Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
WO93/1497~ C A 2 i 1 7 4 2 ~ PCT/US92/00628
HANDLING SYSTEM FOR LIGHTWEIGHT CONTAINERS
_ .TTnTT~ BALLAST DISPENSER
Bauk4~uu.,d of the Invention
l. Field of the Invention
This invention relates to the field of container h~n~l ;ng, for
example in bottling plants, and in particular to an ; UVI L in
h~n~l ing systems for lightweight plastic bottles. A limited
quantity of ballast is inserted into the bottles so as to place
temporary additional weight adjacent the bottoms of the bottles
during h~n~l ;ng prior to filling, thereby lowering the center of
gravity of the bottles for stable transport on horizontal
uull~,~yuIY .
2. Prior Art
Bottling systems and similar container processing devices use
automated hAn~l ing apparatus to provide as high a ~h~uuy1~uL rate
as possible. The h~n~l ;ng ~al~Lus typically carries the bottles
in serial order through a number of processing steps such as
washing, rinsing, filling and capping. The h~n~l ;ng apparatus
normally ;n~ A~c various runs of horizontal ~u.l~yul sections,
which move the bottles while supporting them from below. Such
automated h~n~l ;ng apparatus are effective provided the bottles can
be handled smoothly at the required rate.
In a known bottling system, for example, empty bottles are
supplied on pallets wherein levels of bottles are stacked on one
another with interleaved panels providing a supporting surface for
the bottles on each level or rank. A depalletizer removes each
topmost level or rank of bottles from the pallets, and places the
rank at a receiving platform defining the input section of a
horizontal cu..~u~. The receiving platform has a horizontal
support surface leading to a funnel-like constriction wherein
s1~ccess;ve decreases in width along the conveying path force the
bottles into single file, from which the bottles proceed serially
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C sA ~
one after another through continuously operating processing steps.
The funnel-like section serves to A~ l Ate the bottles because
each rank from the depalletizer requires a certain time to be
converted from an X-Y array of bottles to a single file.
Theoretically, the next rank is supplied just as the previous rank
is exhausted.
The bottles in the single file are then carried by a COII~C~L
typically having one or more endless loops of CG~-vcyu~ belt,
horizontally attached link plates, rollers or the like, which
define a moving horizontal platform for supporting the bottles
while advancing the bottles to the next processing station. Each
bottle simply rests on a horizontal surface which is moved to
advance the bottle. The bottles move through stations typically
including the depalletizer and funnel aL.~n, ~ as described, a
bottle washer or rinser where the bottles are inverted and a fluid
is sprayed in from below and then allowed to drain, and a filler
and capper. The filler and capper has a carousel with a plurality
of filling positions at which an empty bottle can be received,
filled and finally capped, while moving along a conveying path.
The bottling system preferably runs continuously. For maximum
production it is n~csAry to avoid both st~ppagee of the line and
gaps in the single file ~ .escion of bottles. In addition to the
lost production caused by gaps in the line, the bottles to some
extent support one another upright as they are moved along the
COIlvcy~L. Where gaps occur, the bottles leading and trailing the
gap lack support from adjacent bottles and more easily fall over.
When a bottle falls over, the entire line may become jammed.
It is difficult to avoid gaps in the continuous progression
of bottles along the horizontal C~lv~vI. A gap occurs at least
between batches of bottles when starting and stopping any of the
proc~cc;ng stations along the bottle path. Depalletizing is
inherently a batch process. Various oc~uL-c..~es along the path of
the bottles may result in gaps opening up. Typically, one or more
workers are required to watch the line and to clear jams.
The general nature of bottling plants is well known and well
developed. In recent years, however, plastic containers have come
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into use. The plastic containers are thin but durable, and light
~ in weight, which qualities have obvious advantages in reduction of
shipping weight, ability to use lighter production equipment and
the like. However, the bottles are so lightweight as to be
unstable when carried on a horizontal ~o~ vr. In order to avoid
jamming of bottling lines when running plastic bottles, the lines
are run substantially more 610wly than a comparable line running
glass bottles, which are heavier and therefore more stable. Even
at slower rates of th.~u~l-~uL, the plastic bottles tend to fall
over much more frequently than do gla6s bottles, and more workers
are needed to correct recurrent jamming and resume proper operation
of the line.
Plastic bottles are used for a wide variety of products. A
typical lightweight plastic bottle is made of polyethylene
terephthalate (PET). Standard bottle capacities, for example for
beverage containers or bottled water are 12 ounce, 16 ounce, 20
ounce, 1 liter, 1.5 liter, 2 liter and 3 liter. Of course other
size6 are also poss;hlP and in standard use for various products.
Plastic is also a popular material for other forms of containers
which might be described as cans or jars rather than bottles.
In recent years, te~hnicAl advances have reduced the weight
of plastic containers such as bottles by as much as 30%. Whereas
a glas6 bottle in a small Le~_L~ye container size might weigh 6
ounces, a plastic bottle of comparable volume weighs a fraction of
an ounce. The bottles are often taller than they are wide and when
---u~ Led are easily knocked over, for example by uneven conveyor
pA~sAge~, impacts, or even by a breeze in the bottling plant.
Plastic bottles can be made in one integral piece of PET, or
can be as6embled from two or more pieces. A standard two piece
~ 30 variety includes an attached base cup which is bonded to the bottom
of the bottle, tending to protect the base and incidentally adding
to the bottle weight at the bottom. Plastic bottles in one
integral piece also can be made with an exces6 of plastic at the
bottom. A "petaloid" form of bottle has a scalloped bottom with
radially oriented folds which increase the rigidity of the bottle
at the bottom and also provide additional weight at the bottom due
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to the additional material at the fold. Another form of bottle is
the ~rh~ type, which has an inward dome in the bottom. A
form of bottle construction that has a larger proportion of
material at the bottom is inherently more stable than a bottle
which is more top heavy. Of course a bottle with a shorter and
wider form will also be more stable than a bottle which is taller
and ~ r. The present invention is applicable to any of these
forms; however, a relatively tall and narrow bottle with a minimum
of material at the base of course can achieve the greatest
; ~c L in stability.
In bottles having a reinforcing bottom cup, the cup is
generally made of less expensive plastic than PET. The cup is
normally opaque rather than clear. The added bottom weight is
helpful for stability, but on the other hand the reinforcing cup
c~n~eAl~ the contents at the bottom, requires additional
manufacturing steps, and renders the bottle unacceptable for
recycling into new PET material. The bottom cup is also
undesirable in that it adds to the total weight of the bottle after
the bottle is full and stability is no longer a problem. Recycling
operations typically cut off and discard the entire bottom of
cupped bottles in order to recycle the PET top.
It is possible to deal with problems encountered due to the
instability of plastic bottles by varying the nature of the
~u..~v~. According to one method, plastic bottles are not carried
on horizontal support surfaces, but rather are moved along
supporting ~Llu~Lu~es having rails or flanges that face inwardly
to engage the neck of the bottle. The bottles are provided with
a circumferential bead or flange at the neck, that rests on the
CO~ vl rails to support the bottle. In an example known as an
Airveyor, the bottles are supported entirely by such rails, and
blasts of air are used to propel the bottles along the ~o..v~Oyo~
path. While such systems are useful, it would be desirable to
provide a substantially jam-proof arra- L that does not require
added bottle material, processing requirements and/or c~--vc~yvr
sL u~ Lur-O .
As noted above, instability is a critical problem with
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lightweight plastic containers. Instability is less of a problem
with glass containers as they are heavier to begin with. However,
even a glass bottle may have a particularly high ratio of height
to diameter, making it unstable in the same manner as a plastic
bottle.
In connection with glass bottles, U.S. Patent 2,516,998 -
Ximball et al ~;RC1OSOC adding water to containers along a
~u~ yvr. According to Kimball, reusable (i.e., glass) bottles
enter a ~ lAhol ;ng d~L~LUS along a CV~V~YVL leading to a tank
containing a liquid in which the bottles are to be immersed for the
purpose of soaking the labels off the bottle sidewalls. The
bottles are led into the tank via an inclined run of the CU~V~YUL
and would float in the tank unless steps were taken to force the
bottles to sink. A liguid spraying device is provided upstream of
the tank to fill the bottles sufficiently that they sink when
carried into the soaking liquid by the ;n~l ;n~d CUJ~V~YUL . The
bottles are ; Ded until their neck labels are below the level
of liguid in the tank.
According to the present invention the bottles are not filled
to where they would sink. Instead, bottles are stAh;li7od by
pr~l;m;nArily placing a limited quantity of ballast in the bottom
of the bottles. The ballast can be added in an amount comparable
to the empty weight of the bottle, the ballast residing immediately
adjacent the bottom. This lowers the center of gravity of the
bottles as -ed to empty bottles (and also as compared to
substantially filled bottles) such that the stAh;l;~od bottles will
not easily fall over when carried on a VV~V~yuL which supports the
containers from below.
Ximball does not lower the center of gravity of the bottles
or otherwise address stability. Kimball simply increases the
overall weight of the bottles to exceed the weight of the soaking
liquid which the bottles displace when ~;cpos~ in the tank. The
bottles are glass, which is heavier than water (specific gravity
approximately 2.3); however, in view of the thin walled hollow
nature of the bottles it is n~c~csAry to substantially fill them
with water to make them heavy enough to sink as required to their
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necks. Ae _ ;nq that a bottle is filled completely with liquid,
or at least filled to a point substantially above the center of
gravity as empty, the resulting (filled) center of gravity is
approximately at the same height as the center of gravity of the
bottle when empty. Additionally, substantial filling requires
substantial time, as does emptying the container afterwards.
A typical bottling plant includes at least a means for rinsing
the containers. U.S. Patent 2,915,773 - Whelan discloses
dispensing a spray from an upwardly oriented nozzle into a
downwardly oriented bottle, for rinsing. The spray of course
drains away.
U.S. Patent 3,079,936 - Hockett et al discloses complete
immersion of bottles, followed by inverted rinsing. Hockett
requires individual pockets for supporting each bottle, and
therefore avoids problems with the bottles falling over.
U.S. Patent 3,159,164 - NcBrady ~i ep ne~e cleaning fluid
upwardly into the containers when carried around a carousel which
inverts the containers. As in Whelan, the fluid drains away. As
in Hockett, the containers are individually supported, thus
avoiding a need for stability, as in horizontally supportea
bottles.
U.S. Patent 3,270,783 - Hughes discloses a bottle filling
apparatus. The bottles are of course filled substantially
completely with the contents to be stored therein. Whereas the
bottles are filled, the center of gravity is not lowered as occurs
when a limited quantity of ballast is placed in a container to
improve stability.
U.S. Patent 3,545,024 - Randrup discloses cleaning the
external surfaces of bottles. According to the disclosure, gross
a lations of the cleaning liquid are to be removed. The
A~_ lAtiOnS which are described are on the outside surface of the
bottles.
U.S. Patent 3,674,060 - Ruekberg limits the level to which a
container is filled by a filling machine. Nevertheless, the
container is filled substantially completely and no means are
suggested for improving stability by limited filling with ballast
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during hAn~l i ng of the empty containers.
In U.S. Patent 3,985,096 - Gu; etiere, fluids are applied
to medical slides. The slides are supported individually by
suction cups, as needed to incline the slides for removal of excess
fluid which remains after application of the fluid.
U.S. Patent 4,061,152 - Babunovic employs spray heads on a
manifold in a bottle washing apparatus. The ~a.-Lus includes
nozzles which direct fluid over the containers. However, the
containers are supported in a fixed rank by the apparatus and moved
together with the support through a circuitous path including-
inversion of the containers. There is no means to improve
stability of empty containers on a ~u~ u. by prel;m;nAry addition
of a limited quantity of ballast.
U.S. Patent 4,325,775 - Moeller includes a drenching station
with a downwardly directed fluid nozzle 26. The drenching station
is intended to apply water externally for softening labels on the
outer surface. Whereas the drenching nozzle is above the container
in Fig. 2, some of the drenching liquid might be expected to fall
into the container. The ~;~closed drenching uses a "high volume"
of fluid (Column 2, line 33), thereby presumably filling the
container. The container is fully supported by the ~1 Ah~l; ng
~-u~ Lu-~3
U.S. Patent 4,683,009 - Shriver COIl~eLllS spraying a sealing
_ ' on the surfaces of plastic containers. The . ' is
applied externally. A jet of hot air is applied downwardly.
U.S. Patent 4,715,920 - Ruppman et al also handles plastic
bottles. The bottles are supported by their necks, either
individually or on a neck rail. A supplemental polyethylene cup
is attached to the bottom of each bottle, rendering the bottles
~ 30 bottom heavy. Ruppman is an example of the processing steps
required to place protective cups on the bottoms of bottles.
U.S. Patent 4,779,634 - Gutierrez et al applies rinse water
to containers already filled with a food product. The containers
are inverted to drain the surface water from the food while the
food is retained by a perforated panel.
In order to enable an increase in production speed in
W093/14975 C A 2 1 1 7 4 2 0 PCT/US92/~K28
processes such as bottling plants which require the h~n~l inq of
plastic bottles, it would be desirable to render the bottles more
stable without increasing the cost and complexity of bottle
processing and without attaching additional material to the
bottles. It would also be desirable to provide a means to render
the bottle stable when needed, i.e., when the bottle is empty and
being cu..~c~Gd, which does not increase the weight of the bottle
thereafter. These objectives should be met without substantially
interfering with the h~n~l ing of the bottles during washing or
rinsing, filling and/or capping.
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Summarv of the Invention
It is an object of the invention to facilitate hAn~l ;ng of
lightweight containers, ~CpeciAlly plastic bottles, by temporarily
increasing the weight of the bottles during hAn~l ing while empty,
using an easily placed and easily removed ballast.
It is another object of the invention to provide an
~ t for bottle hAn~l ing apparatus in the form of a
particular method and apparatus for adding ballast to bottles.
It is a further object of the invention to add weight to
bottles in a manner that does not add to the permanent weight, use
of materials or hAn~ 1; ng problems associated with bottles.
It is a yet another object of the invention to provide an
amount of temporary water ballast in an empty container sufficient
to lower the center of gravity of the bottle below the center of
gravity of an empty bottle, by filling the bottle for a limited
height adjacent the bottom.
These and other objects are accomplished by a method for
hAnAl ing lightweight open containers, including arranging the empty
containers in an upright orientation, ~;cp~nc;ng a guantity of
ballast into the containers, and moving the containers along a
cvl.~eyu., the ballast tending to keep the containers stable on the
cv,.~y~.. The ballast is preferably water and can be removed after
the bottles have been moved on the vv~VeyvL ~ for example by
inverting the containers to drain the ballast by gravity. In a
bottling plant the typical rinsing a~a.c~us can be used to empty
the bottles of ballast in this manner. This arrAn~, ~ works
quite well with polyethylene terephthalate (PET) bottles. A
limited quantity of water ballast, preferably 2% to 10% of the
container volume (normally about 50% to 150% of the empty container
weight), precludes many of the problems of bottle fallover and
bottle jamming that are associated with very lightweight bottles.
This amount of ballast is minimal, for example one or two ounces
in typical be~ ge containers or containers for bottled water, and
can be ~;cp~nced into the containers very quickly while the
containers are being loaded onto a cv..~o. or p.vcessed along the
COIIveyv~. The water ballast occupies, for example, about 0.5 to
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1.0 inch of the container height (e.g., 6 to 12 inches), or between
4% and 10% of the container height. This limited amount can be
inserted quickly and also can be drained quickly when no longer
needed, e.g., during the bottle washing, rinsing and draining
steps.
Preferably, the ballast is added at an early point in
processing empty containers, for example during or immediately
after depalletizing the bottles. The ballast can be added at this
point by an array of valves associated with a ballast reservoir
under which the bottles are passed while arranged in a
C~L~ ; ng array in an upright orientation. Once the ballast
is added the bottles can be handled at high speeds and through
various Oba~r u~-ions. According to the invention the relatively
low typical speed of a bottling system for lightweight containers
(e.g., several hundred per minute) can be increased substantially
(e.g., to 2500 per minute or more).
The valves c icating with the reservoir or other source
of ballast can by arranged in an X-Y array or in a line. According
to a preferred ~ L the valves are defined by a plurality of
oponingc in a reservoir wall controllably plugged by valve bodies
attached to a common support. The valves are opened simultaneously
by displacing the common support.
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Brief DescriPtion of the Drawinqs
The invention is described herein with reference to a number
of exemplary ~ s but is capable of : ' 'i~ ~ in other
specific forms in accordance with the invention as defined in the
~ A~d claims. In the drawings,
Fig. 1 is a p~LD~uLive view of an initial section of a
container hAn~l inq process according to the invention, with a
depalletizer leading to a horizontal co..v~ur;
Fig. 2 is a pe~D~euLive view from an opposite direction, with
the depalletizer shown generally and the ballast reservoir broken
away;
Fig. 3 is an elevation view thereof;
Fig. 4 is an elevation view of a further section in the
hAn~l inq process, leading to a container rinser;
Fig. 5 is a section view showing a preferred ballast ~;.cp~nc~r
according to the invention;
Fig. 6 is a partial elevation view of the ballast ~i cp~nc~r;
and,
Fig. 7 is a pelD~euLive view of a ballast ~; cp~nC~r according
to an alternative : ~
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Detailed DescriPtion of the Preferred ~ '; Ls
The invention provides a method for ~An~l ing lightweight open
containers, particularly plastic containers such as bcvc~ge
bottles and water bottles, but also including other forms of empty
containers and the like which are subject to falling over when
carried on a cv,.vc~v.. The containers are arranged in an upright
orientation, a quantity of ballast is ~icp~nC~ into the containers
to lower their center of gravity, and thereafter while moving along
a VV~ Vr~ the ballast keeps the containers stable. After serving
its stabilizing function, the ballast is removed, preferably simply
by inverting the containers at a container rinser.
Fig. 1 illustrates the initial section of a container
processing plant, in particular a bottling plant as typically used
in bottling soft drin~s, b_.e~ ges or bottled water. Such bottles
are typically employed in standard sizes with volumes of 12, 16 and
20 fluid ounces and in 1, 1.5, 2 and 3 liters. The containers can
be polyethylene terephthalate (PET) bottles, which are quite light
in weight. The containers in general pass through stages of
depalletizing, ballast loading, rinsing (which includes inverting
the containers and thereby nnloA~ing the ballast), filling and
capping.
The depalletizer 30 receives a pallet 22 of bottles 20 or the
like. The bottles 20 are supplied in a plurality of horizontal
levels or ranks 26. For example, each rank may have 300 or more
bottles, standing upright on their bottoms on a divider panel 24.
The depalletizer 30 includes a vertical ;n~Ying drive means 34
operable to raise the pallet 22 in increments equal to the vertical
height of a rank 26 and its base panel 24. After each index the
uppermost rank is ~iPpos~d at the same level as a cv..~O~vr 40. A
sweep bar or housing 32 encloses around the periphery of the
u~pe~ L rank, and when the l~pp~ ~ rank is in position the
sweep bar 32 advances toward and over cvll~eyv~ 40 to move the
peripherally enclosed bottles onto the ~v...c~v, 40. Conveyor 40
can be arranged to index ~yJlVIl~ onvusly with advance of the sweep
bar or can be continuously moving. Conveyor 40 in the ~
shown defines an endless loop, however, it can be made up in
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sections of smaller endless loops. The cu~ yul can have a
continuous flexible mesh or the like, or can be made of linked
plates. At least the section in the area of the ballast loading
apparatus 160 is foraminous or arranged with gaps, such that
spillage of the ballast can fall through to a receptacle therefor.
The ballast can be loaded by passing the upright bottles
through a continuous downward spray. However, this is somewhat
wasteful of water and/or pumping capacity. Each rank of bottles
at the depalletizing stage in processing is arranged in an orderly
fashion, with the bottles dicros~d in a regular X-Y array. The
ballast loader 160 accordingly preferably has dispensing orifices
for each position in the array, operated briefly when the bottles
are aligned with the d;cpGncing orifices. When the rank 26
advances to a point in registry with the ballast loader, which can
be timed or sensed, the ballast loader is activated and a quantity
of ballast, preferably clean water, is di cp~nC~d into each of the
bottles in the array. The added ballast renders the bottles
substantially more bottom heavy and stable, reducing the tendency
of the bottles to fall over. Without the added ballast the bottles
would often fall over, particularly at the leading and trailing
lines in the rank, where no n~ighhnring bottle is dicpo5~d to help
keep the outermost bottles upright. Without ballast, it is also
sometimes the case that an inwardly falling bottle will cause a
whole line of bottles to fall in a domino effect.
It is also p~cci hl ~ to add ballast to a limited number of
bottles in a rank, although this is not preferred. For example,
ballast could be added to the peripheral bottles only, thus
defining a stable wall of bottles enclosing the unstable internal
bottles. Ballast could also be added to every other bottle, etc.
However, since the relative positions of the bottles is not
retained throughout the process, it is preferred that all the
bottles be loaded with ballast.
Other forms of depalletizers and the like can also be equipped
with ballast loading means. For example, in an ~ ~ 'i L (not
shown) wherein the containers in a row are transferred from a
pallet to a CUIIV~YUL using gripping -. -ni I ~, the gripping
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' -ni F~ can be provided with a nozzle that injects the ballast
during the transfer. Alternatively, the ballast loader can be
placed at another point in the bottle processing sequence.
In the exemplary ~ L shown, the bottles moving in a
stable rank along ~v..~o~ 40 are converted into a row arrA L
to be carried further through the process along CullveyOr 60. There
are a number of posslhilities for converting an X-Y array into a
row. In the : 'i ~ illustrated in Fig. 1, for example, the
lateral sidewalls enclosing cG..~Jvl 40 are narrowed inu,~ Lally,
forcing the bottles 20 to merge into a row for receipt on single
file cu..~u~ 60. This structure is an example of an obstruction
along the cullveyu~ path that could easily cause bottles to fall
over, particularly if the COllVt~ ~ iS moving at a substantial
speed. Various potential obDL~uuLions may be defined along a
typical conveying path. The ballast in the bottles renders the
bottles stable and allows them to be advanced through such
obDL uuLions at a DuLDL~..Lial speed without undue fallovers.
Fig. 2 illustrates an : ~ ~ir L including one or more gates
36 for retaining the rank in position at the dispensing station.
The gates 36 can by pivotable vertically or horizontally, for
example being mounted on supports 42 for the ballast reservoir 44.
An air cylinder (not shown~ can advance and retract the gates for
each ballast loading cycle.
As shown in Fig. 3, the ballast reservoir 44 can be vertically
adjustable, for example via hAn~hPPl 56. This enables the
orifices in the reservoir to be placed immediately over the open
tops of the bottles. The hAn~heel can drive a rack and pinion
positioning ~-ni ~ or a winch for lifting and lowering the
reservoir. Suitable locking means fix the reservoir at the desired
position.
Conveyor 60 (see Fig. 1) advances the bottles, preferably in
single file, to a rinsing apparatus 110. The ir inq COIl~eyur 40
can be positioned at the height of the highest rank of bottles in
a pallet, and the co..~_yu~ path d --DLLe-~ along the bottle path
can include a decrease in elevation via in~l inPd COn~yOr section
70. This enables mounting of the rinsing apparatus and
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filler/capper at floor level. A suitable inclined CUI.veyuL is
available under the tradename Lowerlator.
The rinsing apparatus 110 as shown in Fig. 4 inverts the
bottles initially, thereby draining the ballast via gravity, sprays
a rinse solution (preferably clean water) into each bottle, and
after a draining time replaces the bottle upright. During passage
from the ballast loading apparatus 160 to the rinsing apparatus
110, the bottles are stable, and this is achieved without adding
to the material or expense of the bottles. The ballast system has
a minimal effect on the bottling process as a whole. TnA -' as
the bottles are to be rinsed in any case, the ballast does not
require additional steps to remove or further clean the bottle, in
addition to that already undertaken in the known rinser.
o~L-~lay and drained rinse solution or ballast is preferably
leuu.~,èd. In the area of ballast loader 160 a catch basin 46
defining a wide channel under CUII~YUL 40 receives uv~ ay and
the like from the ballast loader. The channel can extend
continuously along the length of the inclined section 70 to the
rinsing a~LaLus to catch ballast dripping from the outside of the
bottles. Alternatively, the catch basin 46 can be connected by
suitable conduits to the ballast storage reservoir 44 with a pump
provided for moving the collected ballast fluid or material back
to the ballast ~;cp~nc~r. In the ~ L shown in Figs. 3 and
4, the catch basin 46 is arranged to drain into the same reservoir
122 used by the rinser 110. A pump 48 moves the ballast material
back to the reservoir 44 and also provides ~.es~uLized water for
rinser heads 116. Pump 48 or a valve along the path from pump 48
to the reservoir 44 can be operable under control of a level or
~.es~uLe sensor at reservoir 44 (not shown), for maintaining a
~ 30 predet~rmin~d level or ~eSau~ of ballast fluid in the reservoir.
The rinser 110 also includes a catch basin 118 draining into
~ a tank 122, collecting u~r~ay and drainage, and recycling the
solution. The preferred solution for both ballast and rinsing is
clean water, and suitable filtering and/or water purification
apparatus can be associated with the water h~nAl ing systams for
both ballast and rinsing such that the water remains clean for at
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least a number of ballast or rinsing cycles. Of course it is also
possible to use fresh water for ballast and/or rinsing and simply
to discard the water after use.
The rinser 110 receives bottles from the inclined COIlveyu~
section 70 and inverts the bottles via an inverting guideway 112
leading to a section of cu--v~v~ at which the bottles are moved
while inverted. The rinse spray and drainage collection means are
~i~posed at this section. A further inverting guideway 114 returns
the bottles to the upright orientation for filling and capping at
an a~a- aLus (not shown) placed ' ..sL,eam of the rinser along the
bottle path, in a conventional manner. Inverting guideways and
filler/capper apparatus are known in the art per se. However, the
operational speed of Cv~ yuI4, rinsers and filler/capper apparatus
has been limited as applied to lightweight containers due to
lS problems with hAn~l ing the containers in a manner that is not
unduly subject to jamming.
The preferred containers (e.g., bottles) essentially comprise
polyethylene terephthalate, which is lightweight and durable, but
is quite unstable in h~n~l ing of empty containers due to the low
weight of the material and the relatively top heavy arrA , 0 of
thin walled plastic containers in the sizes and shapes which have
become standard for beverage bottles, bottled water containers and
the like. These sizes and shapes are desirable because they are
convenient for pouring and fit into standard storage shelves in
refrigerators and the like. The weights and dimensions of a number
of standard sizes are illustrated in Table 1, including containers
with attached protective bottom cups and those which are one
integral material. The containers vary in ratio of height to
diameter, but generally are two to four times as tall as they are
wide.
TABLE 1
TYPE - WGT - BOTTLE/CUP - DIA - HGT - RATIO D/H
12 oz. water 24g (one piece) 5.6cm 18.lcm 3.3
16 oz. beverage 27-29 (one piece) 6.7 16.8 2.5
1 liter béve~a~e 42 (one piece) 7.6 27.6 3.6
1 liter be~ra~ê 48 39g/9g 7.6 27.6 3.6
1.5 liter water 42-47 (one piece) 8.6 30.2 3.5
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2 liter beve~e 56(one piece) 10.5 29.9 2.9
- 2 liter L~ e 6949/20 10.5 29.9 2.9
3 liter beve~e 80(one piece) 12.1 32.7 2.7
3 liter L_~ e 9672!24 12.1 32.7 2.7
The preferred amount of ballast to be d;cpPnc~d into the
containers is shown in Table 2, together with a comparison of the
volume and height of the preferred amount of ballast to the volume
and height of the container. The preferred amounts of ballast are
small compared to the container volume, and thus can be loaded into
the container quickly, and drained quickly after use. The noted
amounts are preferred and it should be understood that the specific
ratios and volumes can be changed as appropriate in view of
variations in the container height to width ratio, the relative
need for stability in view of other aspects of the hAndl ;ng
apparatus, etc. Stabilitywill always improveprovided the ballast
is added in a sufficient amount to lower the center of gravity to
a point lower than the center of gravity of the empty container.
TA~3LE 2
TYPE RAT.T.A~T %VOLUME HEIGHT %HEIGHT %TOTAL WGT
12 oz. water loz 8.3% 1.7cm 9.3% 123%
16 oz. be~L~e 1 6.3 1.4 8.4 105
1 liter b_~ e 2 5.9 2.5 8.9 143
1 liter (2 piece) 2 5.9 2.5 8.9 123
1.5 liter water 2 3.9 2.2 7.3 133
2 liter beveL-ye 2 3.0 1.8 6.0 105
2 liter (2 piece) 2 3.0 1.8 6.0 85
3 liter be~ e 2 2.0 1.6 4.8 73
3 liter (2 piece) 2 2.0 1.6 4.8 61
As presently preferred, in connection with containers of the
standard sizes noted, with height to width ratios of about 2:1 to
4:1, ballast is added in an amount sufficient to fill the bottle to
about 4 to 10% of the container height, which is equivalent to a
relative volume of ballast to total container volume of about 2 to
10%. TnA ~h as the empty containers are quite light, this
WO93/14975 C A 2 1 1 7 ~ 2 0 PCT/US92/~628
limited amount of added ballast ranges from about 50% to 150% of
the container empty weight. It i8 appropriate for containers with
a relatively higher ratio of height to width to use relatively more
ballast, and for cnn~Ain~rs with a lower ratio to use less ballast.
When c~nCi~ring the two piece containers listed in Table 2
(i.e., containers inrl~l~inq end cups~, Table 3 compares the
supplemental bottom weight (ballast plus end cup) to the weight OL
the overall container. Whereas the total weight added to the
container at the bottom (temporarily by the ballast and permanently
by the end cup) is substantial as ~d to the container weight,
and preferably exceeds the container weight, it will be appreciated
that the effect is to move the center of gravity of the container
much closer to the bottom of the bottle than the center of gravity
of the bottle when empty. According to the invention as applied to
containers without end cups, the added stability of a container
with an end cup is obtained (due to the weight of the ballast).
However the ballast is emptied after h~n~l ing~ and accordingly the
drawbacks of an end cup, including the need for additional
material, added weight, etc., are avoided.
TABLE 3
TWO PIECE TYPE TOTAL WGT. BALLAST PLUS ENDCUP%OF TOTAL
1 liter 48g 68g 142%
2 liter 69 79 114
3 liter 96 83 86
Water ballast ~icp~nced into the bottles in sufficient amounts
to place about 0.4 to 2.0 inches, and preferably 0.5 to 1.0 inch of
ballast in the bottom, effectively places a stabilizing weight on
the order of the empty container weight immediately adjacent the
bottom of the container. Whereas an empty container has a center
of gravity that is near the midpoint of its height (or somewhat
lower for bottles with end cups), the ballast temporarily moves the
center of gravity to a point between the original center of gravity
(e.g., the height midpoint) and the bottom of the bottle. The
WO93/14975 PCT/US92/~628
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19
ballast is preferably filled to a point below the center of gravity
of the empty container. However, the amount of ballast can be
increased to a point above the center of gravity of the empty
container provided the net effect is to move the center of gravity
to a point below that of the empty container. More particularly,
the center of gravity of the added ballast apart from the bottle
must be located lower than the center of gravity of the bottle to
achieve i vved stability.
A fluid ounce of water ballast weighs about 29.5 grams, and in
containers of a volume comparable to the standard containers shown
in Tables 1-3, only one or a few ounces of water provide a
substantial stabilizing weight as compared to the container weight.
Therefore, a very limited quantity of water is normally sufficient
to enable substantially increased production speeds, approaching
the speeds at which glass bottles can be handled. Wh er eas
empty plastic bottles can be handled on horizontal support
COII~C~V~D at nominal rates of several hundred per minute, the same
COII~OYVrD can handle container inrlt~Aing water ballast at up to
2,500 bottles per minute without undue jamming. The particular
speeds obtainable will vary with the particular bottle shape,
~llve~vl arrA~, ~ and other factors. Insofar as any shape of
bottle is apt to fall over due to hAn~l ing, ballast according to
the invention will improve stability and enable hAn~ling at higher
speeds.
The ballast can be ~icp~nc~ into the bottles according to a
number of specific techniques and apparatus. Preferably the
ballast is ~icp~ncDd into a number of the bottles simultaneously,
however it is also possible to ~icp~nce the ballast by sensing the
position of individual bottles and operating a valve or the like to
~icp nRe the ballast into each bottle as it passes the valve.
Another possibility is to operate the ballast ~icp~nR~r
continuously, dispensing spray generally and at a flow rate which
is sufficient to ,A,- 1 Ate the required amount of ballast in each
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CA2i 174~:~
bottle over to the time in which the bottles pass the continuously
operating dirr~n~or. In that case the ballast can be d; epenq~
from one or more wide pattern spray heads directed downwardly over
the path of the bottles along CO-Iveyv~ 40.
Preferably the ballast is disp~ne~d into a group of the
containers from a rank 26 from a pallet as shown in Figs. 1, 3, 5
and 6, before forming the containers into a row. The diep~ne~ can
simultaneou61y load ballast in an X-Y array of the containers, for
example an entire rank 26. Alternatively, the dispenser can
simultaneously load a lateral line of the containers in a rank as
shown in Fig. 7.
For diep~neing ballast into a line or rank, a plurality of
orifices in the lower wall of a reservoir or ~.as~u~ized ballast
storage vessel can be provided. Means can be provided for opening
a plurality of valves as the bottles in a rank pass the valves.
The bottles in the pallet are placed directly against one another
and thus define a regular array. The depalletizer sweep places the
bottles on the CO~ L 40 in a predictable array, and the orifices
or valves in the diFp~nc~r 160 are aligned to the array, as shown
in Figs. 5 and 6. Apart from the depalletizer a gate 36 can be
placed at the end of the di.ep~ne~r 160 along the path of cullveyul
40 such that the bottles queue against the gate and assume a
regular array, as shown in Fig. 2. This array can be a linear
array (Fig. 7) or a matrix array (Fig. 1). The bottles can be
stopped for ballast loading or allowed to advance continuously.
For retaining Al i; L of the ballast orifices and moving bottles,
an i n~oYi ng or tracking drive (not shown) can be associated with
the diFr~ne~r 160 such that the valves or orifices dispensing the
ballast will track moving bottles on the Cu.lveyu~ 40, to direct the
ballast into the open tops of the bottles for a sufficient time to
load the bottles with the required amount of ballast.
According to a preferred ~ L of the diep ne~r as shown
in Figs. 5 and 6, valves in the required array are defined by a
WO93/14975 PCT/US92/00628
CA21 1 7420
plurality of op~n; ngS or valve seats 168 in the bottom wall of the
reservoir. The Op n;ngc or valve seats 168 are controllably
plugged by valve bodies 166 attached to a common support 164. The
common support is displaced upwardly to simultaneously open the
valves by lifting all the valve bodies 166 relative to the seats
168 at one time. A cam drive, air cylinder, ele~L-~ ~gnetic
(solenoid) drive or the like (not shown) can lift the common
support 164, which is preferably slidably d;cposed via guide shafts
174 on support blocks 172 fixed on the inner wall of the reservoir.
It is also possible to arrange the valves in reverse order, i.e.,
with a plate (e.g., the bottom wall of the reservoir) defining a
plurality of valve seats and a LL .JLk supporting the valve
bodies for upward and downward displ A _ L relative to the plate
from outside the reservoir.
An alternative~ of the invention is shown in Fig. 4.
According to this : ~-'i- L, the ballast ~icp~nc~r includes a
p es~uLized fluid supply rather than a gravity feed supply as in
Fig. 3. A pump 184 can be provided to ~.ea~uLize the supply vessel
182, which has an array of solenoid valves 186 directed toward the
containers. The valves 186 can be operated simultaneously, for
example when a row or other array of containers abuts a gate (noL
shown in Fig. 7) along the cu..~ . Alternatively, as indicated
by the dashed lines in Fig. 7, each valve can be operable
individually. A control photoeye is directed downwardly to detect
the passing edge of a bottle 20, whereupon the valve is opened for
a predetermined time, for example a time det~rmin~d as a function
of ~onv~yu~ speed or a preset time controlled by a one shot timer
or the like.
In addition to the foregoing valved ~; cp~nC~rs~ it is also
possible as noted above to direct a steady spray of ballast water
on the area occupied by the bottles. In passing the area, each of
the bottles a lates a quantity of ballast water, which can be
pumped in a circuit between a collection reservoir under the bottle
WO93/14975 PCT/US92/00628
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zone to the spray heads over the bottles.
The invention as disclosed is an i uv~d hAn~l ing system for
empty containers 20, the hAn~l ing system having a ~u~v~yur 40
operable to support and transport the containers when rested
thereon, and means 30 for delivering containers to the COIIV~YUL in
an upright orientation. The ballast dispensing apparatus 160 is
operable to ~i~p~n~e a quantity of ballast into containers 20 in
the upright orientation, the ballast stabilizing the containers
when transported on the co..~yo~ 40. A container inverting
apparatus 112, 114 is associated with a destination 110 of the
cu.,v_yu~, and is operable to invert the containers 20 for removing
the ballast. The containers are preferably bottles, and the means
for delivering the containers is a bottle depalletizer operable to
remove a rank 26 of bottles from a pallet and to funnel the rank of
bottles into a line. The ballast dispensing apparatus 160 can be
~i~p~Fed adjacent the depalletizer and operable to ~i~p~nee ballast
into a plurality of the bottles prior to being funneled into the
line. The container inverting apparatus is associated with a
container rinser 110 operable to invert the containers and to rinse
the containers via a rinse fluid directed upwardly into the
inverted containers. The hAn~l ing system can be a bottling system
and further comprises a filling station.
In a preferred~ L the ballast dispensing apparatus 160
includes a fluid supply 160, 182 with at least one valve 166, 168,
186 directed toward the containers 20 and means 164, 188 for
opening the valve when a container is in position to receive the
ballast. A plurality of valves 166, 168, 186 can be operable
simultaneously to ~i~p~n~e the ballast into a plurality of
containers at once. For this purpose, the fluid supply can include
a reservoir 162 ~i~pos~ over the containers and the valves are
defined by a plurality of op~ning~ 168 in a reservoir wall
controllably plugged by valve bodies 166 attached to a common
support 164. Means 176, 174, 172 for displacing the common support
WO93/1497~ PCT/US92/00628
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23
simultaneously open the valves.
The invention having been disclosed, variations will now occur
to persons skilled in the art and aware of this disclosure. The
foregoing disclosure of preferred : '_'i Ls is not meant to be
limiting, and reference should be made to the AppPn~Pd claims
rather than the foregoing specification to assess the scope of the
invention in which exclusive rights are claimed.
