Automated apparatus and method for consolidating products and packaging

An automated apparatus for controlling the automatic packaging of contact lenses in a contact lens fabrication facility having a contact lens inspection station performing a contact lens quality control evaluation, said apparatus comprising:

• (a) a first robotic transfer device for periodically transferring a first predetermined array of individual packages from said inspection station to a consolidation buffer, said first predetermined array having random variations in said array;
• (b) a controller for tracking and identifying individual packages containing contact lens inspected at said inspection station, said controller including memory and logic for storing the identity of individual packages containing contact lenses determined to be out of specification in accordance with said quality control evaluation and generating a signal to cause said first robotic transfer device to eject any said individual packages identified by said controller as being out of specification while transferring said first predetermined array, said individual ejections creating said random variations in said predetermined array of packages;
• (c) said consolidation buffer receiving said first predetermined array with random variations, said buffer having at least one product follower for consolidating random variations in said product array and a guide means to prevent product shingling of said individual packages when consolidated;
• (d) an automated output device for selecting a predetermined number and arrangement of individual packages, and transporting said number and arrangement to a subsequent processing station.