Apparatus system and method for exposing product filled containers transported via an intermittent conveyer to a controlled environment

Abstract

An apparatus, system and method for exposing product-filled container or tray being transported by an intermittent conveyer to a controlled environment are provided. The apparatus may include a vertically reciprocating gassing rail, a stationary gassing rail, and an angled gassing rail. The vertically reciprocating gassing rail includes a rail head and an outer shell, which clamps to the conveyer. High velocity gas is flowed through a longitudinally oriented manifold in the rail head and the exhaust gas is removed by exhaust channels. The stationary rail provides a laminarized flow, and the angled rail provides a stream of controlled environment gas beneath the film which is sealed to the tray.

We claim:  
     
         1 . An apparatus for exposing product-filled containers being transported by an intermittent conveyer to a controlled environment comprising: 
 a reciprocating gassing rail positioned along the conveyer and timed to engage with the conveyer when the conveyer is paused, the reciprocating gassing rail including an outer shell and a rail head, the outer shell including a bottom surface for sealing to a flange portion of the container, a rail head which includes a longitudinally oriented manifold, the rail head including an opening formed therein for receiving controlled environment gas from a source.    
     
     
         2 . The apparatus of    claim 1    further comprising a bottom shell which seals to a bottom region of the conveyer and allow a vacuum to be pulled on the tray.  
     
     
         3 . The apparatus of    claim 2    wherein the opening formed in the rail head may be used for pulling a vacuum on the tray.  
     
     
         4 . The apparatus of    claim 1    wherein the rail head includes at least one exhaust orifice to receive exhaust gas.  
     
     
         5 . The apparatus of    claim 4    wherein the rail head further comprises a longitudinally oriented exhaust channel in communication with the exhaust orifice.  
     
     
         6 . The apparatus of    claim 1    further comprising a shaft including a distribution orifice, the shaft attached to a feed block, the distribution orifice in communication with the manifold and an inlet formed in the feed block.  
     
     
         7 . The apparatus of claim I further comprising a second manifold formed in the rail head, the second manifold in communication with a second source of controlled environment.  
     
     
         8 . A method of exposing a container to a controlled environment comprising: 
 providing a reciprocating gassing rail including a rail head, and an outer shell, the rail head including a longitudinally oriented manifold;    providing an intermittent conveyer carrying product-filled containers;    conveying a container beneath the rail head;    pausing the conveyer;    clamping the outer shell to a top region of the conveyer;    supplying a high velocity flow of controlled environment gas through the manifold to provide a desired flow pattern of controlled environment gas into the container;    retracting the rail head and the outer shell; and    conveying the container to a sealing station.    
     
     
         9 . The method of    claim 8    wherein the rail head has a longitudinally oriented exhaust channel formed on each longitudinal side of the manifold, removing exhaust gas flowing from the container through the exhaust channels to maintain a desired flow pattern.  
     
     
         10 . A system for exposing a product-filled container being transported by an intermittent conveyer to a controlled environment comprising: 
 a virtually reciprocating gassing rail including a rail head and an outer shell, the rail head including at least one longitudinally oriented manifold positioned to align with a product-filled compartment of the container, the rail head including at least one longitudinally oriented exhaust channel positioned along at least one longitudinal side of the manifold; and    a fixed gassing rail positioned adjacent the reciprocating gassing rail, the gassing rail including at least one longitudinally oriented manifold positioned to align with a middle portion of a product-filled compartment of the container.    
     
     
         11 . The system of    claim 10    further comprising an angled gassing rail positioned adjacent the fixed gassing rail to provide a stream of controlled environment gas beneath film being heat sealed to the containers.  
     
     
         12 . The system of    claim 10    further comprising a bottom shell to clamp to a bottom region of the conveyer to allow a vacuum to be pulled on the container.  
     
     
         13 . The system of    claim 10    further comprising a feed block attached to a shaft, the shaft being attached to the rail head, the shaft including a distribution orifice in communication with the manifold and an inlet formed in the feed block.  
     
     
         14 . The system of    claim 13    further comprising a spring positioned around the shaft between a bottom portion of the feed block and a top portion of the outer shell.  
     
     
         15 . The system of    claim 13    further comprising an exhaust tube in communication with the exhaust channel, the tube extending through an opening formed in the outer shell, a seal positioned around the tube and in contact with the outer shell to prevent gas from escaping when the outer shell is in a clamped position.  
     
     
         16 . The system of    claim 15    wherein the shaft extends through an opening formed in the outer shell, a seal is positioned around the shaft and in contact with the outer shell to prevent gas from leaking when the outer shell is clamped against the conveyer.  
     
     
         17 . The system of    claim 10    wherein the vertically reciprocating gassing rail includes one manifold positioned between two exhaust manifolds.  
     
     
         18 . The system of    claim 10    wherein the vertically reciprocating gassing rail includes one exhaust channel positioned between two manifolds, the manifolds aligned with a divider region of product-filled compartments of the container.  
     
     
         19 . The system of    claim 10    wherein each manifold of the vertically reciprocating gassing rail is supplied with a separate source of controlled environment, the stationary gassing rail includes two manifolds supplied with controlled environment from a separate source.  
     
     
         20 . A method for exposing a container transported by a intermittent conveyer to a controlled environment comprising: 
 providing a reciprocating gassing rail including a rail head and an outer shell, the rail including at least one longitudinally oriented manifold and at least one longitudinally oriented exhaust channel;    providing a fixed gassing rail positioned adjacent the reciprocating gassing rail;    providing an angled gassing rail positioned adjacent the fixed gassing rail and a reciprocating tray sealer;    conveying a container beneath the reciprocating gassing rail and pausing the conveyer;    clamping the outer shell to the conveyer;    flowing high velocity controlled environment gas through the manifold of the rail head;    removing exhaust gas through the exhaust channels;    conveying the container beneath a fixed gassing rail;    flowing a low velocity controlled environment gas through the manifold of the fixed gassing rail;    conveying the container beneath a tray sealer; and    flowing a stream of controlled environment gas beneath a film to be sealed to the containers.    
     
     
         21 . A gassing system for exposing product to a controlled environment being transported along a conveyer comprising: 
 a stationary gassing rail including a first and a second distribution chamber positioned along a conveyer moving product filled containers toward a sealer, the first chamber including a plurality of openings formed therein, a resistance sheet longitudinally oriented adjacent the chamber openings, and a distribution manifold longitudinally oriented adjacent the resistant sheet, a manifold including a plurality of nozzles oriented at an angle to the manifold and aligned with the first chamber openings, the second distribution chamber including at least one opening formed therein, and a resistance sheet longitudinally oriented adjacent the second chamber opening; and    an angled rail including a distribution chamber having at least one opening formed therein, a resistance sheet positioned over the opening, the angled rail being oriented to direct a stream of controlled environment gas parallel to and beneath film being fed to a sealing station, the angled rail positioned adjacent the second distribution chamber.    
     
     
         22 . The gassing system of    claim 21    further comprising a sealing station including a seal head to seal film to the container, the seal head including a seal head blow-off port to direct controlled bursts of gas against an upper side of the film while the seal head vertically descends to clamp the film against the container.  
     
     
         23 . The gassing system of    claim 22    wherein the seal head blow-off port is controlled to direct a controlled burst of gas during both the down stroke of the seal head and immediately prior to the upstroke of the seal head.  
     
     
         24 . The gassing system of    claim 21    further comprising a sealing station including a seal head including a seal head blow-off port for providing a continuous flow of gas against the film.  
     
     
         25 . The gassing system of    claim 21    further comprising an intermittent conveyer to carry the product filled containers along the gassing rails to the sealing station.  
     
     
         26 . The gassing system of    claim 21    wherein the stationary gassing rails include a quick change clamp system including a plurality of clamps screwably attached to a rail bottom to secure and seal a rail top to the rail bottom.  
     
     
         27 . The gassing system of    claim 21    further comprising at least one side rail positioned along the sides of the sealing station to direct a stream of controlled environment gas beneath the film positioned under the seal head.  
     
     
         28 . The gassing system of    claim 21    further comprising an angled exit rail positioned on the side of the sealing station opposite the angled rail to direct a stream of controlled environment gas beneath the film positioned beneath a seal head.  
     
     
         29 . The gassing system of    claim 21    further comprising a hepa-filter system in communication with the gassing system to provide steam sterilization of the gassing system.  
     
     
         30 . The gassing system of    claim 21    further comprising an independently controlled servo-driven film feeder and an independently controlled servo-driven conveyer.  
     
     
         31 . The gassing system of    claim 30    further comprising a sensor bracket attached adjacent the conveyer for locating the edge of any of a plurality of carrier plates positioned on the conveyer.  
     
     
         32 . The gassing system of    claim 21    further comprising a plurality of carrier plate pairs positioned upon a conveyer, each carrier plate of the pair includes a tray opening positioned adjacent the tray opening of the other carrier plate in the pair.  
     
     
         33 . The gassing system of    claim 21    wherein the angled gassing rail includes an opening to provide a flow of controlled environment substantially perpendicular to the film to prevent air from being drawn in as the film advances.  
     
     
         34 . A gassing system for exposing product to a controlled environment being transported along a conveyer comprising: 
 a stationary gassing rail including a rail top and rail bottom positioned along a conveyer moving product filled containers toward a sealer, the rail base including at least one longitudinally oriented opening formed therein, at least one gassing element oriented adjacent the rail base opening; and    an angled rail including a distribution chamber having at least one opening formed therein, a resistance sheet positioned over the opening, the angled rail being oriented to direct a stream of controlled environment gas beneath film being fed to a sealing station, the angled rail positioned adjacent the stationary gassing rail.    
     
     
         35 . The gassing system of    claim 34    further comprising a second stationary gassing rail including a jet manifold for directing high velocity controlled environment toward the product.  
     
     
         36 . The gassing system of    claim 34    wherein the angled gassing rail includes an opening to provide a flow of controlled environment substantially perpendicular to the film to prevent air from being drawn in as the film advances.  
     
     
         37 . The gassing system of    claim 34    further comprising a conveyer and a plurality of carrier plates positioned on the conveyer, a sensor bracket oriented to detect the carrier movement and locate an edge of each of the carrier plates.  
     
     
         38 . The gassing system of    claim 37    wherein the carrier plates comprise a plurality of carrier plate pairs, each carrier plate pair includes a first and second carrier plate, the first plate including a notch in a corner having a first length, the second plate including a notch in a corner having a second length differing from the first length to allow the sensor bracket determine the location of the pair.  
     
     
         39 . The gassing system of    claim 38    further comprising a programmable logic controller preprogrammed to automatically adjust the position of the carrier plate pair based on readings taken by the sensor bracket.  
     
     
         40 . A method of gassing a product moving along an intermittent conveyer comprising: 
 providing a stationary gassing rail longitudinally oriented along a conveyer, a angled gassing rail positioned adjacent the stationary gassing rail;    flowing controlled environment gas through a gassing element positioned over a longitudinally oriented opening formed in the stationary gassing rail; and    flowing controlled environment gas through a gassing element positioned over an opening formed in the angled gassing rail in a direction substantially parallel to film being fed to a sealing station.    
     
     
         41 . The method of    claim 40    further comprising flowing controlled environment gas through a second opening formed in the angled gassing rail in a direction substantially perpendicular to the film.  
     
     
         42 . An apparatus for providing a controlled environment to a tray moving along an intermittent conveyer to a position beneath a vertically reciprocating tray sealer comprising: 
 an angled gassing rail including a manifold oriented to provide a stream of controlled environment gas substantially parallel to film being fed to the tray sealer and around and into the tray positioned under the tray sealer.    
     
     
         43 . The apparatus of    claim 42    further comprising an opening formed in the angled gassing rail to provide a flow of controlled environment gas substantially perpendicular to the film fed to the tray sealer.  
     
     
         44 . A method for providing a controlled environment to a tray moving along an intermittent conveyer to a position beneath a vertically reciprocating tray sealer comprising: 
 providing an angled gassing rail including a manifold oriented adjacent film being fed to the tray sealer; and    flowing gas through the manifold substantially parallel to the film at a velocity sufficient to flow beneath the tray sealer and into and around the tray positioned beneath the tray sealer.    
     
     
         45 . The method of    claim 44    further comprising an opening formed through the angled gassing rail, flowing controlled environment gas substantially perpendicular to the film.  
     
     
         46 . An apparatus for controlling the positioning of carrier plates on an intermittent conveyer comprising: 
 an intermittent conveyer;    a plurality of carrier plates positioned on the conveyer;    a sensor bracket positioned along the conveyer adjacent the carrier plates; and    a programmable logic controller electronically communicating with the sensor bracket to receive signals from the bracket as to location of the carrier plates, the controller automatically sending signals to reposition the carrier plates on the conveyer.    
     
     
         47 . The apparatus of    claim 46    wherein the carrier plates are positioned in carrier plate pairs including a first and second carrier plate, the first plate including a notch formed in a corner having a first length, the second plate including a notch formed in a corner having a second length differing from the first length, the sensor bracket sensing the differing lengths and sending signals to the programmable logic controller which provides return signals to move the conveyer forward or backwards to a desired location.  
     
     
         48 . A method of controlling the positioning of carrier plates on an intermittent conveyer comprising: 
 providing a sensor bracket positioned along a conveyer and connected to a programmable logic controller;    providing a plurality of carrier plate pairs including first and second carrier plates positioned on the conveyer, the first carrier plate including a notch formed in a corner therein having a first length, the second plate including a notch formed in a corner therein having a second length differing from the first length;    sensing the first notch length and second notch length with the sensor bracket and signaling the programmable logic controller to recognize the positioning of the carrier plate pairs; and    automatically determining the direction to correct the positioning of the carrier plate pairs and sending a signal from the programmable logic controller to move the conveyer to correct the position of the carrier plate pairs.    
     
     
         49 . An apparatus from preventing air from contaminating containers positioned under a vertically reciprocating sealing station comprising: 
 an angled gassing rail including a manifold angled to provide a stream of controlled environment gas substantially parallel to film being fed to the sealing station, the manifold including at least one gassing element.    
     
     
         50 . A vertically reciprocating sealing apparatus comprising: 
 a seal head including a seal head blow-off port to provide a stream of gas against a top surface of film positioned beneath the seal head.    
     
     
         51 . The apparatus of    claim 50    wherein the stream of gas is controlled and timed to be released immediately prior to the seal head moving downward, and immediately prior to the seal head moving upward.  
     
     
         52 . A method of sealing trays with film comprising: 
 providing a vertically reciprocating seal head, the seal head positioned over the film, the seal head including a seal head blow-off port; and    flowing a stream of gas from the seal head blow-off port to contact with a top surface of the film during or immediately prior to the movement of the seal head.    
     
     
         53 . An apparatus for exposing a multi-compartment trays to a controlled environment comprising: 
 a stationary gassing rail including at least two longitudinally oriented manifolds, each manifold oriented to align with one compartment of the multi-compartment tray, each manifold including at least one gassing element.    
     
     
         54 . The apparatus of    claim 53    further comprising at least two jet manifolds, each jet manifold positioned over one of the manifold.  
     
     
         55 . The apparatus of    claim 53    wherein the stationary rail comprises at least two separate stationary rails, each separate stationary rail including one longitudinally oriented manifold.  
     
     
         56 . The apparatus of    claim 53    further comprising an exhaust orifice positioned over a partition separating the tray compartments.  
     
     
         57 . A method of exposing multi-compartment trays to a controlled environment comprising: 
 providing a stationary gassing rail including at least two longitudinally oriented manifolds;    each manifold positioned over a compartment of the tray;    each manifold including at least one gassing element; and    flowing controlled environment gas through each of the manifolds into the compartments.