AU2005298457A1 - Method and system for producing a hermetically packed viscous product - Google Patents

Description

Commonwealth of Australia Patents, Trade Marks and Designs Acts VERIFICATION OF TRANSLATION of *4'A4 1 SC11 -- CH E17CAI-JCH HAI am the translator of the English language document attached and I state that the attached document is a true translation of a) *PCT International Application No. PCi/FX2ovs/o~ 3 90 as filed on di, r- 2. 2.c o (with amendments) b) LkA eeFrtied eopy 4f the oifieetion etCeiipaziyiii Patentii (Utilty M@&zl) Applieatiorn filed in on c ) Tiade Mi rk opplinati&Nv. filed in on filed in on *Delete inapplicable clauses Dated this ....... I S ...... day of .... 6 ...................... 20O.. Signature of Translator ... ......... ..... F.B. RICE & CO PATENT ATTORNEYS 15409-EN Method and system for producing a hermetically packed viscous product The invention relates to a method and a system for producing, at a high rate, a hermetically packed viscous product. It further relates to the products obtained by the method for production of packed products. 5 By viscous, or soft, product within the present description, it is understood to mean a product which is of a higher viscosity than that of liquid water. The preferred mode of embodiment of the invention relates to the production of indicators for determining whether a substance is in a fit 10 state to be consumed or used, and in which the evolution according to time and to the temperature is analogous to the evolution of the substance. When the substance is no longer in a fit state for consumption or use, the optical properties of the indicator are modified. The viscous product entering the 15 composition of the indicator is particularly water rich and/or contains micro-organisms. However, the invention is not limited to this application. It relates to all the types of viscous products which could be, for example, medicines or cosmetic or health products.

2 Known methods of production for packed viscous products do not allow for a production at a high rate and at a reasonable cost. The invention overcomes this disadvantage. 5 To this effect, the method, according to the invention, which enables the production, at a high rate, of a hermetically packed viscous product in an individual package, includes the following steps: - the step for unwinding a first lower film, at high 10 speed, especially between twenty and fifty metres per minute, - the step for depositing at regular intervals predetermined quantities of the viscous product on the first film, - the step for applying a second so-called upper film to 15 the first film on which the viscous product is deposited, and - the step for hermetically assembling the first film and the upper film in such a way as to enclose each predetermined quantity of viscous product. In this way, it is possible to produce, using simple 20 means, individual doses of packed viscous products, this production being carried out at a high rate. The rate can be further increased if, on the first film, multiple doses of the viscous products are simultaneously deposited perpendicularly to the direction of the unwinding of the films. 25 In one embodiment, the viscous product is an active gel which is rich in water and/or contains micro-organisms. In one embodiment, the packed product is in a thin layer, for example of a depth that is between 0.03 and 2 millimetres. 30 In one embodiment, the method includes a step for shaping each package, the shaping consisting of at least one of the operations included in the group comprising: - the cutting out in accordance to a determined shape of each package, 35 - the pre-cutting in accordance with a predetermined 3 shape of each package, - the cutting out of a predetermined number of packages, - the pre-cutting of a predetermined number of 5 packages. By pre-cutting, it is understood here to mean, either a partial cutting out, or weakening lines allowing for an easy manual cut later on. In one embodiment, the step for shaping the packed 10 products is embodied using means of a revolving cylinder fitted with blades. In one embodiment, in advance of depositing predetermined quantities of viscous product, receiving cavities for the viscous product are moulded into the lower film and/or 15 before applying the upper film to the lower film, the second film is deformed in such a way as to give it a non-flat shape for each predetermined quantity of viscous product. Because of these deformations, the volume of viscous product enclosed between the two films may be relatively 20 important without compromising the correct application of the upper film to the lower film. However, the application of the invention further relates to the production of packaging without the deformation of the lower film and the upper film. 25 In one embodiment, the deformations of the first and the second film are embodied by thermoforming and/or pressing and/or embossing. In a preferred embodiment, after depositing predetermined quantities of viscous products, these are cooled 30 in order to make them resistant to the constraints to which they are subjected at the moment of applying the second film. In one embodiment, the method includes the step for implementing at least one mouth nozzle for sequentially depositing the viscous product.

4 In one embodiment, the method includes the step for depositing predetermined quantities of a viscous product on the first film by the implementation of a heliography cylinder. In one embodiment, the step for hermetically 5 assembling the first and second films is carried out by bonding, and/or heat sealing and/or by ultrasound. In one embodiment, provision is made for the step for depositing at least one adhesive substance through the means of at least one nozzle and/or a flexography cylinder. 10 In one embodiment, the step for hermetically assembling the first and second films includes - a step for positioning the second film in relation to the first, and - a step for applying pressure to the second film on 15 the first film outside of the zone containing the viscous product. In one embodiment, the shaping is done simultaneously to the application of pressure. In one embodiment, the lower film is coated with glue 20 on the opposite side of the face on which the viscous product is deposited, in such a way that the packed product constitutes an adhesive label, particularly auto-adhesive. In one embodiment, the lower film is integral with a backing film of which the condition of the surface is such that 25 it allows, in one part, for the temporary assembly of the first film onto the backing film, and, in another part, for almost all of the glue to remain on the first film after it is separated from the backing. In one embodiment, the individual package is hermetic at 30 the moment of production and permeable and/or openable for use. In one embodiment, after the depositing of predetermined quantities of viscous products, these products are subjected to an electric field to prevent their spreading out.

5 The invention also concerns a system of production, at a high rate, of hermetically packed viscous products, this system including: - the means for unwinding a first lower film, at high 5 speed, especially between twenty and fifty metres per minute, - the means for depositing, at regular intervals predetermined quantities of viscous products on the first film, - the means for applying a second upper film to the first film on which the viscous product is deposited, and 10 - the means for hermetically assembling the first film and the upper film in such a way as to enclose each predetermined quantity of viscous product in an individual package. In one embodiment, the viscous product is an active 15 water rich gel and/or contains micro-organisms. In one embodiment, the packed product is in a thin layer, for example of a thickness that is between 0.03 and 2 mm. In one embodiment, the system includes the means for 20 shaping each package, these means for shaping including the means for cutting out or for pre-cutting in accordance with a predetermined shape for each package and/or the means for cutting out or pre-cutting of a predetermined number of packages. 25 In one embodiment, the system includes the means for the moulding of receiving cavities for the viscous product in the lower film, and/or the means for bestowing on the upper film, before the application of the said upper film on the lower film, the means for bestowing a non-flat shape for each 30 predetermined quantity of viscous product. In one embodiment, the means for the deformation of the first and/or the second film comprise the means for thermoforming and/or pressing and/or embossing. In one embodiment, the system includes the means for 35 cooling predetermined quantities of viscous product after they 6 have been deposited on the first film, the cooling temperature being such that the viscous product will resist the constraints to which it is subjected at the moment of applying the second film. 5 In one embodiment, the system includes at least one mouth nozzle for sequentially depositing the viscous product. In one embodiment, the system includes at least one heliography cylinder for depositing predetermined quantities of viscous product on the film. 10 In one embodiment, the means for hermetically assembling the first and the second film comprise the means for bonding, and/or heat sealing and/or of ultrasound type. In one embodiment, the system includes at least one nozzle and/or flexography cylinder for depositing at least one 15 adhesive substance on the first and/or the second film. In one embodiment, the means for hermetically assembling the first and the second film comprise: - the means for positioning the second film in relation to the first, and 20 - the means for applying pressure to the second film on the first film outside of the zone containing the viscous product. In one embodiment, the means for shaping are such that they allow for simultaneous implementation of shaping and 25 applying pressure. In one embodiment, the means for shaping packed products comprises a revolving cylinder fitted with blades. In one embodiment, the system includes the means for coating with glue the opposite side of the lower film face on 30 which the viscous product is deposited, in such a way that the packaged product constitutes an adhesive label, particularly auto-adhesive. In one embodiment, the system includes the means for integrating the lower film with a backing film of which the 35 condition of the surface is such that it allows, in one part, 7 for the temporary assembly of the first film on the backing film, and, in another part, for almost all of the glue to remain on the first film after it is separated from the backing. 5 In one embodiment, the individual package is hermetic at the moment of production and permeable and/or openable for use. In one embodiment, the system includes the means for, subsequently to depositing predetermined quantities of viscous products, subjecting these said products to an electric field 10 to prevent their spreading out. An example of an embodiment of the invention is described in a way that is relative, but not limited, to the figures in which: - figure 1 is a schema representing a system 15 which implements the steps of the method according to the invention, and - figure 2 represents a cutting cylinder being a part of the system shown in figure 1. Figure 1 shows schemas of the various steps of the 20 method for production according to the invention. A lower film 10 is unwound at a speed of between 20 and 50 metres per minute. The film used, of a polypropylene or polyethylene type, is of a width w that is between 100 and 330 mm. It is transparent. This film is coated with a backing film 11, or 25 silicone back, by way of forming an auto-adhesive complex. This complex may be assembled upstream on the same production line, the assembly comprising a step for coating the silicone backing film with glue. A first step A for coating the film 10 with glue 12 is 30 carried out. The depositing of glue is carried out at a given temperature, in the upper example, at one hundred degrees Celsius. A second step B for the reticulation of this layer of glue 12 is subsequently carried out, for example, using the means of ultraviolet ray lamps 14. The action of the 35 ultraviolet rays (U.V.) is sterilising, in the same way as the 8 step for coating, at a temperature of 100 C. Sterilisation of film is particularly useful in the case where a viscous product, such as a cosmetic product, sensitive to potential contamination is being deposited, or in the case where it is 5 sought to suppress the population of micro-organisms contained in a label forming a conservation indicator for the substance. Of course, it is possible to use different types of glue, particularly those glues which do not necessitate reticulation using ultraviolet rays. As yet another variation, 10 it is possible to use two types of glue which have different properties in order to combine the advantages of these glues. For example, we can use a first glue, characterized by its strong cohesion, around the edge of the package and a second glue, characterized by its strong tack, closer to the gel. This 15 second glue may also be used for keeping the gel on the film 10. It is herewith noted that the "tack" of a glue refers to its instantly adhesive ability. A step C for depositing individual doses (predetermined quantities) of gel 16 is subsequently carried out, using means 20 of foil nozzles 18. Each nozzle 18 deposits a dose in a noticeably plane-parallel format. The deposited gel is sufficiently viscous as to not instantly run. It is possible, in order to limit running, to choose the temperature of the gel when depositing it. The number of foil nozzles spaced over the 25 width of the lower film 10 will determine the number of gel doses 16 deposited on a width of the lower film. The parameters which define each predetermined quantity 16, such as the length, the width and the thickness, are controlled using foil nozzles 18. These nozzles are, for example, those which are 30 produced and distributed by the North American company Nordson Corp. A step for cooling D is subsequently carried out. The aim of this step is to increase the resistance to mechanical constraints in the predetermined quantities of gel 16. This 35 step is embodied through the circulation of a cold gas, for 9 example by opening the valve of a liquid gas supply, such as liquid nitrogen. Nitrogen is a naturally inert gas and considerably limits the risks of contamination. This gas is sprayed in proximity to the gel, for example by using conical 5 nozzles 20. The liquid nitrogen should be sprayed by conical nozzles 20 in such a way that it vaporises at the moment it leaves the nozzles, so that the temperature of the gaseous stream (nitrogen and air) around the gel is controlled and maintained 10 at a temperature close to -600C. The action of the gaseous nitrogen makes it possible to avoid the disadvantages which would arise if it remained in a liquid state; in particular, it avoids denaturisation of the glue and the gel, and the fragilization of the lower film. 15 In order to ensure that the nitrogen is in a gaseous state when it enters into contact with the gel and to control the temperature of the enclosure later referred to, it is possible to play on several parameters, such as the diameter and the height, the opening angle and the direction of the 20 conical nozzles, the pressure and the flow of the nitrogen in these nozzles, as well as the flow of air renewal. This step for cooling is embodied inside an enclosure (not shown) where the temperature is regulated, as is explained here below. In effect, without regulation, this enclosure 25 progressively cools, bringing about the risk of the nitrogen remaining in a liquid state inside the enclosure. This is why, in order to regulate the temperature of this enclosure, an air ventilation and extraction device is also used. This step for cooling is not necessary in certain cases, 30 in particular when the depth of the gel is not very thick, and/or when the gel is very viscous. Alternatively, the cooling is embodied by the cooling of a horizontal plate situated under the lower film, before the packaging of the gel.

10 Still alternatively, the cooling is made using a cylinder on which the lower film unwinds and in which a mixture circulates, in particular a mixture of water and glycol; the circulation flow of this mixture and the diameter of 5 the cylinder allow for adjustments to the kinetic of the cooling. In place of or as well as by cooling, it is possible to stop the gel from spreading out by applying an electric field to it. It is also possible to prevent the spreading of the gel 10 by applying, beforehand, a pressure or a coating that will delimit in relief the outline of the gel dose. This relief is made of an ink or of glue which will subsequently be used in the assembly of the film 10 with the upper film described further on. 15 The following step is a step E for the application and positioning on the first film 10 of a second film, or upper film 22, in such a way as to enclose the predetermined quantities of gel 16. This upper film 22 is, in this example, of the same nature as the lower film. It is, therefore, also 20 transparent. During this step, the upper film 22 is subjected to the minimum application of pressure necessary for it to come into contact and adhere to the lower film. The upper film is firstly slowed down and submitted to 25 the confines of two guide rollers 21 and 23 in order to stretch it. Stretching of the upper film 22 is necessary in order to avoid the unwanted displacement of this film in respect of the lower film during its application on the lower film 10, such a displacement could provoke the formation of creases. 30 A positioning cylinder 24 allows for the application of the upper film 22 on the lower film 10 with a light pressure. Pressure applied in this way is controlled: if it is insufficient, the upper film 22 does not come into contact with the lower film; if it is too much, there is a risk that creases 35 will form on the film 22 or that warping will occur in the gel 11 under pressure. This cylinder 22 is coated in a foam which has parameters of thickness and hardness that allow, particularly, for the control of pressure applied by the cylinder. A step for sealing and for cutting F is subsequently 5 embodied, using a cutting cylinder 26 and of a pressing cylinder 27 between which are unwound the films 10, 11 and 22 and the doses 16. This rotating cutting cylinder 26 is fitted with a number of cutters 28 which are adapted to the shape of the packages of gel doses. The pressure applied by the cylinder 10 26 on the cylinder 27 is chosen in such a way as to seal the upper film on the lower film around the gel and in such a way as to cut out the package (i.e. the films 10 and 22) without cutting the backing 11. The role of the pressing cylinder is to allow for the 15 application of a strong pressure by the cylinder 26 without this deforming the films 10, 11 and 22. The cutting cylinder 26 turns at a speed which is adjusted according to the speed of the unwinding of the lower film. A detection cell (not shown) allows for locating the 20 position of the cutters 28 on the cylinder 26 and provides a command signal for depositing the gel, in such a way as to ensure the synchronisation of this deposit with the cutting out, that is to say the desired positioning of the blades in relation to the gel dose in question. 25 Figure 2 represents a cutting cylinder 26. The surface 260 of the cylinder, with the exception of the cutting patterns 28, is coated with a layer of foam of a determined thickness and hardness. Each cutting pattern 28 includes a cutting thread 30, which design the desired shape of the cut or the pre-cut to 30 be obtained. On the inside of a shape, as delimited by each cutting thread 30, is a foam liner 32. The foam liners 32 are, in the example, of the same nature and the same thickness as the foam which coats the surface 260 of the cylinder. This thickness is 35 such that, when the foam is not confined, the cutting lines are 12 under the free surface of this foam. In other words, the height of the blades (knives) is lower than the depth of the un confined foam. When a zone of the cylinder 26 comes into contact with the film 22, pressure is applied to the cylinder 5 27, the foam which coats the surface 260 of the cylinder, together with the layers 32 ensuring that the correct pressure is applied for sealing the two films. When this pressure is applied, the foam changes shape and compresses (compacts) revealing the cutting threads which in turn come into contact 10 with the films to carry out the cutting or pre-cutting on the cylinders 26 and 27 generators simultaneously in contact with the films. In order to avoid crushing the gel, each liner 32 has a hollow 34 at its centre for receiving the placement of the gel 15 dose when pressure is applied. In order to improve the "tack" and/or cohesive kinetic of the glue, during this step for sealing, it is advantageous to heat the cylinder. The glue can be deposited on the whole of the surface 20 either of the lower film or of the upper film, or on the two layers of film, this to be done before the viscous liquid is deposited. The efficiency of the bonding depends on the total amount of glue deposited and on its intrinsic qualities. The quantity of the said glue will not exceed, in most cases, 30 25 grams per M 2 . As a variation, thermal welding and/or ultrasonic welding are used. Thermal welding and/or ultrasonic welding can be used instead of or as a complement to bonding. In the case where 30 this type of welding is used as a complement to bonding, the widths of welding may be reduced around the contours of the dose, this allows for a sustained high rate of production; in this case, the welding allows for the improvement of hermetic sealing and/or the increase of pressure for the gel in the 35 package, and therefore its thickness.

13 If thermal welding and ultrasonic welding are used, because of the different speeds of each welding technique, it is preferable that the thermal welding should be transversal in relation to the unwinding direction of the films and that the 5 ultrasonic welding should be in the same direction as the unwinding of the films. The quality of sealing depends on the temperature of sealing, that is to say the frequency of the vibration in the case of ultrasonic welding, the speed at which the films 10 unwind, the width of the welding and the thickness of the films. It is hereby defined that in the case of thermal welding or of ultrasonic welding, the lower film is not backed (complexed) by the silicone film beforehand, but at the end of the production line. 15 Alternatively, the films 10 and/or 11 and/or 22 bear imprints made on line or beforehand. Still alternatively, the step F may be embodied in two sub-steps. The first sub-step consists of applying a sealing pressure and the second sub-step consists of carrying 20 out the cutting or pre-cutting. Assays carried out have made it possible to draw the following conclusions: The quality of packaging is consistent, particularly the size of the gel, the thickness of the gel, the rectilinear 25 outline of the viscous product doses, the hermetic quality of the label. Good stability of temperature is achieved during the step D. The following equipment was used to make these tests 30 - a machine for horizontal winding and unwinding of a flexography printing type and brand MARK ANDY 4000, fitted by the order of the unwinding of the film: - with a module for depositing glue NORDSON Curtin Coated BC 70, 35 - with a module for depositing gel NORDSON EPll, 14 - with a cryogenic tunnel (enclosure) having two continuous extractors and one air inlet for controlling the temperature, - with one spraying rail for liquid nitrogen having 5 two rows of two NPT nozzles placed at 12 mm from the height of the film trajectory, - with a cylinder 24 coated with a 1 mm layer of foam, - with tension rollers 21 and 23, 10 - with cutting cylinders 26 and pressing cylinders 27 on the bonding zone, the cylinder 26 being coated with a 2 mm layer of foam. The raw materials used include: 15 - the lower film 10, 11 shaped by an auto-adhesive complex Raflatac HD70/RH01/PP30 of a 260 mm width. - the upper film 22 is of the type OPP Mobil 52p SBWR of a 260 mm width. - the glue is of the brand HENKEL Hot Melt UV type PS 20 4110. The gel is deposited at 28 0 C; its viscosity is 4.8 pa/sec, its density is 1.0404. The compressed liquid nitrogen is at a temperature of -196 0 C. It was supplied by the AIR LIQUIDE company on a mobile 25 installation OPEX 4000 litres. The production parameters are the following: - The number of tiles (doses) on a width is four. - The thickness of the gel tiles is 450p. - The size of each tile is 30 mm by 25 mm. 30 - The size of the finished label is 38 mm by 38 mm. - The coating of glue is applied over a 250 mm width at 20gr/m 2 on the lower film. - The temperature in the cryogenic tunnel is regulated at between -40'C and -60'C, depending on 35 the viscosity of the gel.

15 - The temperature of the gel surface and of the glue after passing through the tunnel is between 0*C and 4 C. - The temperature of the production tunnel is between 5 220C +/- 50C. The making of tests using mouth nozzles and industrial glues has allowed for validation of feasibility for the depositing of a liquid viscous product, particularly a 10 water rich gel, containing, for example micro-organisms, with mouth nozzle technology being used for the application of glue. These tests have permitted validation of the stability of the product on a film unwinding by at least 40 meters per minute. This system of coating is suited to the depositing of a liquid 15 that is viscous and particularly with a water-rich medium. This system does not destroy the micro-organisms contained in the label and does not substantially modify their behaviour. It is therefore possible, using the means of this technology, to work at a high rate with an adjustable foil 20 nozzle. The foil, internal part of the nozzle, determines the volume and the quality of the cut behind the deposit. It is possible to improve precision when depositing by using a suction nozzle, this allows also for the control of pressures and avoids emulsification. 25 It is also possible to adjust the dimensions of the doses by playing on, on one part, the shape of the foil and, on another part, the opening time of the foil and the pressure in the base depending on the unwinding speed of the film. Depositing tests on a viscous product, and in 30 particular on a water rich gel, with a heliography cylinder were carried out. These testings permitted validation of the depositing of a viscous product and particularly of a water rich gel, containing for example micro-organisms, using a gravure printing device on a film unwinding at a continuous 50 35 metres per minute. The deposit is of a minimum thickness of 300 16 microns. Depositing using gravure printing permits, not only the perfect dosing of the desired quantity on a film which is unwinding at a high rate, but also the realisation of this 5 deposit with high precision into the outline of the deposit. In one mode of embodiment, a system for injecting neutral gas has been adapted in order to limit sticking problems of the product to the heliography cylinder and thus increase the thickness of the deposit. The layer was able to 10 reach a significant thickness, for example 2 millimetres. Tests on hermetic sealing by bonding around a viscous liquid or a water-rich gel previously deposited were also carried out. The assays carried out have permitted the: 15 - selection and validation of those glues which do not denature a viscous liquid, particularly a water based gel, and particularly those which do not significantly limit the development of micro-organisms, that can be deposited in the gel, and 20 - selection and validation of those glues which permit a definitive hermetic seal uncompromised by a significant presence of water contained in the middle. The following selection was thus made, for example, polyurethane glues (PU), and hot melt glues both UV and non UV 25 which ensure sufficient water/airtightness, with a significant tack, a strong cohesion and a maintenance of adhesion stable over time and not water sensitive. It was validated that the PU glues can be applied using cold flexography plates and be coated on the total 30 surface, which also constitutes an assurance for the efficiency of the final hermetic seal; the hot melt glues can be easily applied using coating systems of the type "curting coated" developed by the NORDSON CORP company. The PU glues are bi-components composed of a resin 35 and a hardener which are mixed together when required for use.

17 They are known to be compatible for use with food products by the "Food and Drug Administration" in the United States of America; they are, in effect, currently used in the complexing of films, for example in the packaging of "chips" (complex 5 aluminium and polypropylene). Moreover, they are compatible with inks. The hot melt glues are rubber or acrylic based, and do not therefore represent a risk to human health or to the environment. 10 The tests carried out have therefore confirmed that the selected glues permit a perfectly transparent, hermetic seal, stable over time and respect the properties of a viscous liquid, particularly a water rich gel, containing for example micro-organisms. 15 The carry-out of tests on hermetic sealing by ultrasonic welding around a previously deposited water rich gel, permitted: - the validation that, when a film is continuously 20 unwinding at a high speed, ultrasonic welding will ensure a perfectly hermetic seal, including for periods of contact which are less than a tenth of a second. - the validation that the flexible plastic films retained can be welded ultrasonically, 25 - the validation that ultrasounds do not denature the texture and the properties of a viscous product, particularly a water-rich active gel, which contain for example micro organisms. It was particularly confirmed that a contact period 30 of less than 5 hundredths of a second, with an ultrasound head for carrying out transversal welding, sufficed not only to ensure a perfect and definitive hermetic seal but also permitted the welding of flexible films, of a thickness of between 20 and 80 microns having coatings and/or a barrier 35 complex layer.

18 The results of the exposure of products that have been packaged and sealed by ultrasound at a frequency of 20kHz have demonstrated that there is no influence on the texture and properties of a viscous liquid, particularly of a water-rich 5 gel and has shown, for example an insignificant rate of mortality amongst the micro-organism population contained in the gel. A feasibility study was carried out, concerning the 10 integration of final shaping for packaging in the form of a label, adhesive or not, directly into the production line. Taking into account the sensitivity to pressure of a viscous liquid, particularly of a water-rich gel, and in particular of a gel containing micro-organisms, it is important that this 15 pressure should be perfectly controlled in order for it to be stable and as low as possible during the processes of unwinding, cutting, trimming and other passages through the back pressure cylinders. After study, the possibility of integrating a shaping 20 module into the embodiment of an adhesive label was validated. The cutting, trimming and therefore final shaping of labels is carried out using a module which can be integrated into the high rate production process of a product containing a viscous liquid and particularly a water-rich gel deposited in a 25 thin layer or in a high thickness, the gel being able to itself contain or not contain micro-organisms. Environment linked to the considered application in the example. For an optimal deposit of a viscous liquid in a 30 hermetically sealed label it is noted that: - the mechanical kinetic of the process necessitates a specific quality control adapted for evaluating the influence of the process on the texture and the properties of the viscous liquid, or of the water rich gel and, for example, the 35 monitoring of constraints imposed upon the micro-organisms that 19 may be contained in the gel, this control intervening between each step of the process. - Very high rates of speed necessitate an installation for the continuous preparation of the gel, linked 5 to the rest of the production tool, in order to ensure a sufficient flow. - The sensitivity to contamination linked to the high proportion of water in the gel necessitates the protection of sensitive parts particularly via laminar flows. 10 Whatever the mode of embodiment of the invention, the applications for this type of system of production are numerous and concern all the sectors of activity which need to package viscous liquids in large numbers and at the lowest possible cost price. 15 The sector of time-temperature integrators, level crossing controls, cooling indicators, is an industry which is particularly concerned by this type of industrial tool. In the cosmetic industry, the development of mini or micro doses is forcing industries to review their production 20 lines in order to respond to the demands of a clientele that is increasingly nomadic, in search of practicality and to respond to the regulatory evolution of the sector. In effect, the cosmetic industries have from now on a legal obligation, for reasons of health and safety, to display 25 on their products a limited period of use after opening, independently of the intrinsic stability of the product. The individual packaging of doses fulfils both of these requirements. These applications can also enable the 30 creation of samples at very low cost, which can particularly be distributed inside newspapers, for packaging a cream or a perfume. Industries which are packaging ambiance perfumes, in small format, can not only benefit from high performance 35 productivity, but also from this new mode of packaging which constitutes an adhesive label.

20 More generally, and particularly in the health sector, the technical functions of the invention can be applied to patches, cataplasms, dressings, or all other packaging of active agents in label form. Most particularly the following 5 applications are noted: the production of patches for stopping smoking of contraceptive patches, of wound dressings. The companies which produce rapid detection kits, for example the field of cell culture media which can reveal the presence of a pathogenic micro-organism (detection of listeria, 10 of salmonella), and more generally, developing kits, or the reactives or bioreactives, used in the medical sector, are concerned by these production tools. Of course, in order to permit the distribution of cosmetic doses, of perfume or other products it is necessary to 15 allow for the means for opening each dose or to permit its diffusion. These means are for example a permeable film. In this case, it is possible to package each dose by allowing for a double layer that comprises a permeable film and an impermeable film (of gas and vaporised water), the impermeable 20 film being detectable for diffusion.

Claims (28)

1. A method for producing, at a high rate, a hermetically packed viscous product, the method includes the following steps: - the step for unwinding a first lower film (10), at 5 high speed, especially between twenty and fifty meters per minute, - the step for depositing at regular intervals a predetermined quantity (16) of the viscous product on the first film (10), 10 - the step for applying a second upper film (22) to the first film (10) on which the viscous product is deposited, and - the step for hermetically assembling the first film (10) and the upper film (22) in such a way as to enclose each pre-determined quantity (16) of viscous product in an individual 15 package (17).

2. A method according to claim 1, in which the viscous product is an active gel which is rich in water and/or contains micro-organisms.

3. A method according to claims 1 or 2, in which the 20 packed product is in a thin layer, for example of a thickness of between 0.03 millimetres and 2 millimetres.

4. A method according to one of the claims 1 to 3, including a step for the shaping of each package (17), the shaping to consist of at least one of the operations included 25 in the group comprising: - the cutting according to a predetermined shape of each package (17), - the pre-cutting according to a predetermined shape of each package (17), 30 - the cutting out of a predetermined number of packages (17), - the pre-cutting of a predetermined number of packages (17).

5. A method according to one of the preceding claims, in 22 which, in advance of the depositing of predetermined quantities (16) of a viscous product, receiving cavities for the viscous product are moulded into the lower film(10) and/or before applying the upper film (22) on the lower film 5 (10), the upper film (22) is deformed in such a way as to give it a non-flat shape for each predetermined quantity (16) of the viscous product.

6. A method according to claim 5, in which the deformations of the first and/or the second films are made by 10 thermoforming and/or pressing and/or embossing.

7. A method according to one of the preceding claims, in which, after depositing predetermined quantities of viscous products, these are cooled in order to make them resistant to the constraints to which they are subjected when applying the 15 second film (22).

8. A method according to one of the preceding claims, including the step to implement at least one mouth nozzle (18) for depositing the viscous product.

9. A method according to one the preceding claims, 20 including the step for depositing predetermined quantities of a viscous product on the first film (10) by the implementation of a heliography cylinder.

10.A method according to one of the preceding claims, in which the step for hermetically assembling the first and second 25 films is carried out by bonding, and/or heat sealing and/or by ultrasound. ll.A method according to claim 10, including a step for depositing at least one adhesive substance (12) through the means of at least one nozzle and/or a flexography cylinder. 30 12.A method according to one of the preceding claims, in which the step for hermetically assembling the first and second films includes: - a step for positioning the second film (22) in relation to the first, and 35 - a step for applying pressure to the second film (22) 23 on the first film (10) outside of the zone containing the viscous product.

13.A method according to claims 4 and 12, in which the shaping is done simultaneously to the application of pressure. 5 14.A method according to claim 4 or 5, in which the step for shaping the packed products is made using means of a revolving cylinder (26) fitted with blades.

15.A method according to one of the preceding claims in which the lower film (10) is coated with glue on the opposite 10 side of the face on which the viscous product is deposited, in such a way that the packaged product constitutes an adhesive label.

16.A method according to claim 15, in which the lower film (10) is integral with a backing film (11) of which the 15 condition of the surface is such that it allows, in one part, for the temporary assembly of the first film (10) onto the backing film (11), and, in another part, for almost all of the glue to remain on the first film (10) after it is separated from the backing (11). 20 17.A system of production, at a high rate, of hermetically packed viscous products, this system comprising: - the means for unwinding a first lower film (10), at high speed, especially between 20 m/mn and 50 m/mn, - the means for depositing, at regular intervals a 25 predetermined quantity (16) of viscous products on the first film, - the means for applying a second upper film (22) to the first film (10) on which the viscous product is deposited, and 30 - the means for hermetically assembling the first film (10) and the upper film (22) in such a way as to enclose each predetermined quantity (16) of viscous product in an individual package (17).

18.A system according to claim 17, in which the viscous 35 product is a water rich active gel and/or contains micro- 24 organisms.

19.A system according to claims 17 or 18, in which the packed product is in a thin layer, for example of a thickness of between 0.03 millimetres and 2 millimetres. 5 20.A system according to one of the claims 17 to 19, including the means for shaping for each package (17), these means for shaping comprising the means for cutting or for pre cutting in accordance with a predetermined shape for each package and/or the means for cutting or pre-cutting of a 10 predetermined number of packages (17).

21.A system according to one of the claims 17 to 20, comprising the means for, in advance of the depositing of predetermined quantities (16) of a viscous product, the moulding of receiving cavities for the viscous product into the lower 15 film (10) and/or the means for giving to the upper film (22), before the application of this film on the lower film (10), a non-flat shape for each predetermined quantity of viscous product.

22.A system according to claim 21, in which the means 20 for the deformation of the first and/or the second film include the means for thermoforming and/or pressing and/or embossing.

23.A system according to one of the claims 17 to 22, including the means for cooling predetermined quantities (16) of a viscous product after they have been deposited on the first 25 film (10), the cooling temperature being such that the viscous product will resist the constraints to which it is subjected when applying the second film (22).

24.A system according to one of the claims 17 to 23, including at least one mouth nozzle (18) for depositing the 30 viscous product.

25. A system according to one of the claims 17 to 24, including at least one heliography cylinder for depositing predetermined quantities (16) of the viscous product on the first film. 35 26.A system according to one of the claims 17 to 25, in 25 which the means for hermetically assembling the first and the second film include the means for bonding, and/or heat sealing and/or of ultrasound type.

27.A system according to claim 26 including at least one 5 nozzle and/or flexography cylinder for depositing at least one adhesive substance (12) on the first and/or the second film.

28. A system according to one of the claims 17 to 27, in which the means for hermetically assembling the first and the second film include: 10 - the means for positioning the second film (22) in relation to the first, and - the means for applying pressure to the second film (22) on the first film (10) outside of the zone containing the viscous products. 15 29.A system according to claims 20 and 28, in which the means for shaping are such that they allow for the simultaneous implementation of shaping and applying pressure.

30.A system according to claim 20 or 21, in which the means for shaping the packaged products include a revolving 20 cylinder (26) fitted with blades.

31. A system according to one of the claims 17 to 30 including the means for coating with glue the face of the lower film (10) which is opposite to the face on which the viscous product is deposited, in such a way that the packaged product 25 constitutes an adhesive label.

32.A system according to claim 31, including the means for integrating the lower film (10) with a backing film (11) of which the condition of the surface is such that it allows, in one part, for the temporary assembly of the first film (10) onto 30 the backing film (11) and, in another part, for almost all of the glue to remain on the first film (10) after it is separated from the backing (11).

33.A method according to one of the claims 1 to 16, in which the individual package (17) is hermetic at the moment of 35 production and permeable and/or openable for use. 26

34.A method according to one of the claims 1 to 16 and 33 in which, after depositing predetermined quantities (16) of viscous products, these products are subjected to an electric field to prevent their spreading out. 5 35. A system according to one of the claims 17 to 32, in which the individual package (17) is hermetic at the moment of production and permeable and/or openable for use.

36.A system according to one of the claims 17 to 32 and 35, including the means for, after depositing predetermined 10 quantities (16) of viscous products, subjecting these products to an electric field to prevent their spreading out.