Variable position constant force packaging system and process for using same

A system for packaging rolls of material comprising:

• a process line for packaging selected groups of rolls of material into packages, the process line including an in-feed section, a wrapping section where the groups are wrapped in a flexible film and a sealing section for sealing the packages, the process line containing at least one compression inducing element for applying a compressive force to the rolls of material while the rolls of material are being conveyed down the processing line, the compression inducing element including an adjustment device for varying the compressive force applied to the rolls of material;
• a firmness measuring device for measuring the firmness of the rolls of material, the firmness measuring device measuring the firmness of a roll of material by applying a force to the rolls;
• and
• a controller in communication with the firmness measuring device and the compression inducing element, the controller controlling the adjustment device for maintaining a substantially constant compressive force on the rolls of material based upon information received from the firmness measuring device.

A process for packaging rolls of material comprising:

• conveying rolls of material down a processing line, the processing line sorting the rolls of material into groups, wrapping the groups in a plastic film, and sealing the plastic film to form packages, the processing line applying a compressive force to the rolls of material by a compression inducing element in at least one location while the rolls of material are being conveyed down the processing line;
• measuring the firmness of at least some of the rolls of material;
• and
• adjusting the compression inducing element so as to maintain a substantially constant compressive force on the rolls of material within each compression inducing element based upon the measured firmness of the rolls of material.

A process for packaging rolls of material during a product change comprising:

• conveying first rolls of material down a processing line, the processing line sorting the first rolls of material into groups, wrapping the groups in a plastic film, and sealing the plastic film to form packages, the processing line applying a compressive force to the first rolls of material by a compression inducing element in at least one location while the first rolls of material are being conveyed down the processing line, the first rolls of material comprising a first product;
• changing the product being packaged by conveying second rolls of material down the processing line, the second rolls of material comprising a second product that is different in at least one dimension from the first product;
• measuring the firmness of at least some of the second rolls of material;
• adjusting the compression inducing element so that the amount of compressive force applied to the first rolls of material is substantially the same as the amount of compressive force applied to the second rolls of material within each compression inducing element based upon the measured firmness of the second rolls of material;
• and
• sorting the second rolls of material into groups, wrapping the groups in a plastic film, and sealing the plastic film to form packages.