Method of automating filling and packaging of flat retention inserts

A method of automating filling of flat retention inserts comprising the steps of:

• a) providing at least one flat retention insert including:
• i) a cardboard body to which is adhered a transparent film;
• ii) said film being adhered on sides thereof, with opposed ends of said film being unadhered;
• and
• iii) said body having first flaps adjacent each adhered side of said film, and second flaps perpendicular to said first flaps, each flap being bendable with respect to a remainder of said body;
• iv) whereby bending said first flaps upwardly allows said film to bow upwardly creating an opening at each end of said film where said second flaps are located, and creating a chamber between said film and body;
• b) providing an assembly line for automating filling of flat retention inserts including;
• i) an actuator with a reciprocating ram;
• ii) a first station with a magazine for storing said at least one flat retention insert;
• iii) a second station laterally spaced from said first station and comprising a folding mechanism for manipulating a said flat retention insert to bend said first flaps in a first direction to open said chamber, facilitate insertion of a product into said chamber and bend said flaps in a second opposite direction to stretch said film over said product;
• c) moving said actuator to a position over said magazine;
• d) lowering said ram toward said magazine, a distal end of said ram having a gripping mechanism comprising at least one suction cup for releasably gripping a flat retention insert;
• e) gripping a flat retention insert using said gripping mechanism;
• f) lifting said ram with a flat retention insert gripped by said gripping mechanism;
• g) moving said actuator to a position over said second station;
• h) lowering said ram toward said folding mechanism;
• i) said gripped flat retention insert engaging said folding mechanism, whereby further lowering of said ram causes said first flaps to engage walls of said folding mechanism to bend said flaps upward;
• j) said folding mechanism holding a body of said flat retention insert in place with said first flaps bent upward while gripping said film, and said ram raising to lift said film and open said chamber;
• k) inserting a product into said chamber;
• l) lifting said ram with said folding mechanism bending said first flaps downward to stretch said film over said product;
• and
• m) conveying said flat retention insert and product to a shipping container.