JP6730830B2 - Pocket tissue manufacturing method - Google Patents

Description

The present invention relates to a method of manufacturing a pocket tissue, which mechanizes the process of individually assembling individual packages and collectively packing them, and improves the production capacity while raising the hygiene condition without human intervention by the fully automatic manufacturing integrated manufacturing process. Provided is a method for producing a pocket tissue.

BACKGROUND OF THE INVENTION Conventionally, pocket tissues for collective packaging are manufactured by the following steps.
[1st step] 1st individual wrapping film original fabric preparing step for preparing a printed film original sheet for individual packaging in which the same package design is printed in order [2nd step] Unwinding the original paper from the original fabric, Second folding step of folding and stacking with a folding machine
[Third step] The folded tissue is manually cut into a prescribed number of sheets, and the cut tissue is manually placed on the conveyor for the individual packaging step. [Fourth step] The cut tissue is 4th individual wrapping step, which is conveyed on a conveyor, conveyed to an individual wrapping machine, and individually wrapped by the individual wrapping machine [fifth step] Individually wrapped pocket tissues are collectively packed by manual work involving operation of a hand sealer Fifth Collecting and Packing Step Here, the fifth step, which is an intermediate step, is manually performed, so that defective products are excluded from the process, and the final product is usually considered to include only non-defective individually packaged products. Is.

No matter how good a product is made, it will be evaluated only after it is actually used by consumers. “Reputation”, “price”, “maker image”, and “look” can be the motivation for consumers to compare multiple products at the store and purchase. Since the same package feels monotonous, if the individual packaging packages of multiple design patterns are assorted, the "look" of the collective packaging package can be improved. For example, when actually used by consumers, good quality products can be recognized, and the route for expanding sales to subsequent repeat purchases expands. It would be an advantage for the manufacturer if it is possible to produce a collective packaging product in which such individual packaging packages of a plurality of design patterns are assorted with highly productive equipment. In addition, integrated production from the raw material that can be manufactured in a shielded environment without human intervention makes it possible to reduce the transportation cost between processes and reduce the risk of mixing foreign matter such as hair. Is.

As described above, in the conventional process, the individually wrapped pocket tissues are generally hand-assembled by using a hand sealer. In that case, the assortment of collective packaging is prepared by manually arranging pocket tissues of a plurality of types of design patterns prepared beforehand and packaging them. Manual work has the flexibility to handle any sort of assortment, but is not suitable for mass production. In addition, the manual work is economically disadvantageous in that transportation costs are generated if the process is outsourced, and in terms of quality, there is a problem that the risk of mixing foreign matter such as hair is increased.

As described above, a plurality of individually packaged articles having different package designs are arranged in a predetermined array , and a pocket tissue that is collectively packaged as a unit of a prescribed number of packs is manufactured by the above-described conventional method. Then, the following is obtained.
[ First Step ] Using an individual wrapping film composed of a printing film for individual wrapping in which one of different package designs is printed in order, and preparing a plurality of kinds of individual wrapping film original fabrics for each of the different package designs 1 Individual wrapping film preparation step [Second step] Second folding step of unwinding the raw paper from the raw fabric, folding the raw paper by a folding machine and stacking
[Third step] The folded tissue is manually cut into a prescribed number of sheets, and the cut tissue is manually placed on the conveyor for the individual packaging step. [ Fourth step ] The cut tissue is A fourth individual wrapping step in which the product is conveyed on a conveyor and is conveyed to an individual wrapping machine, individually wrapped by the individual wrapping machine using the plurality of kinds of raw materials, and batch-manufactured individual wrapping products for each package design Process] Fifth collective packing process of collectively packing individual packaged tissues by assorting individually packaged individual hand-packed tissues with multiple package designs individually packaged in different package designs

When a plurality of individually packaged products including different package designs are arranged in a predetermined array, and a prescribed number of individual packaged products are collectively packaged as one set, the pocket tissue is manufactured by the conventional manufacturing method described above. In the fourth step, it is necessary to replace the individual packaging film material used every time when the individual packaging product having the package design to be used is manufactured, which requires time and effort for setup.

It is difficult for the inventor to mechanize the manual work of the setup during the research and development of the steps of the integrated mechanized production of the second step to the fourth step , and rather, it is difficult to mechanize the manual work of the setup. It has been judged that it is more appropriate to provide a plurality of production lines commensurate with the second to fourth steps .

Then, a plurality of folding machines and a plurality of individual wrapping machines are used to manufacture a pocket tissue in which a plurality of individual wrapping articles having different package designs are arranged and collectively packed as a set of a predetermined number of individual wrapping articles. Be understood to require.

Manufacturing of pocket tissues, in which multiple individually packaged items with different package designs are arranged and collectively packaged as a set of a specified number of individual packages, requires a single equipment load to compose individually packaged items. Therefore, the burden of equipment depreciation for each stage will be added.

In this way, the production of pocket tissues, in which a plurality of individually packaged products including different package designs are arranged and collectively packaged with a prescribed number of individually packaged products as one unit, requires at least the utilization efficiency of the existing equipment by the setup. If it is damaged or if it is attempted to mechanize the process so that it can be manufactured continuously, some production lines need to be multiplexed and equipment depreciation costs need to be paid.

In the conventional packer for pocket tissues, the assorting function is not incorporated in the process, and for example, there are only four packs of a single design pattern, specifically, a single color design pattern. It is not realistic to install the same number of individual packaging machines as the number of design patterns in parallel from the viewpoint of equipment cost and installation space. In other words, how to improve the production efficiency of pocket tissues that are grouped into a set of a specified number of individual packages in which multiple individual packages with different package designs are arranged by one individual packaging machine. Whether or not it was possible was the first issue.

Then, the inventors have, in order to assort a plurality of kinds design patterns, the individual packaging film you have purchased from the film makers, be those that have already been printed in color order suitable for assorted at the stage of the original anti-winding of the film This led to the creation of an invention that can significantly improve the production efficiency in the case of manufacturing a single packaging machine . However, as an additional issue , the issue of handling individually packaged products has been reached.

That is, by using the individual packaging film of a specified design pattern, for example, printed in the order of design pattern in color order, one individual packaging machine can support the design pattern. even the packages can be produced in a predetermined design pattern sorted, defective plurality of individually packaged products into a set packing machine from being turned by a set packing units. Prior to being put into the packaging machine, defective products were automatically discharged from the process even if an abnormality could be detected using various inspection devices (image inspection device, metal detector, weight checker). For example, the subsequent sequence is out of order with the specified design pattern of the specified assortment in color order.

If the individual packaging of a single design pattern, that is, the same type of design pattern is used as a component of the collective package, when the defective product is discharged from the process, the difference in the quantity of the individual packaging before and after removing the defective product Although it only needs to occur, the packaging design pattern of the product in question has various variations. In this case, before and after rejecting defective products, not only the difference in the total quantity but also the quality difference in the package design occurs. ..

That is, if a defective individual package that was simply discovered is discharged from the process, a mismatch in the package design pattern between the packaged items occurs, and for example, an individual package that is a houndstooth color array is planned. In addition, the individual packagings of the same color may exhibit the adjacent package design pattern, and the inconvenience of unifying the package product may occur. On the other hand, if an attempt is made to maintain the array design pattern of individual packages in a predetermined collective package, the trouble of arranging the defective defective product lineup occurs. Alternatively, there is no choice but to be uneconomical, such as discarding a certain lot of defective products and sending them to reproduction.

When a plurality of types of package design patterns used in collective packaging are produced on an automated line as described above, not only defective products but also normal products need to be automatically discharged from the line as non-assortment-friendly products for convenience.
In solving the above problems, the present inventor selects a normal product (non-assortment-compliant product) to be discharged from a line when a normal product adjacent to a defective product is automatically discharged from the process together with the defective product. The one-dimensional permutation suitable for assortment is used as a clue for the generation of multiple types of package design patterns that are already printed in color order at the stage of winding the original fabric and are used in collective packaging realized on individual packaging films. In addition, how to select a normal product to be discharged in the vicinity of a defective product from a one-dimensional permutation that gives a plurality of types of package design patterns was an additional issue.

In this case, from the viewpoint of productivity and equipment efficiency, the present inventor uses the individual wrapping film printed in the color order of the design pattern and enables the use of one individual wrapping machine while eliminating defective products. Uses individual wrapping films printed in the order of design patterns in color order, for example, and makes it possible for one individual wrapping machine to handle the design pattern. Focusing on this one-dimensional package design and its design pattern, it is efficient and economical. Inventing a manufacturing method that enables the introduction of individual packages in a prescribed design pattern array consisting of only normal products, and the present invention provides the same effect.

Conventionally, there is Patent Document 1 (Japanese Patent Application No. 2013-173973) as an invention that can be used in a collective packing process for assorting components of a collective package. Patent Document 1 discloses an article processing facility capable of assortment sorting, and a support mechanism for the assortment sorting "... based on the article identification information and the sorting information stored in the storage unit. Assorting assortment control that indicates the loading front of the sorting destination, and...Instructing the loading front selected in the form of changing the loading front according to the setting order, and the container identification information of the container placed in the loading front and the article. And the item identification information of the above item are associated with each other and stored in the storage section as the sorting information. "(Patent Document 1, Claim 1)" For a group of articles that is only once, it is possible to select frontage sorting control and make it easier to predict which is the next inputting frontage” (Patent Document 1, paragraph 0008). By providing it, it is possible to "improve the workability as much as possible when the worker performs the sorting work". There, "assortment control for instructing the frontage of the sorting destination of the articles based on the article identification information and the sorting information stored in the storage unit" is disclosed, but detecting the occurrence of defective products, and The content of the handling process after the defective product is generated is not disclosed, and these problems are not recognized or suggested.

Conventionally, there is Patent Document 2 (Japanese Patent Application No. 2002-48572) as an invention focused on improving the inspection ability of a collective packaging process of assembling and packaging the components of the collective packaging body and utilizing it for automation. "Means for forming a continuously drawn belt-shaped film into a tubular shape, center sealing means for sealing the superposed end of the tubular film formed in the tubular shape, and a center sealing means disposed downstream of the center sealing means. A pillow packaging machine main body having a sealing means for sealing the tubular film in the width direction and a cutting means for cutting a sealing portion sealed by the sealing means, and the seal before being cut by the cutting means A pillow packaging machine including an image inspection device that performs a predetermined inspection based on image data obtained by capturing an image of a part" (Patent Document 2, Claim 1). The inspection device is automated by providing an image inspection device for the seal portion of a product that is formed into a cylindrical shape and packages the contents. Here, the object of inspection is the product after packaging, not the inspection of the contents of the package, not the inspection for determining the processing content in the process. The restriction on the determination time of the content of the process processing differs from that of determining the process after the inspection based on the inspection and the determination result, which is intended for the present invention. As described above, in the description of the invention disclosed in Patent Document 2, there is no stipulation of the process after the determination of the defective product, and no proposal to automate the process process after the determination of the defective product is disclosed. , Neither recognized nor suggested.

In this way, a process that can inspect individual packaged items that are components in the collective packaging process that assorts the components of the collective package, quickly determine the quality of the separate packaged product, and perform subsequent processing with a margin. It is understood that a mechanism to support the equipment is required .
The problem is that the production efficiency of a pocket tissue in which a plurality of individually packaged products having different package designs are arranged, and a prescribed number of individual packaged products are collectively packaged as one set, using one packaging machine as a unit. The first issue, whether it can improve, is closely related.

JP, 2005-40127, A JP, 2003-246307, A

The present invention relates to a method of manufacturing a pocket tissue, which mechanizes the process of individually assembling individual packages and collectively packing them, and improves the production capacity while raising the hygiene condition without human intervention by the fully automatic manufacturing integrated manufacturing process. Provided is a method for producing a pocket tissue.
INDUSTRIAL APPLICABILITY The present invention realizes a mechanism for promptly and reliably recognizing defective products by inspecting individually packaged products with a relatively simple mechanism and accelerating the determination of defective products, and fully automated collective packaging without human intervention. A method of manufacturing a pocket tissue that enables the above.

The present invention which has solved this problem is as follows.
The following configuration is disclosed in one embodiment of the present invention.
A method for manufacturing a pocket tissue in which a plurality of individually packaged items including different package designs are arranged , and the individually packaged items are collectively packaged ,
Hara and anti-preparation process of individual packaging film;
Feeding the individually packaged individually packaged film from raw film, and the individual packaging step of packaging for each one of the individually packaged products the web by the sealing device;
An inspection step of detecting an abnormal product of the individually packaged product by an inspection device and discharging it from the line ;
An assortment process for stacking individual packages as a collective package assembly element ; and
A collective packaging step of packaging each of the collective package assembly elements as a collective packaged product in a collective package packaging bag ;
Including
The individual wrapping film is repeatedly designed as two first package designs and second package designs that are different from each other in the line direction, and
In the smallest unit
In the individual wrapping step, along the line direction of the individual wrapping film, the web is packaged as an individual wrapping product for each package design,
The packaged individual packages are sorted into a row of the first package design and a row of the second package design,
In the assortment step, two collective package set elements are formed by stacking each of the first package design and the second package design,
In the collective packaging step, each of the two collective package assembly elements, in a stacked state, is packaged in one collective package packaging bag,
In the inspection step, the abnormal product is discharged from the line, and the normal product in the repeating unit of the first package design and the second package design to which the abnormal product belongs is also discharged from the line.
A method of manufacturing a pocket tissue, which is characterized by the following .

(Effect of the above, which appears in one form)
With a single wrapping machine, multiple individually packaged products with different package designs are arranged , enabling continuous production of pocket tissues that are collectively packaged as a set of individually packaged products with a specified number of packs. Can be improved.

There are various modes for accommodating the individual packages individually packaged in the collective package in the collective package, even if a collective package including the same assortment is realized.
From the opposite side, there are multiple variations in the packing sequence of individual packages that make up an array consisting of a combination of a certain package and individual packages when the array is decomposed into one or more permutations. Then, if one variation is selected from among them, the permutation of each row/column that constitutes the sequence variation is expressed when the permutation is rearranged into one individual package permutation 1 Corresponding to the dimensional individual packaging product line permutation, by preparing an original packaging film capable of delivering individual packaging film that expresses the package design in this one-dimensional line order, by using one packaging machine, This is a book that enables continuous production of pocket tissues, in which multiple individually packaged items with different package designs are arranged, and which is collectively packaged as a set of a prescribed number of individually packaged items, thus improving production efficiency. It is an invention.

The following configuration is disclosed in another embodiment of the present invention.
In the individual packaging film original fabric preparation step, one unit of the minimum repeating unit is specified from the line- designed package design sequence designed for the individual packaging film fed from the individual packaging film original fabric, and the assortment within the one unit is specified. Including a preliminary step of identifying permutation information for the element,
An inspection process is further included between the individual wrapping process and the assortment process to detect an abnormal product in the individual wrapping product by the inspection device and discharge the product from the line.
The assortment step includes an assortment nonconforming product discharging step in which an assortment element specifying device identifies an assortment element of an individually packaged product on a line and an assortment nonconforming product is discharged from the line by an individual packaging product discharging device. ;
It is a method of manufacturing a pocket tissue.

(Effect of the above, which appears in one form)
Decomposing the rows and columns of the array consisting of a combination of individual packages, correspond to the 1-dimensional individual packaging line permutation of expressing configurable individually packaged products each resolution element for accommodating the package to the group package, the If defective products are to be inspected in the order of the line order of the one-dimensional individually packaged products, the minimum repeating unit of the line order of the one-dimensional individually packaged products is specified as one unit, and the unit for the assortment element in the unit is specified. When a defective product such as insufficient weight or metal fragments is found in the unit, the non-defective product in the unit including the defective product is also discharged from the line.
If the minimum repeating unit in this case is specified as the management target, the permutation information of the assortment elements in the one unit is specified, and the inspection of the assortment element of the minimum repeating unit in the permutation information is focused, the minimum repeating unit is It is possible to manage the discharge of the assortment elements based only on the permutation of, and discharge the nonconforming assortment from the line by the individual packaged product discharge device, which simplifies the processing.

The following configuration is disclosed in another embodiment of the present invention.
A method of manufacturing a pocket tissue, which is capable of continuously manufacturing a collective package in which a plurality of individually packaged products having different package designs are assorted, uses an assortment control device and the following:
In the preparatory step, the assortment control device previously communicates with the outside the assortment information including the assembling package identification information and the assortment element key that identifies the assortment element and the permutation information of the assortment element key. Means or data input means for receiving and storing in a storage mechanism, and in the assortment nonconforming product discharging step,
The assortment control device communicates between the assortment control device and the assortment element identification device an assortment element key identified by the assortment element identification device from the next individual package on the line. An individual packaging line data information receiving step that is received by communication means;
The assortment control device, the next sequence of assortment element keys used in the immediately preceding assortment nonconforming product determination (when the immediately preceding sequence is at the end of the permutation and when the immediately preceding determination cannot be used, Indicates the beginning of the permutation (same below), and the assortment element key of the individual packaging line data is compared, and when both keys do not match, the individual packaging product is regarded as an assortment nonconforming product. And an assortment nonconformity determination step of determining that the individual packaged product is a good assortment when the both keys match; and an individual packaged product discharge command signal for the non-assortment non-conforming product with the assortment control device and the individual packaged product. A communication step of sending to the individual package discharging device by communication means for communicating with the product discharging device;
A method for manufacturing a pocket tissue using an assortment control device, which is capable of providing a control method including the above.

(Effect of the above, which appears in one form)
Individual packaging film Unrolled from the original fabric, the sequence of the individual packaging before and after the permutation information within one unit of the design, which is the minimum repeating unit of the line design package design sequence designed for the individual packaging film whether or not capable of generating an array of assortment element of a line-on sequence of the packaging set packaging because it is determined in advance preparation step and the arrangement of the front and rear individual package, is accepted store the storage order In comparison with the individual packaging line data information, more specifically, the assort element key that identifies the assort element of the package design of the next individual packaging product on the line is identified and determined. By this operation, it is possible to determine whether or not the individually packaged product is an assortment nonconforming product with less data, and the processing can be simplified.

The following configuration is disclosed in another embodiment of the present invention.
In the step of ejecting non-assortment nonconforming products of the method for manufacturing pocket tissue, which is capable of continuously manufacturing a collective package in which a plurality of individually packaged products having different package designs are assorted, the assortment element identifying device includes a monitoring camera and a monitoring camera. A device including a color digital image processing mechanism that communicates with a device, the package color or form of an individually packaged product, and the color and form are detected as specific information, and the specific information is communicated from the assortment element specifying device. A method of manufacturing a pocket tissue, which is transmitted to the assortment control device by data communication means, and the assortment control device specifies an assortment element from the color information.

(Effect of the above, which appears in one form)
Patterns and colors of the package design are used to identify the package design associative elements. In the present embodiment, a device including a surveillance camera and a color digital image processing mechanism communicating with the surveillance camera, wherein the package color or form and the color and form of an individual package are input to the color digital image processing mechanism as a video signal, for example, It is an invention that uses color information in a more specific form that realizes determination as to whether or not an adjacent individual packaged product is within a minimum repeating unit based only on color information.

Thus, the present invention relates to a method of manufacturing a pocket tissue, which mechanizes the process of individually assorting and collectively packing individual wrapping, and the fully automatic manufacturing integrated manufacturing process does not require human intervention and raises the production capacity while raising the hygiene condition. A relatively simple mechanism is used for the method of manufacturing a pocket tissue that improves the quality of the product, which enables quick and reliable recognition of defective products by inspecting individually packaged products and realizes a mechanism for accelerating the determination of defective products without human intervention. Provided is a method for manufacturing a pocket tissue that enables full automation of collective packaging.

It is a side surface schematic diagram which shows the folding web manufacture of the pocket tissue by the folding machine which is the first half process of the individual packaging process 1 used for the manufacturing method of the pocket tissue which concerns on the embodiment of this invention. FIG. 9 is a schematic rear view showing folding web cutting and tissue production of a pocket tissue by a folding machine which is the latter half step of the individual wrapping step 1 used in the method for producing a pocket tissue according to the embodiment of the present invention. It is a perspective schematic diagram of the packaging process 101 of the pocket tissue by the manufacturing method of the pocket tissue which concerns on one embodiment of this invention. It is step (process) figure S1 including the individual packaging process and the collective packaging process in the process of the manufacturing method 1 of the pocket tissue which concerns on one Embodiment of this invention.

First, the manufacturing apparatus 1 used in the method for manufacturing a pocket tissue according to the embodiment of the present invention will be described. FIG. 1 is an individual packaging step 1 used in the method for manufacturing a pocket tissue according to the embodiment of the present invention by using the manufacturing apparatus 1 used in the method for manufacturing a pocket tissue 1 according to the embodiment of the present invention. FIG. 7 is a schematic side view showing the production of a folded web of pocket tissue by a folding machine, which is the first half step of FIG. FIG. 2 shows a folding process of a pocket tissue by a folding machine, which is the latter half step of the individual wrapping step 1 used in the method for manufacturing a pocket tissue according to the embodiment of the present invention, using the apparatus 1, and cutting the web and manufacturing the tissue. FIG.

FIG. 1 is a schematic diagram of a manufacturing apparatus 1 used in a method for manufacturing a pocket tissue according to an embodiment of the present invention.
The raw fabric 2 can be held by a raw fabric roller , and the raw paper from the raw fabric 2 is fed in the direction D1 and passes through the rollers 5 and 6 .
Between the intermediate roller 8 is capable load appropriate tension by dancing roller 7, the base paper is intermediate roller 8 or al, is directed to Kajigyo correcting mechanism 9, 10 are capable of modifications of steering lines .. A slitter blade 14 capable of cutting the base paper 3 with the roller 12 is installed, where the base paper is cut into two base papers. Before cutting, an appropriate wrap angle is set by the intermediate rollers 11 and 12, and an appropriate tension is applied to the base paper before cutting.
The folding guide mechanism 16 can individually fold the cut base paper into tissues, and the base paper flows along the guide mechanism 16 to be folded, and the folding tissues 18, 19 (reference numeral ) by the downward roller 60 (see FIG. 2). 19 is not shown in FIG. 1, but is shown in FIG. 2) is sent to the carving mechanism shown in FIG .
Hereinafter will be described with reference to FIG. In FIG. 2, the downward folding tissues 20 and 30 are swung 90° in the traveling direction as they are by triangular plate mechanisms 21 and 31 (hereinafter, only reference numerals 21 and below are described, 31 and below are to be interpreted in parallel). (22) is fed to the cutting mechanism by the feed roll 23, guided by the pinch roll 24, cut by the cutter roll 25, folded into a web by the folding roll 26 (28 , 38) , and dropped on the conveyor 40. (Reference numerals 29 and 39). The tissues 41 and 42 output from the two lines to the conveyer 40 are placed on the flight conveyers arranged at equal intervals.

The tissues 41 and 42 are sent to the individual wrapping mechanism by the flight conveyor. FIG. 3 is a schematic perspective view of a pocket tissue packaging process 101 according to the method of manufacturing a pocket tissue according to one embodiment of the present invention. An embodiment will be described.

The tissues 41 and 42 placed on the flight conveyor are put into the individual wrapping mechanism and wrapped with a long polymer film for individual wrapping pack fed out from the individual wrapping film , and then fused by a fusing mechanism ( sealing device: not shown). Both sides are individually sealed and sent as they are to a collective packaging mechanism (not shown) in the subsequent process by a conveyor.
Set packing mechanism is individually packaged tissue a predetermined number of, for example, only write down one mountain to the bucket 1030,1400, and each bucket 1030,1400 elements that 1x3 pieces (1 column 3 stages), two buckets One set is packaged from a collective packaging machine into a collective packaging bag, and one individual package of vertical 1 row x horizontal 2 rows x height 3 stages = 6 pieces is packaged as one group, and for each predetermined collective package, for example, 1 It is packaged in corrugated cardboard (not shown) in 8 steps with 2x3 steps.

A pocket tissue manufacturing method will be described with reference to the step S1 step (process) chart of the pocket tissue manufacturing method according to the embodiment of the present invention shown in FIG. In the following, a process is synonymous with a step, and a stage is synonymous with a substep within the step. As shown in FIG. 4, the manufacturing step S1 of the present invention includes an individual wrapping film preparing step S10, an individual wrapping step S20 including a folding step (not shown) , and a dividing step (not shown) , an inspection step S30, It is composed of an assortment process S40 including an assortment nonconforming product discharging stage, a collective packing process S50, and a remaining process S99. Hereinafter, among the methods for producing using the pocket tissue manufacturing method S1 with reference to FIG. 3, from the pocket tissues 41 and 42 shown in FIG. 2, a pocket tissue individual packaged product (hereinafter, simply referred to as an individual packaged product) is obtained. The process from manufacturing to collective packaging will be described in detail.

<Manufacturing method 1>
A pocket tissue manufacturing method S1 (see FIG. 4) according to an embodiment of the present invention will be described using the components of the manufacturing apparatus 1 .
The manufacturing method S1 according to the present invention is
As shown in FIG. 3, different packaging design R, B (R is red, B is the code a is to identify the characteristics of the blue packaging design) more individual packages 3020,3030 array comprising (1 column x2 This is a method of manufacturing pocket tissues that are arranged in 3 rows .
This manufacturing step S1 includes the following steps. That is,
Individual packaging film original fabric preparation step S10;
Feeding the individually packaged raw film material 200 from individual packaging film 201, the sealing device (not shown) the web individually packaged products 0,1000,2000,3000,4000,5000 (hereinafter the sign of forming a permutation individually packaged products 0,..., etc.) and individual packaging step S20 for packaging;
The individual packaging products 0,... Are used as an assortment element for the collective packaging device 1 (the whole is not shown, and in FIG. 3, the distribution routes R1 and R2 at the entrance of the device and the individual packaging products after distribution are dropped. The buckets 1030 and 1400 are schematically shown in FIG. 1). An assortment step S40 in which a predetermined storage order is arranged so that the buckets 1030 and 1400 can be received , and individual packing items with a prescribed pack quantity N=6 are put into the collective packing apparatus in a line. And; and a collective packaging step S50 of packaging the individual packages 3020, 3030 in a predetermined array (1 column x 2 rows x 3 stages) into the aggregate packaged product 3100 by the collective packaging device (not shown) .
The line-feeding order U3 of individual packaging to the collective packaging step S50 is a storage order that is reduced and generated from the array of the assortment elements of the collective packaging 3100 (1 column x 2 rows x 3 stages).
The line input to the assortment step S40 is a one-dimensional line order U3, and the line order U3 is an integrated configuration that can configure the line input order of individual packaging to the collective packaging step S50.
The original individual wrapping film 201 delivered from the individual wrapping film original fabric 200 prepared in the individual wrapping film original fabric preparing step S10 is characterized in that the package design is developed in a one-dimensional line order U1. This is a pocket tissue manufacturing method S1 capable of continuously manufacturing a collective packaged product 3100 in which a plurality of individually packaged products 0,...
More specifically, the individual packaging step S20 is
A folding step of forming the base paper 3 into a folding tissue 17;
The method is a method S1 for manufacturing a pocket tissue, which includes a step of cutting the tissue 17 into a specified number of sheets and placing the tissue 17 on the conveyor 40, and the process can be fully automated.
This embodiment, as one of the individual packaging machine, different packaging design R, a plurality of individually packaged products 0 containing B, · · and the like are arranged in a predetermined arrangement U6, individual packaging of the provisions of the number of packs N It is possible to continuously produce pocket tissues that are collectively packed as a set, and improve production efficiency.

Another embodiment of the present invention is a pocket tissue manufacturing method S2 capable of continuously manufacturing a collective package in which a plurality of individually packaged products having different package designs are assorted, and the following features are added to S1. It was done,
In the individual wrapping film original fabric preparing step S10, one unit of the minimum repeating unit U2 from the package design sequence U3 in the line order designed for the individual wrapping film 201 fed from the individual wrapping film original fabric 200 (line feeding order U3). And a permutation information B and R of the assortment elements 300 and 400 in the unit U2 are included, and an inspection device (not shown) is provided between the individual packaging process S20 and the assortment process S40. The method further includes an inspection step S40 of detecting an abnormal product from the individually packaged product and discharging it from the line,
In the assortment step S40, the assortment element identifying device 400 (not shown) identifies the assortment elements R and B of the individual packaging items on the line, and the non-assortment sorting device discharges the individual packaging items (not shown). Is a method of manufacturing a pocket tissue including a step of discharging non-assortment-compliant products discharged from the line L by.

Row and column of the array consisting of a combination of individually packaged product (1 column x2 line x3 stage) (1 column x1 line x3 stage), broken down into (1 column x1 line x3 stage), houses a package U6 to set package 3100 Corresponding to the one-dimensional individual-wrapping product line loading order U3 that develops the individual packaging products that can configure the respective disassembling elements 2010, 2020, the one-dimensional individual-packaging product line loading order U3 is arranged in the order of 0, 1000, When a defective product is inspected at 2000, 3000, 4000, 5000, etc., the minimum repeating unit R, B of the line order of the one-dimensional individually packaged product is specified as one unit, and the assortment element in the unit is identified as a unit. If a defective product such as insufficient weight or metal fragments is found in the unit, non-conforming assortment products (non-defective product) in the unit including the defective product are also discharged from the line. The minimum repeating unit U2 of the case identified as managed, identified permutation information R assortment elements in the one unit, the repetition of the unit of B, assortment elements of the minimum repeating unit U2 in the permutation information Focusing on the inspection, the discharge control of the assortment elements can be performed based on only the permutation of the minimum repeating unit U2 , and the non-assortment products can be discharged from the line by the individual package discharge device, which simplifies the processing. It becomes possible to do.

Then, in order to realize this simple processing, the individual packaging film used in the individual packaging film original fabric preparation step has the repeating unit of the package design {R, B} as the repeating unit of the minimum unit U2 in the deferred state. Is printed as 300, 400, 500, 600, 700...

The following configuration is disclosed in another embodiment of the present invention.
A pocket tissue manufacturing method S3 capable of continuously manufacturing a collective packaged product 3100 in which a plurality of individually packaged products 0, 1000, 2000, 3000, 4000, 5000 and the like including different package designs R and B are assorted. Using the device, the following:
In the preparatory stage of the individual wrapping film original fabric preparation step S10, the assortment control device preliminarily identifies the collective packaging item identification information and the assortment element keys {0, 1} and the assortment element keys {R, B}. Of the element element key {0,1}, including a data input step of receiving the assortment information including the permutation information by an external data communication means or a data input means and storing it in a storage mechanism, and the assortment of the assortment step S40. At the non-conforming product discharge stage,
The assortment control device (not shown) identifies an assortment element key {0} (assortment) specified by the assortment element identification device (not shown) from the individual packaged product 2000 next to the individual packaged product 1000 on the line. An individual wrapping line data information receiving step for receiving the assortment element key being 0 because the element is red R) by the data communication means for communicating between the assortment control device and the assortment element specifying device;
The assortment control device is arranged such that the next sequence of the assortment element key {1} used in the determination of the immediately preceding assortment {B} nonconforming product stage (when the immediately preceding sequence is the end {B}{1} of the permutation) And when the previous determination cannot be used, the next sequence refers to the first {R}{0} of the permutation, and the same applies to the following) assortment element key (at the time of testing the individual package 2000, the immediately preceding test). The sorted sequence is {1} from the test of the individually packaged item 1000 {B}, and {B} is the last assortment of the sequence of two assortments of the permutation unit U2{R, B}. Of the assortment element key {0} corresponding to the assortment element {R} of is an assortment element key that should be used in the determination condition of the test of the individual package 2000) Assortment element Key verification data is obtained by an assortment element identification device. Specifically, a digital camera is used to obtain digital image frame data, and the data is transferred to a color digital image processing mechanism. The color of the color is identified and the identification color is transmitted to the assortment control device. If the color of the individual package 2000 is {B}, the assortment control device assigns the assortment element key {1} to the test result, which is the assortment element to be used in the determination condition of the test of the individual package 2000. Since it does not match the key {0}, it is determined that the individually packaged product 2000 is an assortment nonconforming product, and if the color of the assortment element that is transferred to the color digital image processing mechanism and identified by the mechanism is {R}. For example, the assortment control device assigns the assortment element key {0} corresponding to the transmitted identification color {R} to the test result, which is the assortment to be used in the judgment condition of the test of the individual package 2000. An assortment nonconformity determination step of determining the individual packaging product 2000 as an assortment conforming product because it matches the element key {0}; and an individual packaging product discharge command signal for the assortment nonconformance product with the assortment control device. A communication step of sending to the individual package discharging device by communication means for communicating with the individual package discharging device;
It is a method S3 of manufacturing a pocket tissue using an assortment control device capable of providing a control method including the above.

(Action effect)
From the permutation information in one unit U2 of the design, which is the minimum repeating unit of the package design sequence of the line sequence U3 designed on the individual wrapping film 201 unrolled from the individual wrapping film raw sheet 200, the sequence of the individual wrappings before and after the unit packaging is collected In order to determine in step S50 whether or not the array U6 of the assortment elements of the collective package can be generated and the arrangement of the individual packages before and after the sequence and the individual packaging film raw fabric preparatory step S10, the reduction generation is performed. Contrast the storage order U2 with the individual packaging line data information that has been previously input to the assortment control device and stored in the storage mechanism of the device, and more specifically, the assortment of the package design of the next individual packaging product on the line. The assort element key {0, 1} that specifies the element {R, B} is specified and determined. By this operation, it is possible to determine whether or not the individual package is an assortment non-conforming product with less data, which is the verification data/reference master data of the individual package before and after the verification, and the processing can be simplified. Become.

The following configuration is disclosed in another embodiment of the present invention.
The assortment element identification device communicates with the surveillance camera during the assortment non-conforming product discharge stage of the pocket tissue manufacturing method that can continuously manufacture a grouped package in which multiple individually packaged products with different package designs are assorted. A device including a color digital image processing mechanism that detects a package color or form of an individually packaged product and a color and form as specific information, and the specific information is communicated from the assortment element specifying device to the assortment. A method for manufacturing a pocket tissue, which is characterized in that the assortment control device transmits the data to a control device by data communication means, and the assortment control device specifies the assortment element from the color information.
(Action effect)
Patterns and colors of the package design are used to identify the package design associative elements. In the present embodiment, a device including a surveillance camera and a color digital image processing mechanism communicating with the surveillance camera, wherein the package color or form and the color and form of an individual package are input to the color digital image processing mechanism as a video signal, for example, It is an invention that uses color information in a more specific form that realizes determination as to whether or not an adjacent individual packaged product is within a minimum repeating unit based only on color information.

The collective packing step S50 included in S1 will be briefly described with reference to FIG.
The individually packaged products 0, 1000, 2000, etc. flowing on the line L are sampled and imaged by the surveillance camera installed immediately above the line L immediately before the distribution mechanism to the routes R1, R2, and the assortment element specifying device is provided. The individual packaging line data information which is judged by the color and is received by the data communication means for communicating between the assortment control device and the assortment element specifying device receives the specific information from the assortment element specifying device in the step of receiving the individual packaging line data information. After the communication step of receiving and sending an individual package discharge command signal for an assortment nonconforming product from the assortment control device to the individual package product discharge device by communication means for communicating the assortment control device and the individual package product discharge device, The individual packaged product discharging device discharges the nonconforming product from the line, and only the assortment element compatible product is distributed to the routes R1, R2 by the distribution mechanism, and the red individual packaged products 1001, 1020, 1030 are stored in R1. The individual packages 1100, 1300 and 1500 of blue color are dropped into the bucket 1400 in three stages and in the R2 into the bucket 1400 in three stages. The set package assembly elements 2010 and 2020 of U6 of the set that configures the individual packaging arrangement elements 3020 and 3030 that form the set package 3100 have a lift mechanism (not shown) for each bucket in the arrangement U5 on R1 and the arrangement U4 on R2. ), is housed in a collective packaging bag by a pusher mechanism (not shown), and is package-sealed to complete a collective packaged product.

Then, after the above individual packaging process, inspection process, assortment process, and collective packaging process, the following as a remaining process (details not shown):
Using the corrugated cardboard caser means; and a conveyor connecting these means, the individual packaging produced in the individual packaging step is arranged into a predetermined number of vertical and horizontal directions and a predetermined number of layers, and collectively packaged by the collective packaging machine means ( In one embodiment, there is a total of 6 packaging packs of 3 layers with 1 column x 2 rows), and the collective packaging is packaged in corrugated cardboard by corrugated cardboard caser means arranged in a predetermined number of rows and columns and number of layers. (In one embodiment, there are a total of 48 collective packing pack configurations of 8 steps in which one step is 2×3), and when further including a post-process that is consistently automated from collective packing to cardboard case packing, manufacturing It is possible to realize a pocket tissue manufacturing method that can be mechanized in a continuous line from the production of individual wrapping to the packaging of corrugated cardboard boxes in a collective packaging after the raw material of the stencil is put into the process and then the individual wrapping film is put into the process. Is. In realizing this, full automation of the assortment process is most effective, and the present invention provides a manufacturing method for realizing the full automation of the process.

By adopting the fully automated line of the individual packaging process and the assortment process and the remaining process described in the preceding paragraph, it is possible to perform integrated production up to case packing on the manufacturing line in one line, and further improve the production capacity.

INDUSTRIAL APPLICABILITY As described above, the present invention mechanizes the process of individually assembling individual packages and collectively packing them, and the fully automatic manufacturing integrated manufacturing process does not require human intervention and raises the hygiene situation while improving the production capacity of pockets. The tissue manufacturing method uses a relatively simple mechanism to quickly and surely identify defective products by inspecting individually packaged products, and realizes a mechanism for accelerating the determination of defective products. It is possible to provide a method for manufacturing a pocket tissue that enables automation.

Although the embodiment of the present invention has been described above, the present invention is not limited to the embodiment. The assortment key may be R or B itself, but an ascending or descending key is convenient. The number of assortment elements is not limited, and may be, for example, a three-color configuration or a multi-color configuration, and a permutation of the minimum repeating unit determined as a one-dimensional line order of line input to the assortment process. , The number of elements of the minimum unit having {R, B} as one unit is 2, but the number of elements of the minimum unit having {R, R, B, B} as one unit is 4, Depending on the control of, the controllable configuration may be {B, R}, {B, B, R, R}, or {R, R, R, B, B, B} as one unit. The number of elements in the minimum unit may be 6, but if two or more of the same elements continue, it is necessary to retroactively determine the assortment element key to be referred to two more previous test results. However, those skilled in the art can also realize such a configuration in various ways according to the present embodiment, depending on the unit provided by the lift mechanism, the bucket management unit, the route design of the distribution mechanism, and the distribution conditions. .. Further, the constituent elements of the present invention can be variously modified and implemented without departing from the gist of the present invention. The effects of the invention described here are not limited to those that all appear in one embodiment at the same time, and it is sufficient for at least one of them to be achieved to achieve the object of the invention product. , It can be easily judged.

INDUSTRIAL APPLICABILITY The present invention is applicable to the production of pocket tissues in the paper manufacturing industry.

1 Pocket Tissue Manufacturing Device 2 Raw Fabric 3 Raw Paper 5, 6 Intermediate Roller 7 Dancing Roller 8 Intermediate Roller 9, 10 Rudder Correction Mechanism 11, 12 Intermediate Roller 13 Roller 14 Slitter Blade 15 Intermediate Roller 16 Folding Guide Mechanism 17, 18, 19 Folding tissue 20,30 Folding tissue 21,31 Triangular plate mechanism 22,32 Folding tissue 23,33 Feed roll 24,34 Pinch roll 25,35 Cutter roll 26,36 Folding roll 29,39 Web 30,31,37,38, 41,42 Conveyor web 40 Conveyor
60 downward roller 101 manufacturing process 200 original packaging film roll 201 deferred individual packaging film
300,400,500,600,700,800,900 Package design printing 0,1000,2000,3000,4000,5000 Individual packaging 1001,1020,1040 R assortment element 1100,1300,1500 B assortment element 1030,1400 bucket 1900 bucket lift 2010,2020 collective package assembly element 3100 collective packaged product 3010 collective package packaging bag 3020,3030 individual packaging array element S1 manufacturing method S10 individual packaging film preparatory step S20 individual packaging step S30 inspection step S40 Assortment process S50 Assembly packing process S99 Remaining process R Assortment element Red B Assortment element Blue {} Assortment element set U1 Line order U2 Minimum repeating unit U3 Line loading order U4 Sorting unit U4 Sorting unit 1
U5 sorting unit 2
U6 set package set (unit)
L line direction R1 distribution line 1
R2 sorting line 2
UW conveyor transport direction

Claims (1)

A method for manufacturing a pocket tissue in which a plurality of individually packaged items including different package designs are arranged , and the individually packaged items are collectively packaged ,
Hara and anti-preparation process of individual packaging film;
An individual wrapping process in which the individual wrapping film is unwound from the original web of the individual wrapping film and the web is packaged as one individual wrapping product by a sealing device;
An inspection step of detecting an abnormal product of the individually packaged product by an inspection device and discharging it from the line ;
An assortment process for stacking individual packages as a collective package assembly element ; and
Each of the group package assembly elements, a set packaging process to package as a collection pack goods into one group package packing bag;
Including
The individual packaging film is repeatedly designed as two first package designs and second package designs that are different from each other in the line direction,
In the individual wrapping step, along the line direction of the individual wrapping film, the web is packaged as an individual wrapping product for each package design,
The individually packaged products are sorted into a row of the first package design and a row of the second package design,
In the assortment step, the individual package products are stacked for each of the first package design and the second package design to form two collective package assembly elements ,
In the collective packing step, each of the two collective package assembly elements is packed in a single collective package packing bag in a lined state,
In the inspection step, the abnormal product is discharged from the line, and the normal product in the repeating unit of the first package design and the second package design to which the abnormal product belongs is also discharged from the line.
A method of manufacturing a pocket tissue, which is characterized by the following .

Images