number, a loyalty number, or the like) may also be added to the
record The record
140 may also be updated to include an amount of a deposit paid by the consumer
for the
container body.
In some embodiments, the consumer 66 may update the record 140 for the
container
body associated with the mark 26 by scanning the mark 26 with a device such as
a smart
phone. In this manner, the consumer 66 can be associated with the record for
the mark in
the database record for purposes of a deposit return program where containers
are returned
at designated locations for recycling.
The mark 26 beneficially provides a way to track the complete life and
movement
of a container body 2, from the uncoiler 12 to a collection point 68 at end of
life. The ability
to track and trace individual container bodies through their life cycle will
provide useful
information and insight into the manufacturing process, distribution, sale,
consumption, and
end of life collection.
The collection point 68 may be in communication with the control system 100.
For
example, the collection point 68 may communicate with the control system over
a network
122, such as the intemet. Thus, data collected by a sensor 340 associated with
the collection
point 68 can be added to a record 140 for a mark 26 on a container body stored
in a database
120/124 described herein in conjunction with the control system. In this way,
a database
120/124 can receive information regarding scanning of a mark 26, such as:
which device (or
sensor 34) conducted the scan at what time, information about the container
body itself,
where the container body is located, etc. The database can also distribute
data as necessary
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to fulfill functions of the system such as signaling a mobile device or other
computer system
that a particular container body has been received at the collection point 68.
Referring now to Fig. 6, a control system 100 according to embodiments of the
present disclosure is generally illustrated. More specifically, Fig. 6
illustrates embodiments
of a control system 100 of the present disclosure operable to create unique
marks 26 for a
plurality of container bodies in accordance with embodiments of the present
disclosure. The
control system 100 is generally illustrated with hardware elements that may be
electrically
coupled via a bus 102. The hardware elements may include one or more central
processing
units (CPUs) 104; one or more input devices 106 (e.g., a mouse, a keyboard,
etc.); and one
or more output devices 108 (e.g., a display device, a printer, etc.). The
control system 100
may also include one or more storage devices 110 In embodiments, the storage
device(s)
110 may be disk drives, optical storage devices, solid-state storage device
such as a random
access memory ("RAM") and/or a read-only memory ("ROM"), which can be
programmable, flash-updateable and/or the like.
The control system 100 may additionally include one or more of a computer-
readable storage media reader 112; a communications system 114 (e.g., a modem,
a network
card (wireless or wired), an infra-red communication device, etc.); and
working memory
116, which may include RAM and ROM devices as described above. In some
embodiments,
the control system 100 may also include a processing acceleration unit 118,
which can
include a DSP, a special-purpose processor and/or the like. Optionally, the
control system
100 may also include a database 120.
The computer-readable storage media reader 112 can further be connected to a
computer-readable storage medium, together (and, optionally, in combination
with storage
device(s) 110) comprehensively representing remote, local, fixed, and/or
removable storage
devices plus storage media for temporarily and/or more permanently containing
computer-
readable information. The communication system 114 may permit data to be
exchanged
with a network 122 and/or any other data-processing. Optionally, the control
system 100
may access data stored in a remote storage device, such as database 124 by
connection to
the network 122. In some embodiments, the database 124 may be known as cloud
storage.
In embodiments, the network 122 may be the internet.
The control system 100 may also comprise software elements, shown as being
currently located within the working memory 116. The software elements may
include an
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operating system 126 and/or other code 128, such as program code implementing
one or
more methods and aspects of the present invention.
One of skill in the art will appreciate that alternate embodiments of the
control
system 100 may have numerous variations from that described above. For
example,
customized hardware might also be used and/or particular elements might be
implemented
in hardware, software (including portable software, such as applets), or both.
Further,
connection to other computing devices such as network input/output devices may
be
employed.
In embodiments, the control system 100 is a personal computer, such as, but
not
limited to, a personal computer running the MS Windows operating system.
Optionally, the
control system 100 can be a smart phone, a tablet computer, a laptop computer,
and similar
computing devices. In embodiments, the control system 100 is a data processing
system
which includes one or more of, but is not limited to: at least one input
device (e g a
keyboard, a mouse, or a touch-screen); an output device (e.g. a display, a
speaker); a
graphics card; a communication device (e.g. an Ethernet card or wireless
communication
device); permanent memory (such as a hard drive); temporary memory (for
example,
random access memory); computer instructions stored in the permanent memory
and/or the
temporary memory; and a processor.
The control system 100 may be any programmable logic controller (PLC). One
example of a suitable PLC is a Controllogix PLC produced by Rockwell
Automation, Inc.,
although other PLC s are contemplated for use with embodiments of the present
invention.
Optionally, the control system 100 can send instructions to the marker 24 to
adjust
operation of its laser, printer, inkjet print head, or other means of forming
the mark 26.
Additionally, or alternatively, the control system 100 can adjust a duty cycle
of the marker.
In embodiments, the control system 100 is in communication with one or more of
the sensors 34 of the present disclosure. The control system can create a
record 140 in a
database 120/124 for each mark 26 of each container body 2. The control system
100 may
then update the record 140 with additional data as the mark 26 is scanned when
the container
body travels through the production line 10, is transported to a filler,
shipped to a point of
sale, purchased by a consumer 66, and returned to a collection point 68.
Referring now to Fig. 7, one embodiment of a data structure 130, such as a
database,
is generally illustrated. In at least one embodiment, the data structure 130
is stored in a
memory of the control system 100, such as a database 120. Additionally, or
alternatively,
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the data structure 130 may be accessed by the control system 100 using network
122.
Accordingly, in one embodiment, the data structure 130 is stored in a remote
location, such
as database 124 or cloud storage.
The data structure may include one or more of data files or data objects 132,
134.
Thus, the data structure 130 may represent different types of databases or
data storage, for
example, object-oriented data bases, flat file data structures, relational
database, or other
types of data storage arrangements.
Embodiments of the data structure 130 disclosed herein may be separate,
combined,
and/or distributed. As indicated in Fig. 7, there may be more or fewer columns
or portions
in the data structure 130, as represented by ellipses 136. Further, there may
be more or
fewer row (files) or records 140 in the data structure 130, as represented by
ellipses 138.
A first data object 132 includes data related to a plurality of container
bodies 2
organized into individual records 140 In some embodiments, the first data
object 132 may
include records of container bodies 2 produced by a first production line 10,
by an impact
extrusion production line, by a first manufacturer, produced for a
distributor, produced for
a specific client, or produced during a certain period of time (such as a day,
a week, a month,
or a year).
The first data object 132 has several portions or fields 142 - 154
representing
different types of data. Each of these types of data may be associated with an
individual
container body 2 by its unique mark 26. As a container body 2 (such as
"container A" in
record 140A) moves through a production line and its mark 26 is scanned by
sensors 34,
fields within record 140A may be populated with data from the sensor(s). There
may be
one or more records 140 and associated data stored within the first data
object 132.
In one embodiment, each record 140 includes a field for an identifier 142. The
identifier 142 may be the unique mark 26 (such as an alphanumerical code)
associated with
each container body 2. Other fields include different data collected by
sensors 34 of the
production line, fillers 62, points of sale 64, consumers 66, collection
points 68 and other
sensors 34 that scan marks on the container bodies.
The fields may include, but are not limited to, field 144 for a production
date, field
146 for a production time, field 148 for a production location, field 150 for
a production line
identifier, field 152 for an identifier for a cupper 22 that cut a cup formed
into the container
body, and field 154 for another piece of equipment that handled the container
body or that
performed an operation on the container body.
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The first data object may include more or fewer fields. Optionally, the fields
142 ¨
154 may be arranged in a different order. Moreover, the fields may be added or
removed
based on the type of production line that produced the container body. More
specifically, a
data object with records 140 for container bodies produced by a draw and iron
production
line 10 may have different fields than a data object with records for
container bodies 2
produced by an impact extrusion process.
Other fields may be added to the first data object 132 as indicated by
ellipses 136.
For example, each record 140 may include fields for one or more of: a batch
number; a shift
identifier; material specifications of the metallic material of a continuous
sheet; an identifier
for a manufacturer of a coil of metallic material; an identifier for a
material of a slug used
to produce an impact extruded container body; an identifier or serial number
of the coil; a
position of a mark on the continuous sheet; an identifier for a bodymaker that
formed the
metallic container; an identifier for a washer that handled the container
body; information
about a fluid used to wash the container body, an identifier for a dry-off
oven the processed
the container body; information about operation conditions of the dry-off
oven; an identifier
for a basecoater that formed a basecoat on the container body; information
about the
basecoat material; an identifier of a basecoat oven that cured the basecoat;
an identifier of a
decorator that formed a decoration on the sidewall; information about the
decoration formed
by the decorator; information about the decorator material used to form the
decoration; an
identifier for a deco oven that cured the decoration, information about
operation conditions
of the deco oven (such as a temperature within the oven); an identifier for an
internal coater
that sprayed a coating into a hollow interior of the container body;
information about the
internal coating material used by the internal coater; an identifier for
internal bake oven that
cured the internal coating; information about operation conditions of the
internal bake oven;
an identifier for a necker (or necking station) that formed a neck on the
container body; an
identifier for a fl anger that formed a flange on the container body;
information about a sorter
58 that processed the container body; an identifier for a palletizer that
placed the container
body into a first pallet; an identifier for the pallet; information about a
storage location in
which the pallet was stored (such as a temperature within the storage
location), an identifier
for a shipper that transported the container body to a filler, an identifier
for a filler that filled
and sealed the container body; information about a product stored in the
container body
(such as type, brand, quantity, expiration date, and the like); an identifier
for a second pallet
used to transport the filled container body; an identifier for a distributor
that received the
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second pallet; an identifier for a point of sale that received the container
body; an identifier
for a consumer who purchased the container body; information about a deposit
collected
upon sale of the container body; an identifier for a collection point that
received the
container body; and information about redemption of the deposit when the
container body
was received at the collection point. In some embodiments, each field includes
a timestamp.
Optionally the time stamp will indicate at least a date and a time the mark of
the container
body was scanned.
In some embodiments, a record 140 for a container body 2 may be updated with
information received from other databases or control systems without scanning
the mark 6
by a sensor 34. A record 140 for a container body 2 may be modified with
information
about operation of equipment of the production line 10 after the container
body has been
manufactured. For example, the record 140 may include information about fluids
used to
wash the container body and/or coatings and decorations applied to the
container body
If a fluid, coating, or a decorating material is subsequently identified for
recall or
due to a health concern, records 140 for all container bodies 2 which had
contact with the
fluid, coating or decorating material could be modified by a computer system,
such as
control system 100. Similarly, if a piece of equipment of the production line
10 is found to
be malfunctioning after processing the container body, a record 140 for the
container body
and associated with its unique mark 26 may be modified.
The record 140 of a container body 2 may be updated automatically by the
control
system 100 each time a mark 26 on the container body is scanned. Optionally,
the record
140 may also be manually revised by a user of the control system. A user may
use an input
device 106 of the control system to add, alter, or delete a record 100 in a
database that is
associated with a container body. In this manner, a user (such as a worker on
a production
line) may enter information such as a shift identifier, a serial number for a
coil, an identifier
for a manufacturer of a coil, a date and a time that a coil was loaded into an
uncoiler,
information about a coating used by an internal coater, a weight or quantity
of one or more
coatings applied to a container body, an identifier for a decoration applied
to a container
body, and other production data.
Optionally, data structure 130 may include second data object 134. Second data
object 134 may include the same or similar fields 142 - 154 as first data
object 132. In one
embodiment, the control system 100 may store data for container bodies 2
produced by a
second production line (such as an impact extrusion production line) in data
object 134.
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The tracking and tracing facilitated by the mark 26 is also beneficial for
encouraging
recycling. Tracking and tracing are important for improving the performance of
deposit
return programs, which can be accomplished in a number of ways. For instance,
a consumer
66 can be incentivized to return a container body to a collection point 68 by
receiving a
credit to a mobile device, a loyalty or rewards account, or to a financial
account. The credit
may be a monetary credit, a credit or message on a social network or
application on the
mobile device, or a credit in a loyalty account.
In addition, data from one or more databases 120/124 and records 140 can be
harvested to determine broader trends such as the recycle rate for a
particular production
batch, shift, or production facility, the recycle rate for container bodies
sold at a particular
point of sale 64 or a particular time, recycle rates for container bodies
filled by a particular
filler 62, recycle rates associated with various collection points 68, recycle
rates of specific
consumers 66, etc
In some embodiments, the consumer 66 may be encouraged to scan the mark 26 and
permit a record 140 of the container body stored in a database 120/124 to
include
information about the consumer. The consumer 66 may also provide feedback on
the
performance of the container body 2 which may be added to the record 140
associated with
the mark 26. For example, the consumer may be encouraged to provide feedback
on a
failure of the container body. Similarly, the consumer could provide a review
of a product
stored in the container body.
A consumer 66 may receive benefits when the consumer stores consumer data in
the
record 140 for the container body. In this manner, the control system 100, a
database
120/124, and/or an application on a mobile device or other computer system
associated with
the consumer can push notifications or messages to the consumer regarding
recalls for the
container body or contents within the container body. The consumer 66 may also
receive a
reminder or alert about an expiration date or recall of the contents within
the container body.
In addition, the mark 26 can serve a safety function for the consumer 66 where
the consumer
can scan the mark and determine that the container body is not counterfeit and
that the
container is genuine.
Similarly, a customer such as a brand owner can identify products outside of
typical
distribution channels. For instance, if a finished container with a mark is
found in an
unexpected location or in an unexpected store, the mark can be scanned to
precisely
determine the origin of the container and where the container has traveled to
arrive in the
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unexpected place. Then, a brand owner can determine if the distribution
process for the
particular container comports with, for instance, any contractual obligations,
etc. Similarly,
when a finished container has a mark with a unique code, then any finished
container itself
can be easily identified as legitimate or counterfeit.
Data received by the control system 100 when a mark 26 on a container body is
scanned by a sensor 34 can cause any number of actions. The control system 100
can update
a record 140 in a database 120/124 each time the mark is scanned with
information collected
by the sensor 34. For example, the record 140 can be updated to change a
status of the
particular container (e.g., location, recycled or not recycled, date and time
of the scan, etc.).
The information collected by scans of marks 26 may be used to keep track of
the total
number of container bodies produced, their status, and how many container
bodies have
been recycled within a time period, etc.
Scanning marks 26 on container bodies during the manufacturing process and
storing information about each scan in a record 140 of a database provides
many benefits to
manufacturers of container bodies. For example, the data collected by the
scans allows a
manufacturer to track minute details of the manufacturing process. With this
information,
the manufacturer may identify deficiencies in the manufacturing process, such
as equipment
failures, equipment inefficiencies, or other deficiencies.
The information may also help to identify successes or best practices. For
example,
the data may indicate that one facility (or one production line) is performing
better than
anther facility or production line. Analyzing the data from the different
production lines or
facilities may identify differences that can be used to improve performance of
one or more
other production lines or facilities.
Moreover, scanning marks 26 on container bodies after they leave a production
facility will also provide many benefits to the manufacturer. For example, the
manufacturer
may receive data from the filler when a container body is filled. This
information can be
used for inventory control and may trigger a replacement order.
By tracking and tracing the distribution and sale of container bodies,
manufacturers,
distributors, and recycling centers can identify regions, or demographics,
that are purchasing
particular container bodies. By reviewing information in records 140
associated with the
marks 26 on the container bodies 2, sales of container bodies can be tracked
to consumers
based on a shape or style of container, a product in a container body, as well
as decorations
and advertisements on container bodies.
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Data from a scan of a mark 26 by a sensor 340 at a collection point 68 or by a
consumer 66 may be used to provide a credit or some other benefit to the
consumer 66 to
encourage recycling. In some embodiments, the consumer 66 can redeem a credit
for
currency, receive points or rewards through a loyalty program, buy a product,
etc.
Once a specific container body 2 identified by a mark 26 is received at a
collection
point 68, a signal associated with the collection event can cause a message or
post on a
social network indicating that the consumer 66 has recycled. Thus, the control
system 100
can incentivize the consumer 66 to recycle with financial incentives, social
incentives,
loyalty rewards, etc. In addition, sensors and scanners 34 at other locations
such as a
recycling plant can also read marks 26 on container bodies and transmit
information over a
network to a database 120/124.
The database 120/124 and data structure 130 can take any number of forms, and
the
present disclosure encompasses many embodiments of the system for tracking and
tracing
For example, a database can be remotely located from any of the other
locations and devices
of the tracking and tracing system. Alternatively, the database can be part of
the mobile
device, part of the collection device, part of a control system 100, etc.
Moreover, the
database and/or the actions or functions associated with the database can be
separated
among multiple electronic devices in one or more locations.
In addition to incentivizing an individual consumer, the data received
throughout the
lifecycle of a container body can be used for other purposes. Data from a
plurality of
containers can indicate recycling rates for containers sold at a geographic
location, recycling
rates at a collection device for different times of the day, of the week, of
the year, etc. A
substandard recycling rate can be identified and then, for instance, an
advertisement
campaign can be targeted at this location.
Similarly, success rates for a deposit return program used with an application
on a
mobile device can be tracked using the marks 26 of the present disclosure.
Incentives can
be changed or increased within a geographic area, for a particular brand, or
for a product
based on recycling rates. For example, incentives may be increased within the
geographic
area if recycling rates are low. However, when recycling rates are acceptable,
the incentives
may be maintained at their current levels or decreased. Similarly, incentives
may be
adjusted based on recycling rates for a brand, a product. Data provided by
consumers 66
and stored in a record 140 for a container body may be used to target
advertising to promote
sales and/or encourage recycling based on consumer demographics.
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The marks 26 on container bodies and the tracking and tracing of container
bodies
facilitated by the present disclosure is expected to increase recycling over
the current state
of the art. The increased recycling rates divert container bodies from
landfills and oceans to
recycling plants and reduce the consumption of raw resources used to construct
the
containers.
While various embodiments of the system and method have been described in
detail,
it is apparent that modifications and alterations of those embodiments will
occur to those
skilled in the art. It is to be expressly understood that such modifications
and alterations are
within the scope and spirit of the present disclosure. Further, it is to be
understood that the
phraseology and terminology used herein is for the purposes of description and
should not
be regarded as limiting. The use of "including," "comprising," or "having" and
variations
thereof herein are meant to encompass the items listed thereafter and
equivalents thereof, as
well as additional items Further, it is to be understood that the claims are
not necessarily
limited to the specific features or steps described herein. Rather, the
specific features and
steps are disclosed as embodiments of implementing the claimed systems and
methods.
The term "automatic- and variations thereof, as used herein, refer to any
process or
operation done without material human input when the process or operation is
performed.
However, a process or operation can be automatic, even though performance of
the process
or operation uses material or immaterial human input, if the input is received
before the
performance of the process or operation. Human input is deemed to be material
if such
input influences how the process or operation will be performed. Human input
that consents
to the performance of the process or operation is not deemed to be "material."
The term "bus" and variations thereof, as used herein, can refer to a
subsystem that
transfers information and/or data between various components. A bus generally
refers to the
collection communication hardware interface, interconnects, bus architecture,
standard,
and/or protocol defining the communication scheme for a communication system
and/or
communication network. A bus may also refer to a part of a communication
hardware that
interfaces the communication hardware with other components of the
corresponding
communication network. The bus may be for a wired network, such as a physical
bus, or
wireless network, such as part of an antenna or hardware that couples the
communication
hardware with the antenna. A bus architecture supports a defined format in
which
information and/or data is arranged when sent and received through a
communication
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network. A protocol may define the format and rules of communication of a bus
architecture.
A "communication modality" can refer to any protocol or standard defined or
specific communication session or interaction, such as Voice-Over-Internet-
Protocol
("VoIP), cellular communications (e.g., IS-95, 1G, 2G, 3G, 3.5G, 4G, 4G/IMT-
Advanced
standards, 3GPP, WIMAXTm, GSM, CDMA, CDMA2000, EDGE, 1xEVDO, iDEN, GPRS,
HSPDA, TDMA, UNIA, UNITS, ITU-R, and 5G), BluetoothTM, text or instant
messaging
(e.g., AIM, Blauk, eBuddy, Gadu-Gadu, IBM Lotus Sametime, ICQ, iMessage, IMVU,
Lync, MXit, Paltalk, Skype, Tencent QQ, Windows Live MessengerTM or Microsoft
Network (MSN) MessengerTM, Wireclub, Xfire, and Yahoo! MessengerTm), email,
Twitter
(e.g., tweeting), Digital Service Protocol (DSP), and the like.
The term "communication system" or "communication network" and variations
thereof, as used herein, can refer to a collection of communication components
capable of
one or more of transmission, relay, interconnect, control, or otherwise
manipulate
information or data from at least one transmitter to at least one receiver. As
such, the
communication may include a range of systems supporting point-to-point or
broadcasting
of the information or data. A communication system may refer to the collection
individual
communication hardware as well as the interconnects associated with and
connecting the
individual communication hardware. Communication hardware may refer to
dedicated
communication hardware or may refer a processor coupled with a communication
means
(i.e., an antenna) and running software capable of using the communication
means to send
and/or receive a signal within the communication system. Interconnect refers
to some type
of wired or wireless communication link that connects various components, such
as
communication hardware, within a communication system. A communication network
may
refer to a specific setup of a communication system with the collection of
individual
communication hardware and interconnects having some definable network
topography. A
communication network may include wired and/or wireless network having a pre-
set to an
ad hoc network structure.
The term "computer-readable medium," as used herein refers to any tangible
storage
and/or transmission medium that participates in providing instructions to a
processor for
execution. Such a medium may take many forms, including but not limited to,
non-volatile
media, volatile media, and transmission media. Non-volatile media includes,
for example,
non-volatile random access memory (NVRANI), or magnetic or optical disks.
Volatile
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media includes dynamic memory, such as main memory. Common forms of computer-
readable media include, for example, a floppy disk, a flexible disk, hard
disk, magnetic tape,
or any other magnetic medium, magneto-optical medium, read only memory (ROM),
a
compact disc read only memory (CD-ROM), any other optical medium, punch cards,
paper
tape, any other physical medium with patterns of holes, a random access memory
(RAM),
a programmable read only memory (PROM), and erasable programmable read only
memory
EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other
memory
chip or cartridge, a carrier wave as described hereinafter, or any other
medium from which
a computer can read. A digital file attachment to an e-mail or other self-
contained
information archive or set of archives is considered a distribution medium
equivalent to a
tangible storage medium When the computer-readable media is configured as a
database,
it is to be understood that the database may be any type of database, such as
relational,
hierarchical, object-oriented, and/or the like Accordingly, the disclosure is
considered to
include a tangible storage medium or distribution medium and prior art-
recognized
equivalents and successor media, in which the software implementations of the
present
disclosure are stored. It should be noted that any computer readable medium
that is not a
signal transmission may be considered non-transitory.
The terms display and variations thereof, as used herein, may be used
interchangeably and can be any panel and/or area of an output device that can
display
information to an operator or use. Displays may include, but are not limited
to, one or more
control panel(s), instrument housing(s), indicator(s), gauge(s), meter(s),
light(s),
computer(s), screen(s), display(s), heads-up display HUD unit(s), and
graphical user
interface(s).
The term -module" as used herein refers to any known or later developed
hardware,
software, firmware, artificial intelligence, fuzzy logic, or combination of
hardware and
software that is capable of performing the functionality associated with that
element.
The terms "determine," "calculate," and "compute," and variations thereof, as
used
herein, are used interchangeably and include any type of methodology, process,
mathematical operation, or technique.
While the exemplary aspects, embodiments, options, and/or configurations
illustrated herein show the various components of the system collocated,
certain components
of the system can be located remotely, at distant portions of a distributed
network, such as
a local area network (LAN) and/or the Internet, or within a dedicated system.
Thus, it should
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be appreciated, that the components of the system can be combined in to one or
more
devices, such as a Personal Computer (PC), laptop, netbook, smart phone,
Personal Digital
Assistant (PDA), tablet, etc., or collocated on a particular node of a
distributed network,
such as an analog and/or digital telecommunications network, a packet-switch
network, or
a circuit-switched network. It will be appreciated from the preceding
description, and for
reasons of computational efficiency, that the components of the system can be
arranged at
any location within a distributed network of components without affecting the
operation of
the system. For example, the various components can be located in a switch
such as a private
branch exchange (PBX) and media server, gateway, in one or more communications
devices, at one or more users' premises, or some combination thereof.
Similarly, one or
more functional portions of the system could be distributed between a
telecommunications
device(s) and an associated computing device.
Furthermore, it should be appreciated that the various links connecting the
elements
can be wired or wireless links, or any combination thereof, or any other known
or later
developed element(s) that is capable of supplying and/or communicating data to
and from
the connected elements. These wired or wireless links can also be secure links
and may be
capable of communicating encrypted information. Transmission media used as
links, for
example, can be any suitable carrier for electrical signals, including coaxial
cables, copper
wire and fiber optics, and may take the form of acoustic or light waves, such
as those
generated during radio-wave and infra-red data communications.
Optionally, the systems and methods of this disclosure can be implemented in
conjunction with a special purpose computer, a programmed microprocessor or
microcontroller and peripheral integrated circuit element(s), an ASIC or other
integrated
circuit, a digital signal processor, a hard-wired electronic or logic circuit
such as discrete
element circuit, a programmable logic device or gate array such as PLD, PLA,
FPGA, PAL,
special purpose computer, any comparable means, or the like. In general, any
device(s) or
means capable of implementing the methodology illustrated herein can be used
to
implement the various aspects of this disclosure. Exemplary hardware that can
be used for
the disclosed embodiments, configurations and aspects includes computers,
handheld
devices, telephones (e.g., cellular, Internet enabled, digital, analog,
hybrids, and others), and
other hardware known in the art. Some of these devices include processors
(e.g., a single
or multiple microprocessors), memory, nonvolatile storage, input devices, and
output
devices. Furthermore, alternative software implementations including, but not
limited to,
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distributed processing or component/object distributed processing, parallel
processing, or
virtual machine processing can also be constructed to implement the methods
described
herein.
In embodiments, the disclosed methods may be readily implemented in
conjunction
with software using object or object-oriented software development
environments that
provide portable source code that can be used on a variety of computer or
workstation
platforms. Alternatively, the disclosed system may be implemented partially or
fully in
hardware using standard logic circuits or very-large-scale-integration (VLSI)
design.
Whether software or hardware is used to implement the systems in accordance
with this
disclosure is dependent on the speed and/or efficiency requirements of the
system, the
particular function, and the particular software or hardware systems or
microprocessor or
microcomputer systems being utilized.
In yet another embodiment, the disclosed methods may be partially implemented
in
software that can be stored on a storage medium, executed on programmed
general-purpose
computer with the cooperation of a controller and memory, a special purpose
computer, a
microprocessor, or the like. In these instances, the systems and methods of
this disclosure
can be implemented as program embedded on personal computer such as an applet,
JAVA
or computer-generated imagery (CGI) script, as a resource residing on a server
or computer
workstation, as a routine embedded in a dedicated measurement system, system
component,
or the like. The system can also be implemented by physically incorporating
the system
and/or method into a software and/or hardware system.
Although the present disclosure describes components and functions implemented
in the aspects, embodiments, and/or configurations with reference to
particular standards
and protocols, the aspects, embodiments, and/or configurations are not limited
to such
standards and protocols. Other similar standards and protocols not mentioned
herein are in
existence and are considered to be included in the present disclosure.
Moreover, the
standards and protocols mentioned herein and other similar standards and
protocols not
mentioned herein are periodically superseded by faster or more effective
equivalents having
essentially the same functions. Such replacement standards and protocols
having the same
functions are considered equivalents included in the present disclosure.
Examples of the processors as described herein may include, but are not
limited to,
at least one of Qualcomm Snapdragon 800 and 801, Qualcomm Snapdragon 610
and
615 with 4G LTE Integration and 64-bit computing, Apple A7 processor with 64-
bit
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architecture, Apple M7 motion coprocessors, Samsung Exynos series, the
Intel
CoreTM family of processors, the Intel Xeong family of processors, the Intel
AtomTM
family of processors, the Intel Itanium family of processors, Intel Core i5-
4670K and
i7-4770K 22nm Haswell, Intel Core i5-3570K 22nm Ivy Bridge, the AlVID FXTm
family of processors, AMD FX-4300, FX-6300, and FX-8350 32nm Vishera, AMDO
Kaveri processors, Texas Instruments Jacinto C6000TM automotive infotainment
processors, Texas Instruments OMAPTm automotive-grade mobile processors, ARM
COrtCXTMM processors, ARM Cortex-A and ARM926EJ-STm processors, other
industry-
equivalent processors, and may perform computational functions using any known
or future-
developed standard, instruction set, libraries, and/or architecture.
To provide additional background, context, and to further satisfy the written
description requirements of 35 U.S.C. 112, the following references are
incorporated by
reference herein in their entireties: British Pat. Pub. No 2154775A, European
Pat. App.
No. 1467306A2, Japanese Pat. No. 3,971,064, Japanese Pat. No. 4532259, PCT
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W02005/104005, PCT Pub. No. W02013/135899A1, PCT Pub. No. W02013/138595A2,
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