Casing method and apparatus

Abstract

A caser is disclosed for packing filled containers in empty cases. The caser includes a conveyor belt that carries filled containers to the caser for loading and a pusher assembly for pushing the containers onto the loading tables wherein the containers are gravity fed into cases positioned below the loading tables. The loading tables preferably retract linearly to allow the containers to drop into the cases. A pair of bottle guides pivot to grip the containers while the loading tables retract.

What is claimed is:  
     
         1 . A caser for packing filled containers in empty cases, the caser comprising: 
 a support frame having an upper level and a lower level;    a conveyor belt having a traveling direction and delivering containers to a loading area of the caser;    a pusher assembly movable in a loading direction, wherein at the loading area, the traveling direction is substantially perpendicular to the loading direction;    a pair of bottle guides hingably connected to the upper level of the support frame;    a pair of loading tables linearly retractable to provide access between the upper level and the lower level of the support frame; and    wherein the bottle guides pivot to grip containers when the containers are loaded on the loading tables and pivot to release the containers when the loading tables have retracted.    
     
     
         2 . The caser of  claim 1  wherein the caser is made substantially of stainless steel.  
     
     
         3 . The caser of  claim 1  wherein the loading tables are pneumatically powered.  
     
     
         4 . The caser of  claim 3  wherein the loading tables comprise a first section operatively connected to a first piston and cylinder assembly, and a second section operatively connected to a second piston and cylinder assembly, wherein the first and second piston and cylinder assemblies linearly move the first and second sections of the loading tables away from each other.  
     
     
         5 . The caser of  claim 4  further comprising: 
 an intake air manifold; and  
 a centralized air manifold in communication with the intake air manifold and positioned substantially equidistant from the first and second piston and cylinder assemblies, wherein the centralized air manifold distributes air evenly to the first and second piston and cylinder assemblies.  
 
     
     
         6 . The caser of  claim 5  further comprising a surge tank in communication with the intake air manifold.  
     
     
         7 . The caser of  claim 1  further comprising a central processor and a plurality of sensors, wherein the sensors detect predetermined conditions and transmit signals to the central processor regarding the conditions.  
     
     
         8 . The caser of  claim 7  further comprising an alarm operatively connected to the central processor wherein the alarm is activated upon detection of a predetermined condition by one of the plurality of sensors.  
     
     
         9 . The caser of  claim 4  further comprising a piston sensor positioned on each of the first and second piston and cylinder assemblies, wherein the piston sensors detect the position of the piston when the loading tables are fully retracted and transmit a signal to the central processor, and wherein, in response, the central processor signals the bottle guides to release the containers.  
     
     
         10 . The caser of  claim 4  wherein the first and second sections of the loading tables each have an inclined ledge extending therefrom such that when the loading tables are retracted, the inclined ledges of the first and second sections define a tapered passageway.  
     
     
         11 . The caser of  claim 10  wherein the inclined ledges each have an angle of inclination of 85 degrees.  
     
     
         12 . The caser of  claim 10  wherein the inclined ledges each have a wear protective insert.  
     
     
         13 . The caser of  claim 12  wherein the wear protective insert is plastic.  
     
     
         14 . The caser of  claim 13  wherein the wear protective insert is Nylatron.  
     
     
         15 . The caser of  claim 1  further comprising a stabilizer plate pivotally attached to the support frame, wherein the stabilizer plate is weighted to counteract inertial force of the containers.  
     
     
         16 . The caser of  claim 15  wherein the stabilizer plate has an initial vertical position at rest, wherein the stabilizer is pivoted upward when the containers advance on the loading tables and wherein the stabilizer plate returns to its initial vertical position when the containers are loaded into cases.  
     
     
         17 . The caser of  claim 15  wherein the stabilizer plate is made of a self-lubricating material.  
     
     
         18 . The caser of  claim 15  wherein the stabilizer plate is made of Nylatron and U.H.M.W.  
     
     
         19 . The caser of  claim 1  further comprising, a cover having a flat working surface, wherein the cover is removably secured to the support frame of the caser.  
     
     
         20 . The caser of  claim 19  further comprising a clip attached to the support frame defining a channel between the clip and the support frame, wherein the cover comprises an edge configured to fit in the channel to secure the cover to the support frame.  
     
     
         21 . A easer for packing containers in cases, the caser comprising: 
 a pair of loading tables that are retractable, the loading tables having a longitudinal direction along the length of the table and a transverse direction along the width of the table; and    a pusher assembly actuatable to push containers onto the loading tables in the longitudinal direction.    
     
     
         22 . The caser of  claim 21  further comprising a drive chain traveling substantially perpendicular to the longitudinal direction proximal the pusher assembly.  
     
     
         23 . A caser for packing containers in cases, the caser comprising: 
 a support frame having an upper level and a lower level;    a pair of loading tables having a closed position and an open position, wherein in the closed position, the loading tables support containers thereon and in the open position, the loading tables provide access from the upper level to the lower level; and    at least two bottle guides attached to the support frame, wherein the bottle guides are movable to hold the containers and release the containers when the loading tables are in the open position.    
     
     
         24 . The caser of  claim 23  wherein the loading tables retract linearly.  
     
     
         25 . The caser of  claim 23  wherein the loading tables include a first section and a second section, and wherein the first and second sections move apart from each other linearly.  
     
     
         26 . The caser of  claim 23  wherein the bottle guides pivot such that a lower portion of each bottle guide contacts containers.  
     
     
         27 . The caser of  claim 25  wherein each of the first and second sections comprise an inclined surface, wherein in the open position, the inclined surfaces define a tapered path.  
     
     
         28 . The caser of  claim 27  wherein the inclined surface comprises a plastic insert.  
     
     
         29 . A caser for packing containers in cases, the caser comprising: 
 a pair of loading tables; and    a stabilizer plate swingably positioned over the loading tables, the stabilizer plate weighted to counteract the inertial force of containers pushed onto the loading tables and to prevent the containers from tipping over.    
     
     
         30 . The caser of  claim 29  wherein the stabilizer plate is plastic.  
     
     
         31 . A caser for packing filled containers in empty cases, the caser comprising: 
 a support frame having an upper level and a lower level;    a conveyor belt having a traveling direction and delivering containers to a loading area of the caser;    a pusher assembly movable in a loading direction, wherein at the loading area, the traveling direction is substantially perpendicular to the loading direction;    a pair of bottle guides hingably connected to the upper level of the support frame;    a pair of air springs, each air spring operatively connected to one of the bottle guides, the air springs operational to pivot the bottle guides;    a pair of loading tables having a first section and a second section, wherein the first and second sections are linearly retractable in opposing directions to provide access between the upper level and the lower level of the support frame;    a first and second piston and cylinder assembly, each piston and cylinder assembly connected to a respective one of the first and second sections of the loading tables, the piston and cylinder assembly operational to move the first and second sections linearly toward each other and away from each other; and    wherein the bottle guides pivot to grip containers when the containers are loaded on the loading tables and pivot to release the containers when the loading tables have retracted.    
     
     
         32 . A method of packing jugs into cases, the method comprising the steps of pushing jugs at a rate greater than 160 jugs per minute.  
     
     
         33 . The packing method of  claim 32  wherein the jugs are pushed at a rate greater than 180 jugs per minute.  
     
     
         34 . The packing method of  claim 33  wherein the jugs are pushed at a rate of about 200 jugs per minute.  
     
     
         35 . A method of packing jugs into cases, the method comprising the steps of: 
 carrying jugs on a conveyor belt;    pushing the jugs together; and    letting the jugs fall into cases.    
     
     
         36 . A method of packing jugs into cases, the method comprising the steps of: 
 carrying jugs on a conveyor belt;    pushing the jugs together in a predetermined pattern; and    letting the jugs fall into cases.    
     
     
         37 . A method of packing jugs into cases, the method comprising the steps of: 
 carrying jugs on a conveyor belt;    pushing the jugs together in a predetermined pattern; and    releasing the jugs after the jugs have been pushed together; and    dropping the jugs into cases.    
     
     
         38 . A method of packing jugs into cases, the method comprising the steps of: 
 providing a caser having a support frame with an upper level and a lower level, a conveyor belt, a pusher assembly, a pair of bottle guides and a pair of loading tables;    delivering jugs to the upper level of the caser via the conveyor belt;    pushing the jugs onto the loading tables;    gripping the jugs with the bottle guides;    retracting the loading tables; and    releasing the bottle guides to drop the jugs into cases.    
     
     
         39 . A method of packing jugs into cases, the method comprising the steps of: 
 providing a sensor in communication with a central processor;    detecting the presence of jugs at a staging area using the sensor;    transmitting a first signal to the central processor if jugs are present at the staging area; and    transmitting a second signal to the central processor if jugs are not present at the staging area.    
     
     
         40 . The packing method of  claim 39  wherein the first signal corresponds to a first predetermined number of strokes, and wherein the second signal corresponds to a second predetermined number of strokes.