System and method for automatically packaging an item
A system, apparatus, and method for automatically packaging one or more articles as a set of items to be shipped is disclosed. The system, apparatus, and method processes packaging material based at least in part on a scan of the set of items to be shipped, and forms cushioning of two matched streams of packaging material, with height of each package automated to size for the set, yielding shipping-ready customized packages. The customized packages are configured to conform to each individual article's size. The packaging material preferably is fully recyclable and is made from paper which is selectively expandable to create a cushioning layer around the set.
1 . A system for packaging a set of items to be shipped, comprising:
a roll section that provides support for a pair of rolls of prefabricated expandable packaging material that are unrolled into webs and matched into a web set; and
a package section that provides a form zone, a fill zone and a finish zone;
wherein the form zone comprises a set of grippers, wherein the set of grippers comprises at least one gripper configured to move in a direction opposite a direction of the web path to expand a determined amount of the web set;
wherein the expanded matched web set in the fill zone, receives a shipping item in the fill zone, and is finish-sealed and separated from the webs in the finish zone to form a finished package;
wherein the package section further comprises an insertion assistance set configured to spread the webs of the matched web set for receiving the shipping item, the insertion assistance set including a spacer and a tab transitioning into a spreader, the spacer and the tab are configured to extend between at least a portion of the matched web set to thereby spread the webs apart from one another.
2 . The system of claim 1 , wherein the roll section further comprises:
a pair of support rollers configured to support the pair of rolls of prefabricated expandable packaging material;
a mating roller downstream of the pair of support rollers configured to match the webs into the matched web set; and
a plurality of feed rollers downstream of the mating roller configured to feed the matched web set to the package section.
3 . The system of claim 2 further comprising:
a scan device configured to obtain data from the shipping item; and
a controller communicatively connected with the scan device, the roll section and the package section, wherein the controller is configured to control a set of movements of the matched web set through the roll section and through the package section based at least in part on the data scanned from the shipping item and at least in part on a selected mode.
4 . The system of claim 3 , wherein:
the controller provides alignment to the pair of rolls of prefabricated packaging material and controls the matching of the webs into the web set by way of the mating roller.
5 . The system of claim 4 , wherein the package section further comprises:
a labeler configured to label an outer side of a portion of the expanded matched web set in the fill zone; and
the controller is communicatively connected with the labeler.
6 . The system of claim 4 , wherein
the controller is communicatively connected with the insertion assistance set.
7 . The system of claim 6 , wherein the insertion assistance set comprises the spacer and the tab;
wherein the spacer is configured to protrude into the webs of the web set and the tab is configured to translate between the webs of the web set in the fill zone prior to the system receiving the shipping item in the fill zone;
wherein the insertion assistance set further includes a loading chute, the loading chute including a platform matingly sized to the spreader and a pair of sides;
wherein the loading chute and the tab are communicatively connected to the controller; and
the controller provides control over insertion and withdrawal of the loading chute to provide the pair of sides to a depth between the webs of the web set in the fill zone prior to the system receiving the shipping item in the fill zone such that the pair of sides protect against a collision of the web set and the shipping item.
8 . The system of claim 6 , further comprising:
a quality/transport set that examines the package based on predetermined criteria including at least one of a sealing characteristic or a labeling characteristic;
the controller communicatively connected with the quality/transport set; and
the package is transported according to a result of the examination.
9 . The system of claim 1 , wherein alignment of the pair of rolls of prefabricated expandable packaging material and matching of the webs into the web set is completed in the roll section.
10 . The system of claim 9 , further comprising:
a back sealer configured to seal a back portion of the web set in the fill zone; and
a labeler configured to label an outer side of a portion of the matched web set in the fill zone.
11 . The system of claim 9 ,
wherein the spacer is configured to protrude into the webs of the web set and the tab is configured to translate between the webs of the web set in the fill zone prior to the system receiving the shipping item in the fill zone.
12 . The system of claim 11 , wherein the insertion assistance set further comprises:
a loading chute configured to insert and withdraw between the webs of the web set in the fill zone, the loading chute including a pair of sides and a platform;
wherein the platform is matingly sized to the spreader; and
wherein the pair of sides is configured such that upon insertion of the loading chute and prior to the system receiving the shipping item in the fill zone, the pair of sides protects against a collision of the web set with the shipping item.
13 . The system of claim 11 , wherein
the set of grippers are configured to index the matched web set from the fill zone to the finish zone after placement of the shipping item between the spread webs of the matched web set.
14 . The system of claim 11 , further comprising:
a quality/transport set that examines the package based on predetermined criteria including at least one of a sealing characteristic or a labeling characteristic; and
the package is transported according to a result of the examination.
15 . An update kit for a system for packaging a set of items, the system for packaging including a roll section that provides support for a pair of rolls of prefabricated expandable packaging material that are unrolled into webs and matched into a web set, a package section that provides a fill zone and a finish zone, and a controller configured to control the roll section and the package section, the update kit comprising:
a set of grippers configured to provide a form zone of the package section;
a computer readable medium comprising a controller programming update;
wherein the computer readable medium is configured to be received by the controller such that the controller receives the controller programming update when the update kit is incorporated with the system for packaging;
wherein the set of grippers comprises a subset of grippers, wherein the subset of grippers is configured to be implemented in the package section and communicatively connected with the controller and controlled by the controller based on the controller programming update;
wherein the subset of grippers comprises at least one gripper that, upon being connected to the controller comprising the controller programming update, is configured to expand a determined amount of a web set of the prefabricated expandable packaging material in the form zone based at least in part on a data from a shipping item of the set of items, the web set configured to travel along a web path, the at least one gripper configured to move in a direction opposite the web path to expand the determined amount of the web set; and
wherein the set of grippers is configured to have at least another gripper of the set of grippers of the subset of grippers to index the expanded amount of web set from the form zone to the fill zone.
16 . The update kit of claim 15 , wherein the determined amount of web set is controlled by the controller and is based at least in part on maintaining a portion of the web set throughout the fill zone upon index of the expanded amount of web set from the form zone to the fill zone, and at least in part on a data of a pair of rolls of prefabricated expandable packaging material.
17 . A kit for a system that provides packaging of one or more shipping items, the kit comprising:
a set of rollers configured to provide support for a pair of rolls of a prefabricated expandable packaging material, to unroll the prefabricated expandable packaging material into webs, and to match the webs creating a web set, the web set configured to travel along a web path;
a computer readable medium, comprising a controller programming update, configured to be received by a controller associated with the system;
a set of grippers configured to provide a form zone of a package section and configured to expand a determined amount of the web set in the form zone based at least in part on a data from a shipping item of the one or more shipping items, the set of grippers including at least one gripper configured to move in a direction opposite the web path to expand the determined amount of the web set; and
wherein the set of rollers and the set of grippers are configured to be controlled by the controller based on the controller programming update.
18 . The kit of claim 17 , wherein once implemented:
the set of rollers feeds the web set to the form zone of the package section; and
the package section further provides a fill zone and a finish zone;
wherein the matched web set from the set of rollers and expanded in the form zone receives the shipping item of the one or more shipping items in the fill zone, and is finish-sealed and separated from the webs in the finish zone to form a finished package.