Systems and methods for preparing and packaging wax, such as scented wax for use with wickless candles, and other similar products

Abstract

Systems and methods for preparing and packaging scented wax for use with wickless candles, and for preparing and packaging other types of wax and non-wax products, are disclosed herein. A wax product manufacturing machine configured in accordance with an embodiment of the disclosure can include a container loading assembly that loads a plurality of empty product containers onto a conveyor for transfer to container filling assembly. The container filling assembly can simultaneously fill the plurality of empty product containers with colored and/or scented wax. The manufacturing machine can further include a cooling assembly through which the filled wax containers move for cooling and hardening of the wax therein. The manufacturing machine can additionally include a discharge assembly that closes the product containers to encapsulate the wax product therein, and transfers the closed product containers to a labeling machine for automatic application of a suitable label.

1 . A system for manufacturing wax for use with wickless candles, the system comprising:
 a product conveyor;   a plurality of product containers moveably supported by the product conveyor;   a filling assembly having a plurality of wax dispensing outlets in fluid communication with a wax hopper, wherein the filling assembly automatically dispenses molten wax from the wax hopper into the product containers through the dispensing outlets; and   a cooling assembly having a plurality of air movers, wherein the product conveyor automatically moves the wax-filled product containers away from the filling assembly and through the cooling assembly, and wherein the air movers are operable to move cooling air over the product containers.   
     
     
         2 . The system of  claim 1  wherein each of the wax dispensing outlets includes a heater. 
     
     
         3 . The system of  claim 1  wherein the filling assembly automatically dispenses a metered portion of molten wax from the wax hopper into the product containers through the dispensing outlets. 
     
     
         4 . The system of  claim 1  wherein the wax hopper includes at least one partition dividing the wax hopper into a first hopper portion and a second hopper portion, wherein the first hopper portion can hold a first wax mixture having a first composition and the second hopper portion can hold a second wax mixture having a second composition different from the first composition. 
     
     
         5 . The system of  claim 1  wherein the product conveyor moves the product containers in a product feed direction, and wherein the plurality of wax dispensing outlets are arranged in a row above the product conveyor and transverse to the product feed direction. 
     
     
         6 . The system of  claim 1  wherein the product conveyor includes a plurality of container pockets therein, and wherein each of the product containers is releasably supported in one or more of the container pockets. 
     
     
         7 . The system of  claim 6 , further comprising a container loading assembly, wherein the container loading assembly includes a plurality of container extraction units that simultaneously load the plurality of product containers into a row of the container pockets on the product conveyor. 
     
     
         8 . A system for manufacturing wax products, the system comprising:
 at least one product container;   a product conveyor that movably supports the product container;   a filling assembly having at least one wax dispensing outlet in fluid communication with a wax hopper, wherein the filling assembly automatically dispenses molten wax from the wax hopper into the product container through the dispensing outlet; and   a cooling assembly having at least one air mover, wherein the product conveyor automatically moves the product container away from the filling assembly and through the cooling assembly, and wherein the at least one air mover is operable to move cooling air over the product container and harden the wax therein.   
     
     
         9 . The system of  claim 8 :
 wherein the product container includes a lid portion;   wherein the filling assembly automatically dispenses molten wax from the wax hopper into the product container when the lid portion is in an open position;   wherein the product conveyor automatically moves the product container through the cooling assembly when the lid portion is in the open position; and   wherein the product conveyor automatically moves the product container away from the cooling assembly and through a product discharge assembly that automatically moves the lid portion from the open position to a closed position to enclose the hardened wax in the product container.   
     
     
         10 . The system of  claim 8  wherein the filling assembly includes a plurality of wax dispensers, and wherein each of the wax dispensers includes a corresponding wax dispensing outlet in fluid communication with the wax hopper. 
     
     
         11 . An automated method for producing wax products for use with wickless candles, the method comprising:
 releasably engaging a product container with a conveyor of a wax product manufacturing machine;   automatically moving the product container to a filling assembly with the conveyor;   automatically dispensing molten wax into the product container from the filling assembly; and   automatically moving the filled product container from the filling assembly through a cooling assembly to cool and harden the wax in the product container.   
     
     
         12 . The method of  claim 11 , further comprising automatically closing a lid on the filled product container and discharging the filled product container from the conveyor. 
     
     
         13 . The method of  claim 11  wherein the product container is a first product container, and wherein the method further includes:
 while releasably engaging the first product container with the conveyor, simultaneously releasably engaging a second product container with the conveyor;   while automatically moving the first product container to the filling assembly with the conveyor, simultaneously moving the second product container to the filling assembly with the conveyor; and   while automatically dispensing molten wax into the first product container from the filling assembly, simultaneously dispensing molten wax into the second product container from the filling assembly.   
     
     
         14 . The method of  claim 11  wherein the product container includes a lid, and wherein the method further comprises automatically closing the lid on the product container before discharging the product container from the conveyor.