Horizontal form-fill-seal packaging system

Abstract

A machine including a first film dispenser which dispenses a first film, a second film dispenser which dispenses a second film, a first form system configured to form a first shape in the first film, a second form system configured to form a second shape in the second film, and a seal system configured to join the first film to the second film after the first shape is formed in the first film and the second shape is formed in the second film, wherein the first form system includes a bucket configured to hold a forming plate and a form head configured to form a cavity between the form head and the bucket that receives the first film.

1 . A machine comprising:
 a first film dispenser which dispenses a first film;   a second film dispenser which dispenses a second film;   a first form system configured to form a first shape in the first film, the first form system comprising:
 a bucket configured to hold a form plate, and 
 a form head configured to form a cavity between the form head and the bucket, the cavity configured to receive the first film; 
   a second form system configured to form a second shape in the second film; and   a seal system configured to form a package by joining the first film to the second film after the first shape is formed in the first film and the second shape is formed in the second film.   
     
     
         2 . The machine according to  claim 1 , wherein
 the first form system presses the first film in a first direction,   the second form system presses the second film in a second direction, and   the first direction is perpendicular to the second direction.   
     
     
         3 . The machine according to  claim 2 , wherein
 the first film advances in the machine along a direction perpendicular to the first direction, and   the second film advances in the machine along a direction perpendicular to the second direction.   
     
     
         4 . The machine according to  claim 1 , wherein
 the first form system further comprises an air port configured to supply positive air pressure and to draw a vacuum within the cavity.   
     
     
         5 . The machine according to  claim 4 , wherein
 the first form system further comprises a form bar configured to heat a portion of the first film inside the cavity when the air port supplies the positive air pressure within the cavity.   
     
     
         6 . The machine according to  claim 5 , wherein the first form system is configured to form the first shape in the first film with the form plate when the air port draws a vacuum within the cavity after the form bar heats the portion of the first film. 
     
     
         7 . The machine according to  claim 1 , further comprising
 a gripper chain system configured to draw the first film to the seal system, wherein the seal system is configured to join the first film to the second film such that the second film advances through the machine by being pulled by the first film.   
     
     
         8 . The machine according to  claim 1 , wherein
 the first shape of the first film is a first pocket and the second shape of the second film is a second pocket, and   the seal system comprises seal head that is configured to form the package by joining the first film to the second film such that the first pocket and the second pocket are directly opposing, the package comprising the first pocket and the second pocket with a cavity formed therebetween.   
     
     
         9 . The machine according to  claim 8 , wherein
 the first pocket of the first film has a same shape of the second pocket of the second film, and   the seal system is configured to form a seam along a longitudinal axis of the package, the first pocket and the second pocket being symmetrical to each other around the longitudinal axis.   
     
     
         10 . A method of forming a package with a machine, the method comprising:
 dispensing a first film;   dispensing a second film;   forming a first pocket in the first film by pressing the first film with a first form head;   forming a second pocket in the second film by pressing the second film with a second form head; and   forming a package comprising the first pocket and the second pocket by joining the first film with the second film such that the first pocket aligns with the second pocket.   
     
     
         11 . The method of  claim 10 , wherein
 the forming the first pocket includes pressing the first film with the first form head in a first direction,   the forming the second pocket includes pressing the second film with the second form head in a second direction, and   the first direction is perpendicular to the second direction.   
     
     
         12 . The method of  claim 11 , further comprising:
 advancing the first film in the machine along a direction perpendicular to the first direction, and   advancing the second film in the machine along a direction perpendicular to the second direction.   
     
     
         13 . The method of  claim 10 , wherein
 the forming the first pocket includes performing an air-over-vacuum process comprising supplying positive air pressure and drawing a vacuum within a cavity that receives the first film, the cavity formed between the first form head and a first bucket.   
     
     
         14 . The method of  claim 13 , wherein
 the air-over-vacuum process further comprises heating a portion of the first film inside the cavity when the positive air pressure is supplied within the cavity.   
     
     
         15 . The method of  claim 14 , wherein
 the air-over-vacuum process further comprises forming the first shape in the first film with a form plate when drawing a vacuum within the cavity after heating the portion of the first film.   
     
     
         16 . The method of  claim 10 , wherein
 the forming the package includes joining the first film with the second film such that first pocket and the second pocket are directly opposing.   
     
     
         17 . The method of  claim 16 , wherein
 the forming the package includes forming a seam along a longitudinal axis of the package, the first pocket and the second pocket being symmetrical to each other around the longitudinal axis.   
     
     
         18 . The method of  claim 10 , wherein
 the forming the package includes welding the first film to the second film.   
     
     
         19 . The method of  claim 10 , further comprising
 inserting a product into the first pocket before forming the package.   
     
     
         20 . The method of  claim 10 , further comprising
 inserting the product into the first pocket before forming the package such that a portion of the product rests above a top edge of the first pocket, wherein   the forming the package includes forming such that the portion of the product rests within the second pocket.