Hffs packaging method and apparatus for refrigerated dough

Abstract

A method for packaging products utilizes a horizontal form, fill and seal (HFFS) system in combination with a vertical loading system. The packaging method includes creating product receiving cavities in a lower film, directly vertically stacking products in the product receiving cavities and then sealing the vertically stacked products in the cavities with an upper film to form product pouches. In one embodiment of the invention, a product fill station of the HFFS system is advantageously defined by a shaped packer including a stamping unit for directly vertically stacking the products. In another embodiment, a vertical lift and feed mechanism is employed to vertically stack the products in the receiving cavities.

1 . A method of packaging refrigerated dough products in a horizontal form, fill and seal assembly comprising:
 delivering a first plastic film to a thermoforming device;   thermoforming pouches from the first plastic film, with each pouch defining multiple dough product receiving cavities;   vertically stacking multiple dough products in each of the dough product receiving cavities by vertically supplying the dough products directly into the dough product receiving cavities;   delivering a second plastic film across multiple ones of the dough product receiving cavities;   sealing the second plastic film to the first plastic film of the pouches about the dough product receiving cavities; and   severing the first and second plastic films in order to establish individual thermoformed pouches containing vertically stacked dough products for refrigeration.   
     
     
         2 . The method of  claim 1 , wherein vertically stacking the multiple dough products in each of the dough product receiving cavities includes delivering a sheet of dough onto a cutter plate, forcing the dough into openings formed in the cutter plate, directing the pouches below a packer unit and sequentially shifting numerous ones of the dough products into each of the dough product receiving cavities. 
     
     
         3 . The method of  claim 1 , further comprising: heating the first plastic film from the first supply unit to establish a heated first plastic film which is supplied to the thermoforming device. 
     
     
         4 . The method of  claim 1 , further comprising:
 directing the pouches in a first direction from the thermoforming unit;   conveying a supply of dough to a cutter unit along a second direction, with the second direction being angled relative to the first direction;   cutting the dough with the cutter unit to form the dough product; and   vertically loading the dough product into the dough product receiving cavities such that dough of the dough product is re-directed to travel along in the first direction.   
     
     
         5 . The method of  claim 4 , wherein the second direction is substantially perpendicular to the first direction. 
     
     
         6 . The method of clam  4 , further comprising: continuously supply the dough to the cutter unit while intermittently moving the pouches in the first direction. 
     
     
         7 . A method of packaging refrigerated dough products comprising:
 directing pouches, created in a thermoforming unit of a horizontal form, fill and seal packaging assembly, in a first direction;   directing a sheet of dough to a cutter unit along a second direction, with the second direction being angled relative to the first direction;   cutting the sheet of dough with the cutter unit to form dough products; and   directly vertically loading the dough product into the dough product receiving cavities such that dough of the dough product is re-directed to travel along in the first direction.   
     
     
         8 . The method of  claim 7 , wherein the second direction is substantially perpendicular to the first direction. 
     
     
         9 . The method of  claim 7 , wherein multiple dough products are vertically stacked in each of the dough product receiving cavities. 
     
     
         10 . The method of  claim 7 , wherein vertically loading the dough product includes directing the pouches below the cutter unit and vertically supplying the dough products directly into the dough product receiving cavities. 
     
     
         11 . The method of  claim 7 , wherein both the cutting and the vertically loading is performed by a dough stamping apparatus. 
     
     
         12 . A packaging system for refrigerated dough products comprising:
 a first supply unit providing a first plastic film;   a thermoforming device, said thermoforming device being adapted to receive the first plastic film and create thermoformed pouches, with each pouch defining multiple dough product receiving cavities;   a product loading device, said product supply device being adapted to directly, vertically stack multiple dough products in each of the dough product receiving cavities;   a second supply unit providing a second plastic film across multiple ones of the dough product receiving cavities;   a sealing unit for sealing the second plastic film to the first plastic film of the pouches about the dough product receiving cavities; and   a cutter unit, said cutter unit being adapted to sever the first and second plastic films in order to establish individual thermoformed pouches containing vertically stacked dough products for refrigeration.   
     
     
         13 . The packaging system according to  claim 12 , wherein the first supply unit, the thermoforming device, the second supply unit, the sealing unit and the cutter unit are collectively part of a horizontal form, fill and seal packaging assembly. 
     
     
         14 . The packaging system according to  claim 13 , wherein the product loading device is positioned above the pouches made by the horizontal form, fill and seal packaging assembly and includes a stamping unit for cutting and vertically supplying the dough products into the dough product receiving cavities. 
     
     
         15 . The packaging system according to  claim 13 , wherein the horizontal form, fill and seal packaging assembly further includes a heating device, said heating device being adapted to receive and heat the first plastic film from the first supply unit and to establish a heated first plastic film which is supplied to the thermoforming device. 
     
     
         16 . The packaging system according to  claim 13 , wherein the first supply unit delivers the first plastic film in a first direction and the stamping unit receives a supply of dough conveyed along a second direction, with the first direction being substantially perpendicular to the second direction.