Systems and methods for packaging products using conveyors

1 . A conveyor-based apparatus for packaging products, the apparatus comprising:

a first conveying surface for supporting and conveying product packaging material in a first direction thereon;

a second conveying surface for supporting and conveying the product packaging material in the first direction thereon, the second conveying surface oriented above and in parallel with the first conveying surface;

a gate movable between an inactive position, where the gate does not obstruct movement of the product packaging material on the first conveying surface or on the second conveying surface, a first deployed position, where the gate obstructs movement of the product packaging material on the second conveying surface in the first direction, and a second deployed position, where the gate obstructs movement of the product packaging material on the first conveying surface in the first direction; and

a control unit operatively coupled to the first conveying surface, the second conveying surface, and the gate, the control unit configured to:

cause the second conveying surface to move in the first direction;

cause the gate to move toward the second conveying surface;

when the gate is in the first deployed position and a leading end of the product packaging material is in contact with the gate, cause the gate and the second conveying surface to stop moving;

cause the gate to move toward the second conveying surface and cause the second conveying surface to move in a second direction opposite to the first direction to withdraw a portion of the second conveying surface from under the product packaging material such that the leading end of the product packaging material descends toward the first conveying surface while the leading end of the product packaging material remains in contact with the gate and while a trailing end of the product packaging material remains supported by the portion of the second conveying surface; and

after the gate is in the second deployed position and the product packaging material descends onto the first conveying surface, cause the gate to lift from the second deployed position toward the first deployed position and cause the first conveying surface to move in the first direction to advance the product packaging material past the gate and toward packaging equipment located downstream of the gate.

2 . The apparatus of claim 1 , wherein the second conveying surface comprises a packaging film being unrolled in the first direction from a packaging film roll.

3 . The apparatus of claim 1 , wherein the second conveying surface includes a horizontal portion, a front end, and a downwardly-tapered portion extending from the horizontal portion to the front end.

4 . The apparatus of claim 1 , further comprising a third conveying surface located upstream of the second conveying surface and a fourth conveying surface located upstream of the third conveying surface, wherein, during the movement of the product packaging material in the first direction, the product packaging material moves on the fourth conveying surface and is then transferred from the fourth conveying surface onto the third conveying surface and is then transferred from the third conveying surface onto the second conveying surface.

5 . The apparatus of claim 4 , further comprising a positioning belt having a portion disposed over portions of the third second conveying surface and the second conveying surface, the positioning belt including a plurality of lugs oriented transversely to the positioning belt and extending therefrom in a direction toward the second conveying surface and the third conveying surface, wherein:

the positioning belt is operably coupled to a drive shaft:

the control unit causes rotation of the drive shaft, thereby causing movement of the positioning belt; and

during the movement of the positioning belt, the lugs of the positioning belt come into contact with the product packaging material being transported on the second conveying surface and the third conveying surface, thereby adjusting a position of the product packaging material on the second conveying surface and on the third conveying surface.

6 . The apparatus of claim 4 , further comprising a movable side shift belt coupled to at least one pulley and positioned on at least one side of the third conveying surface, wherein, during movement of the product packaging material on the third conveying surface, a side of the product packaging material comes into contact with the side shift belt, and the side shift belt adjusts a position of the product packaging material on the third conveying surface by shifting the product packaging material toward a centerline of the third conveying surface.

7 . The apparatus of claim 4 , wherein the fourth conveying surface includes a plurality of lugs extending upwardly therefrom, the lugs disposed on the fourth conveying surface at spaced intervals such that, during movement of the product packaging material in the first direction on the fourth conveying surface, a first group of the lugs is located forwardly relative to the product packaging material and a second group of the lugs is located rearwardly relative to the product packaging material to restrict the product packaging material from shifting forwardly past the first group and rearwardly past the second group.

8 . The apparatus of claim 1 , wherein:

when in the first deployed position, the gate is positioned such that a bottom of the gate is positioned in contact with the second conveying surface;

when in the second deployed position, the gate is positioned such that the bottom of the gate is positioned in contact with the first conveying surface; and

when in the inactive position, the gate is positioned such that the bottom of the gate is positioned above the first conveying surface and above the second conveying surface.

9 . The apparatus of claim 1 , wherein the gate is coupled to a gate control assembly, the gate control assembly including one or more pneumatic actuators or one or more drive shafts and gears, the gate control assembly configured to receive a control signal from the control unit and move in response to the control signal, and wherein movement of the gate control assembly causes movement of the gate.

10 . The apparatus of claim 1 , wherein after the control unit cause the gate to lift from the second deployed position toward the first deployed position, the control unit transmits a signal that causes activation of the packaging equipment located downstream of the gate.

11 . A method of packaging products using conveyors, the method comprising:

supporting and conveying product packaging material on a first conveying surface moving in a first direction;

supporting and conveying the product packaging material on a second conveying surface moving in the first direction, the second conveying surface being oriented above and in parallel with the first conveying surface;

moving a gate between:

an inactive position where the gate does not obstruct movement of the product packaging material on the first conveying surface of the second conveying surface;

a first deployed position where the gate obstructs movement of the product packaging material on the second conveying surface in the first direction; and

a second deployed position where the gate obstructs movement of the product packaging material on the first conveying surface in the first direction; and

controlling the first conveying surface, the second conveying surface, and the gate via a control unit by:

causing the second conveying surface to move in the first direction;

causing the gate to move toward the second conveying surface;

when the gate is in the first deployed position and a leading end of the product packaging material contacts the gate, stopping movement of the gate and the second conveying surface;

causing the gate to move toward the second conveying surface while causing the second conveying surface to move in a second direction opposite to the first direction to withdraw a portion of the second conveying surface from under the product packaging material and cause the leading end of the product packaging material to descend toward the first conveying surface while maintaining contact with the gate and while a trailing end remains supported by the portion of the second conveying surface; and

after the gate reaches the second deployed position and the product packaging material descends onto the first conveying surface, causing the gate to lift from the second deployed position toward the first deployed position while causing the first conveying surface to move in the first direction to advance the product packaging material past the gate toward downstream packaging equipment.

12 . The method of claim 11 , wherein the second conveying surface comprises a packaging film, and further comprising unrolling the packaging film in the first direction from a packaging film roll.

13 . The method of claim 11 , wherein the second conveying surface includes a horizontal portion, a front end, and a downwardly-tapered portion extending from the horizontal portion to the front end.

14 . The method of claim 11 , further comprising:

conveying the product packaging material on a third conveying surface located upstream of the second conveying surface and on a fourth conveying surface located upstream of the third conveying surface; and

during movement of the product packaging material in the first direction, transferring the product packaging material from the fourth conveying surface to the third conveying surface, and then transferring the product packaging material from the third conveying surface to the second conveying surface.

15 . The method of claim 14 , further comprising:

moving a positioning belt disposed over portions of the third and second conveying surfaces, the positioning belt including transversely oriented lugs extending toward the second and third conveying surfaces;

rotating a drive shaft coupled to the positioning belt to cause the moving of the positioning belt; and

adjusting the position of the product packaging material on the second and third conveying surfaces by contacting the product packaging material with the lugs during the moving of the positioning belt.

16 . The method of claim 14 , further comprising:

adjusting a position of the product packaging material on the third conveying surface by contacting a side of the product packaging material with a movable side shift belt positioned adjacent the third conveying surface; and

shifting the product packaging material toward a centerline of the third conveying surface.

17 . The method of claim 14 , wherein the fourth conveying surface includes upwardly extending lugs spaced at intervals, the method further comprising restricting movement of the product packaging material on the fourth conveying surface by positioning a first group of lugs forwardly and a second group of lugs rearwardly relative to the product packaging material.

18 . The method of claim 11 , wherein:

in the first deployed position, the gate contacts the second conveying surface;

in the second deployed position, the gate contacts the first conveying surface; and

in the inactive position, the gate is positioned above both the first and second conveying surfaces.

19 . The method of claim 11 , further comprising:

coupling the gate to a gate control assembly, the gate control assembly including one or more pneumatic actuators or one or more drive shafts and gears; and

moving the gate control assembly in response to a control signal to cause movement of the gate.

20 . The method of claim 11 , further comprising, after lifting the gate from the second deployed position toward the first deployed position, transmitting a signal by the control unit to activate the downstream packaging equipment.