Seal integrity monitoring and adaptive control method and apparatus

An apparatus for sealing and monitoring the integrity of a seal in packaging film when forming a bag in a form, fill and seal packaging machine, comprising:

• sealing jaws adapted for forming said seal by movement between closed and opened positions;
• means for selectively moving said sealing jaws in a first direction toward the closed position for sealing, and in a second direction toward the open position upon completion of the seal;
• a sensor operatively coupled to said sealing jaws for sensing the relative position during forming of the seal;
• said sensor being effective to determine the presence or absence of product charge matter in said seal;
• a processor to generate a signal indicative of the integrity of the seal dependent upon the product charge matter in the seal area;
• and
• a controller for providing adaptive control of the packaging machine in response to the input signal representative of the relative seal integrity.

A method for sealing and monitoring the integrity of a seal in a tube of packaging film during forming of a bag of substantially loose, free flowing product by opposed sealing jaws in a packaging operation, comprising the steps of:

• moving said tube along a longitudinal path;
• feeding the product into the tube along a parallel path relative to said tube;
• moving said sealing jaws in a first direction toward the closed position for sealing, and moving said sealing jaws in a second direction toward the open position upon completion of the seal;
• monitoring the pressure being exerted between said sealing jaws upon reaching the closed position;
• analyzing said pressure to evaluate the presence or absence of product in said seal so as to affect seal integrity;
• and
• adjusting the relative product charge flow with respect to movement of said tube in accordance with the determination of product in said seal,
• whereby the packaging speed and efficiency can be maximized independent of ambient conditions and product variations.

A method for sealing and monitoring the integrity of a seal in a tube of packaging film during formation of a bag with a charge of substantially loose, free flowing product by opposed sealing jaws in a packaging operation, comprising the steps of:

• moving said film along a longitudinal path;
• introducing and feeding the product charge along a defined flow path;
• sensing the presence of the charge at a first time point representing a selected location along said path;
• comparing the sensed charge presence to a defined time target;
• adjusting at least one operating step of the packaging operation in accordance with any deviation found during the comparing step to cause the charges to approach the time target;
• sealing of said tube to form said bag;
• determining the integrity of the seal formed during the sealing step based on the presence or absence of matter from said charge in the seal;
• and
• modifying said adjusting step upon determination of charge matter in said seal,
• whereby through adaptive control of the relative product charge flow with respect to the movement of said tube and the determination of the integrity of said seal, the packaging operation including the speed and efficiency of the transitional product flow and the product feeding can be maximized.