BR112016028522B1 - METHOD OF MANUFACTURING AND FILLING A PACKAGE WITH A POWDERED NUTRITIONAL PRODUCT; AND PACKAGING FOR A POWDERED NUTRITIONAL PRODUCT - Google Patents

Abstract

method of manufacturing and filling a package with a powdered nutritional product; and packaging for a powdered nutritional product The present invention relates to a method of manufacturing and filling a package with a powdered nutritional product, such as a nutritional formula or baby milk, the method comprising providing a thermoformed reservoir having side walls and a base defining a product receiving space, filling the product receiving space with the powdered nutritional product, and sealing a membrane by an open nozzle of the reservoir to seal the product therein; and folding an empty space of the box with a plurality of panels around the filled reservoir to form a box sleeve, wherein the box sleeve comprises a peripheral wall that surrounds at least the side walls of the reservoir. The invention also relates to a packaging for such a powdered nutritional product, manufactured in accordance with this method.

Description

HISTORY OF THE INVENTION FIELD OF INVENTION

[001] The present invention relates to the manufacture of packaging and, in particular, the manufacture of packaging for powdered nutritional products, such as nutritional formula or baby milk. The invention also relates to such packaging.

DESCRIPTION OF RELATED TECHNIQUE

[002] Powdered material, such as baby milk formula, has been sold in various forms of packaging for many years. Metal cans were initially the preferred container as they were relatively easy and inexpensive to produce and could be sealed for long-term storage. The seal comprised an aluminum plate by the mouth of the container that was removed on first use. Since a single container could be used for an extended period, the containers were provided with open-and-close plastic lids that snapped over the outer rim of the metal can. A measuring spoon was often included with the container, either packaged separately or inside the can itself. These cans are, however, relatively heavy and expensive to produce.

[003] More recently, alternative packaging forms have become available that have improved over existing cans. They include laminated container bodies and plastic hinged lid and rim structures that can be glued to the container body. Such a package is described in US 2008041861 having a seal to initially close the package and a space between the seal and an upper edge of the container to partially receive the spoon before use. The container part can consist of a laminate of paper, sheet metal and plastic material. Additional similar packaging is shown in WO2010071424. One disadvantage of composite packaging is that they can be difficult to recycle. Proposals for multi-component packages have been made, which allow for disassembly to separate for recycling, but to this day, adequate manufacturing processes capable of achieving these packages are lacking.

[004] It is known to manufacture multi-component packages by providing a box around thermoformed containers, before filling the container, for example by using a mandrel to support the container and form the box around the container or by using a mold to support the box before coating the box with a thermoformed container. A disadvantage of these multi-component packages is that this form of manufacture is undesirable for high-care products such as baby formula.

[005] In view of these requirements, it would be desirable to provide a package capable of being assembled in a manufacturing process that can be disassembled for recycling purposes. It would also be desirable to provide a method by which such a package could be manufactured.

BRIEF SUMMARY OF THE INVENTION

[006] According to the invention, there is provided a method of manufacturing and filling a package with a powdered nutritional product, the method comprising: a) providing a thermoformed reservoir having side walls and a base defining a reception space of product, filling the product receiving space with the powdered nutritional product, and sealing a membrane by an open mouth of the reservoir to seal the product therein; b) folding a box void with a plurality of panels around the filled reservoir to form a box sleeve, wherein the box sleeve comprises a peripheral wall surrounding at least the side walls of the container.

[007] If both parts of the package were manufactured separately, both the inner shell and the outer sleeve will have dimensions that are within tolerances. As the sleeve is slid over the inner reservoir, the sleeve will need to be able to receive even the largest inner reservoir within these tolerances. This can lead to a relatively small inner reservoir in a relatively large sleeve, so the sleeve does not support the inner reservoir as much as desired. Additionally, the finish of this combination of a relatively large sleeve and a small reservoir is unpleasant, due to the gaps that appear along the edges and corners.

[008] The folding of the empty space of the box around the filled reservoir has the advantage that the sleeve formed from the empty space of the box fits around the thermoformed reservoir, regardless of the external dimensions of the thermoformed reservoir. By folding the empty space of the box around the filled inner reservoir, the sleeve snugly encloses the inner reservoir, leading to a more acceptable end product. Additionally, the precise fit between these two components provides maximum support for the inner vessel, which is particularly important in the case of vessels having relatively thin walls.

[009] Additionally, mandrels or male molds to retain the thermoformed reservoir in shape may be omitted, due to the shape retention of the thermoformed reservoir by the powdered nutritional product. Adding mandrels or core molds to a manufacturing machine is costly. Furthermore, the thermoformed vessel has internal dimensions that are within tolerances and even the smallest of thermoformed vessels must be fitted to the male mold. This can lead to less support by the male mold in the case of a relatively large thermoformed vessel, so that the mold cannot provide both the desired support and the folding of the empty space in the box around the vessel. Most importantly, it is only possible to use a mandrel inside the reservoir before filling. As will be further described below, for processes in which filling takes place under conditions of high care, it may not be desirable for the box sleeve to enter the high care zone and therefore a mandrel-based assembly is excluded from being used.

[010] According to a surprising effect of the present invention, it is believed that improved retention and support during the folding of the empty space of the box around the reservoir can be achieved due to the fact that the reservoir is filled with a product nutritional powder such as baby formula or baby nutrition. Powdered products such as baby formula or other powdered milk products tend to have greater resistance to deformation due to the flow properties of the powder, ie they may compress to denser states or consolidate rather than flow. by applying external pressure, contrary to fluids. The consolidated product can then act as a shape retainer while folding the empty space in the box around the full reservoir. This resistance to deformation results in a pressing force against the inner wall of the reservoir, thereby supporting the reservoir and retaining its shape. For other products, such as liquids or granular products, the contents may not provide adequate strength during a folding process and the resulting product may be less than adequate.

[011] The bulk density of the powdered nutritional product can be between 0.4 and 0.7 g/ml, preferably between 0.45 and 0.6 g/ml.

[012] According to the present method, the reservoir is filled with powdered material before folding the box sleeve around the reservoir and the product therefore provides additional support to the peripheral wall of the reservoir. Additionally, the contents of the reservoir can exert an outward counter force on the sleeve during the folding operation, thus promoting attachment between the reservoir and the sleeve. In addition, the membrane is provided over the upper edge of the reservoir prior to folding the sleeve around the reservoir to give extra support to the reservoir and to protect the product from the surrounding atmosphere. With the method according to the invention, it is believed that the mandrelless assembly of a multi-component package is achieved while being able to maintain high standards of care for the nutritional product.

[013] The membrane seal may comprise a sheet of metal or it may be a sheet of plastic only. It can be removed entirely before use or it can comprise a weakened serrated line defining an opening region, and a pull tab. The membrane can be provided in several locations, but more preferably the membrane is sealed by the upper edge of the container. In particular, it will be understood that thermoformed reservoirs generally have an externally extending flange forming the upper edge and the membrane can be sealed by the flange. In an alternative embodiment, the membrane can be sealed to the lower frame to close the opening. In this case, the person skilled in the art will understand that the connection between the lower frame and the upper edge of the container must be a sealed connection.

[014] Preferably, the void space of the box comprises a bottom panel and side wall panels and wherein, after folding the void space of the box to a sleeve, the sleeve surrounds the side walls and at least a part of the base of the reservoir . This sleeve provides additional support to the base of the thermoformed reservoir. More preferably, the box blank is formed as a one-piece blank with a plurality of panels.

[015] Composite packaging can benefit from improved strength and the box sleeve can be printed easily. Because the sleeve is added at a later stage in the production cycle, the sleeve design or language may change, even after the reservoir has been filled. For recycling, the sleeve and reservoir can be separated and disposed of as needed.

[016] According to another embodiment, step b) further comprises gluing the panels to the reservoir after folding towards the reservoir. Preferably, step b) further comprises gluing the bottom panel to the base of the reservoir. Connecting the sleeve panels to the reservoir ensures that the sleeve and reservoir support each other. Additionally, the sleeve is formed from the empty space of the box and covers an outer surface of the reservoir in this way. Preferably, step b) further comprises connecting the panels to each other after folding towards the reservoir, preferably by gluing. Preferably, the empty space is shaped like a cross, defining a base and four side panels. The side panels can be provided with lobes or flaps that fit together and can be glued or otherwise adhered together. Preferably, step b) further comprises centralizing the empty space of the box and the thermoformed reservoir in relation to one another. Additionally, step b) may comprise gripping the reservoir to the lid assembly for transporting and for gaining free access to the peripheral wall and base of the reservoir. The empty space in the box can then be connected on the bottom panel to the base of the reservoir by an adhesive, such as glue. According to one embodiment, the side panels are folded towards the reservoir in pairs of opposite side panels. Preferably, the tabbed side panels are folded towards the reservoir first, after which the remaining side panels are folded towards the reservoir. The flaps are preferably provided on the side panels of the void, covering relatively longer side walls of the reservoir. In this embodiment, the folding of the side panels covering the relatively shorter sidewalls of the reservoir over and connecting to the flaps provides more packaging strength. Furthermore, it is preferred that the flaps have this extension so that they do not overlap by folding around or over the reservoir.

[017] According to a further embodiment, step b) comprises applying a lateral displacement to the side panels to place them in engagement with the side walls of the reservoir after folding towards the side walls of the reservoir. To securely connect the sleeve side panels to the reservoir, a force applied laterally to press the side panels into the outer surface of the inner reservoir can be utilized. Pressure can be applied to regions where the glue has been applied in order to cause adhesion of these points. Preferably, pressure is applied to a center of the sleeve side panels, close to an upper edge thereof.

[018] In a preferred embodiment, step b) further comprises providing a box blank of a box blank compartment retaining multiple box blanks. The filled and sealed thermoformed reservoir is provided with the filling and sealing machines to the assembly line by a conveyor device. The box blank is then preferably separately provided with a box or cartridge blank compartment which retains multiple box blanks to allow for continuous assembly of the packages.

[019] In a preferred embodiment of the method, step a) may further comprise adjustment of a lower rim to an upper edge of the reservoir. This rim can advantageously assist in strengthening the otherwise relatively thin thermoformed reservoir. The lower rim is preferably adhered or welded to the top of the membrane seal, although it is not excluded that it can be connected to the upper rim of the reservoir directly, prior to application of the membrane. The lower rim is preferably formed from the same class of material as the reservoir so that both can be recycled together. According to an important aspect of the invention, the step of applying the lower rim may further comprise centering the reservoir in relation to the lower rim before connection. In this way, the lower rim can subsequently serve as a guide for further operations in the reservoir.

[020] In a further preferred embodiment of the invention, step a) further comprises

[021] fit a lid assembly to the reservoir, the lid assembly comprising a top rim and a lid opens and closes. The upper rim is preferably circumferential, defining an access opening

[022] and the cover can be hingedly affixed to the upper rim to close the access opening.

[023] This allows the reservoir to be opened by a user by removing the membrane seal and subsequently opening and resealing using the cover to close the access opening. A fastener on the front edge of the cover can snap onto a rib in the top frame to keep the cover closed. The lid may comprise a support surface on an outer side of the lid assembly to support a base of another package itself upon stacking the packages.

[024] In a more preferred embodiment, the upper rim and the lower rim are mechanically connected together in an interference fit. The lower rim, therefore, has the function of reinforcing the upper rim of the reservoir, allowing the upper rim and lid to be effectively connected to it.

[025] Of significant importance, for powdered nutritional products and especially for infant nutrition, all packaging elements that come into contact with the product must be manufactured in accordance with strict standards. To address this need, certain manufacturing steps are preferably carried out in a high-care environment. Additional components, such as spoons and the lid or closure, are also manufactured to the same standards if they are in contact with the product. According to an important aspect of the invention, step a) can take place in a high care zone. In this context, it is understood that all individual actions included in step a) must take place within this high-care zone. Thus, the package is filled and sealed and all element surfaces that come into contact with the powdered nutritional product are only exposed to the high care zone.

[026] For the purpose of the present invention, high care is intended to denote that the environment is at an excessive pressure relative to atmospheric pressure, preferably, an excess pressure between 5 Pa and 50 Pa, more preferably, an excess pressure between 5 Pa and 30 Pa, more preferably between 5 Pa and 20 Pa. The temperature in the high care zone is preferably kept between 18 °C and 25 °C, more preferably between 19 °C and 23 °C and the relative humidity is preferably controlled between 20% RH and 80% RH, more preferably between 30% RH and 60% RH, most preferably between 35% RH and 50% RH. Also, the atmosphere within the high-care environment is preferably filtered to remove particulates, as with a HEPA (High Efficiency Particulate Absorption) filter including an H10 filter or larger, in accordance with EN 1822:2009. Preferably, all components that come into contact with the product are cleaned by blasting ionized air, sterile and checked with a vision system for imperfections or foreign bodies.

[027] In addition, the package is filled in a low oxygen atmosphere. This can include washing with nitrogen and/or carbon dioxide before and during the filling process and before membrane application. Regardless, the person skilled in the art will understand that other criteria can be applied to that zone if necessary, for example by local regulations. Using a low oxygen atmosphere, in particular a carbon dioxide atmosphere, during filling has the advantage that the powder material is relatively dry compared to the ambient atmosphere. Furthermore, after filling, certain powders absorb carbon dioxide, causing a slight under-pressure in the package. Therefore, the powder can be consolidated even more than under ambient atmosphere, so that the shape-retaining function of the reservoir contents is improved.

[028] As swelling of the container that comprises the food is generally associated with deterioration of the contained food, this impression is preferably avoided as much as possible. Due to the relatively thin thermoformed container, the packaging of the present invention may be more sensitive to a swollen appearance than containers made of thicker, more rigid plastic, for example, formed by injection molding. Thicker, stiffer plastic walls are less susceptible to the force exerted by the contents of the containers than the relatively thin thermoformed peripheral wall of the reservoir. Therefore, it is preferred that the thermoformed reservoir is filled with the powder material having a particular temperature. This may be of particular importance if the finished package contains formula or baby food, as these products that do not require refrigeration are placed in less conditioned circumstances on the shelf in stores, unlike packages containing fresh products such as yogurt. . Thus, in a preferred embodiment, the powdered nutritional product has a temperature between 10 to 30oC, more preferably between 15 to 25oC when the reservoir is filled with it...

[029] Preferably, a spoon is provided within the package and can be located above the membrane seal prior to use. It is also conceivable for a spoon to be formed integrally with the lid construction and separated on first use. In any case, the spoon is also preferably included inside the package in step a) and can therefore also be handled exclusively in the high care zone.

[030] In a preferred embodiment, the spoon is positioned above the membrane seal when the sleeve is folded around the reservoir, whereby a distance between the spoon and the membrane seal is limited to less than 4 mm, preferably, less than 3mm, more preferably less than 2mm. Limiting the distance between the spoon and the membrane seal, i.e. limiting the excess space in the package, is beneficial in reducing plastic waste.

[031] An additional important point in defining the actions performed in the high caution zone is to specify that step b) occurs outside the high caution zone. These actions, therefore, can be characterized as those that cannot be allowed within the high-care zone. In particular, box handling can be associated with considerable process debris and must be kept separate from the actions that take place in step a). For the purpose of the present invention, low care is intended to denote that your environment is maintained in ambient conditions. This includes ambient pressure, which means that excessive pressure is not created. Furthermore, the temperature in the low pressure zone is preferably less strictly controlled compared to high care conditions, which means that the temperature in low care can be between 12°C and 30°C, more preferably 15°C and 26°C. Particulate filtration can be installed in the low care area or installed for airflow to the low care zone, but HEPA filtration is preferably not implemented to save cost.

[032] It will be understood that bonding can be a construction step in erecting the empty space of the box and/or an assembly step at the junction of the reservoir to the sleeve. Preferably, the connection between the reservoir and the sleeve can be easily broken to allow disassembly in recycling the package after use. The glue is preferably a hot melt adhesive and is applied at locations on the inner surface of the empty space of the box and/or the outer surface of the inner reservoir prior to folding the respective panels towards the filled thermoformed reservoir.

[033] According to yet an additional aspect of the invention, the reservoir is a preformed reservoir, of stabilized size, of thermoplastic material. In the present context, preformed is understood to require that the reservoir has been formed at least 24 hours and preferably at least 48 hours before filling. This allows residual stresses within the reservoir, due to the thermoforming process, to be relieved.

[034] The invention is particularly applicable to thin-walled reservoirs and, in particular, to reservoirs that define a single compartment. These containers can be relatively inexpensive, due to the use of minimal amounts of plastic. Additional strength is provided by the box sleeve. Preferably, the reservoir has a wall thickness of about 0.10 mm to 0.50 mm, preferably between 0.15 and 0.40 mm. It will be understood by the person skilled in the art that, due to the thermoforming process, the wall thickness may not be uniform throughout the reservoir. In particular, the upper edge of the reservoir can form a flange having greater thickness and hardness. The reservoir can be made of any suitable material capable of being thermoformed. A more suitable material is polypropylene. However, other polymer materials such as polyethylene terephthalate (PET) or polyethylene (PE) can be used as well. Multilayer materials can also be used, subject to recycling requirements. More preferably, the reservoir comprises a multilayer laminate including a central barrier layer having reduced oxygen transmission, i.e., the formation of an oxygen barrier, such as EVOH or the like.

[035] As indicated above, the strength of the package can be achieved by the combined forces of the reservoir and the sleeve. The sleeve thus also has a structural function, in addition to providing a printable surface. Preferably, the box used for the empty space has a weight between 50 g/m2 and 400 g/m2, preferably from 100 g/m2 to 300 g/m2. The expression box empty space is defined as an empty space comprising paper material. The material void can further comprise other suitable materials such as a coating to protect the outer surface from environmental influences. In general, the void space of the material box has greater weight and thickness than the side walls of the reservoir. It can have a wall thickness between 0.10mm to 0.50mm and it can also have a wall thickness of 0.6mm. The empty space of the box can have a thickness that is at least twice the wall thickness of the side walls.

[036] According to the invention, the reservoir and the sleeve are supported in order to provide a wall structure that is stronger than would be the case for each of the elements, when considered separately. It will be understood that the sleeve base can be open or at least partially closed. It will be appreciated that the weight of the powder contents can aid in pressing the side walls into contact with the sleeve. The side walls of the inner reservoir and the sleeve are preferably slightly tapered. The taper of the outer sleeve and/or reservoir can be between 1° and 7°, preferably about 3°. An advantage of this tapered shape is that the reservoirs can be stacked one inside the other.

[037] Additionally, an upper edge of the sleeve may be at a different distance from the upper edge of the reservoir. In order for the sleeve to properly support the reservoir, the upper edge of the sleeve does not necessarily have to coincide with the upper edge of the reservoir. When a relatively small distance is maintained between the upper edges, the tolerances of the respective heights of the reservoir and the sleeve can be accommodated, so that the support of the sleeve to the reservoir can be optimized. This distance can be a maximum of 5.0 mm, preferably 2 mm, more preferably 1 mm, whereby the side walls are supported over the top edge, without the reservoir actually being suspended from its top edge.

[038] The membrane used to seal the open mouth of the reservoir can be any conventional membrane of sheet metal or plastic film or combination thereof. The membrane can act as a seal to protect the product from the ambient atmosphere, ie it forms a barrier against oxygen and, preferably, moisture. Preferably, the membrane comprises a weakened serrated line defining an opening region, and a pull tab to remove the membrane prior to use. The membrane can seal to an inner surface of the side walls. However, most preferably, the reservoir comprises a flange that extends outwardly on the upper edge to this flange, the membrane is connected.

[039] The invention also relates to a package for a powdered nutritional product, the package being manufactured, according to any of the method embodiments, as described above. The resulting packaging can be easy to produce and dispose of. Other advantages will be apparent based on the additional description below.

[040] The invention is particularly applicable to infant formula and more preferably the package is filled with infant formula milk powder.

[041] Preferably, a spoon is provided within the package and may be located above the membrane seal prior to use. It is also conceivable that a spoon is formed integrally with the construction of the lid and separated on first use.

[042] According to a further aspect of the invention, the process is particularly applicable to wide-access packages of the type in which the reservoir is rectangular and has an access opening with a minimum dimension of at least 70 mm, plus preferably about 100 mm and an area of at least 100 cm2. The overall length of the package can be between 150 mm and 250 mm, preferably about 185 mm. The width of the package can be between 100 mm and 150 mm, preferably about 120 mm. The packaging can be available in multiple heights, according to the volume needed, ranging from 80 mm to 150 mm. In this context, rectangular is understood to include square and does not exclude the presence of rounded corners. The volume of the package can be between 0.8 liter or 800 ml and 3 liters, or 3000 ml, preferably about 1.5 liters, or 1500 ml. These wide-access packages are particularly susceptible to wall strength issues. BRIEF DESCRIPTION OF THE DRAWINGS

[043] The aspects and advantages of the invention will be further appreciated, by reference to the following drawings of the various exemplary embodiments, in which:

[044] Figure 1 shows a package for powdered nutritional products, manufactured according to the method of the invention.

[045] Figure 2 shows a semi-finished package for mounting the package of Figure 1 in an explored view.

[046] Figure 3 shows an empty space of the box and the semi-finished packaging of Figure 2 for assembly of the packaging of Figure 1.

[047] Figure 4 shows side panels of the empty space of the box in Figure 3 folded towards the thermoformed reservoir; and

[048] Figure 5 presents a schematic flowchart of the production of the packaging in Figure 1.

DESCRIPTION OF ILLUSTRATIVE ACHIEVEMENTS

[049] Figure 1 shows, in perspective view, a package 1 manufactured in accordance with the present invention. Package 1 is in its complete state and includes a reservoir 2, encased in a sleeve 4, and a lid assembly 3.

[050] Figure 2 shows a partially explored view of the reservoir 2 and the lid assembly 3, further showing a membrane 6, a lower ring 8, an upper ring 10 and a lid 12 forming a first assembly part 1' of the package 1 Reservoir 2 is thermoformed from a laminate of relatively thin inner and outer layers of polypropylene material and an intermediate EVOH barrier layer. It includes a base 14 and a peripheral wall 16 defining a product containment space 20, i.e. the reservoir 2 is filled with a powdered nutritional product 21 before the membrane 6 is connected over the open mouth 15 of the reservoir. Peripheral wall 16 extends to an upper edge 18 having an outwardly directed flange 19.

[051] The lower ring 8 is formed as a flat annular ring of a similar dimension to the outwardly directed flange 19. The lower ring 8 is injection molded from polypropylene, although it will be understood that other suitable materials may also be employed. Top rim 10 and cap 12 form cap assembly 3 and are also formed from injection molded polypropylene. Top hoop 10 is designed to mechanically mate to bottom hoop 8 in an interference fit, including snap connectors not shown. Seal 6 includes a serrated line 22 defining an opening region 24 and includes a pull tab 26.

[052] The production line 40 of package 1, of which a flowchart is shown in Figure 5, is divided into several zones, defined as a first low care zone 41, a high care zone 42, a second care zone low 43 and a third low caution zone 44. Reservoir 2, lower rim 8, lid assembly 3 and membrane 6 are all released via the first low caution zone 41 to high caution zone 42. It is noted that reservoirs 2 are preformed thermoformed reservoirs of stabilized size that have been formed at least 48 hours previously. In the high care zone 42, after the initial cleaning and washing operations have been carried out, the reservoir 2 is filled with milk powder 21. Subsequently, the membrane 6 is applied to close the product containment space 20 and hermetically seal the milk powder inside the reservoir 2. Thereafter, the lower rim 8 is applied over the membrane 6 to the outwardly directed flange 19 on the upper edge 18 of the peripheral wall 16 and subsequently welded into position.

[053] Thereafter, the cap assembly 3 is applied to the lower rim 8 and locked in position. At this point, all components that come into contact with the milk powder 21 are wrapped inside a semi-finished package 1', shown in Figure 2. This can now proceed from the high care zone 42 to the second zone of low care 43. It will be understood that only processes relevant to the present invention have been described at this point and that many other additional operations may take place within the high care zone 42, including cleaning, inspection, testing and the like.

[054] Within the second low care zone 43, the sleeve 4 will be formed around the semi-finished package 1' to form a final package 1, as will be described in further detail below. The final package 1 is passed to the third low care zone 44 for later shipment.

[055] Figure 3 shows a perspective view of a void 28 used to form the sleeve 4 and the filled and deer reservoir 2 centered on a lower panel (not shown) of the void 28. The void space material can be high quality board, coated with polyethylene (PE) of 300 g/cm2. The void 28 defines a number of side panels 30 and the bottom panel (not shown) the corner section 32 and connecting tabs 34.

[056] Figure 4 shows a perspective view of the assembly of package 1, first, when folding the 30" side panels toward the 16" side walls of the reservoir 2. Before folding the 30" side panels, a layer of adhesive , or glue, is provided in an adhesive area 31. After connecting the side panels 30" to the side walls 16" by adhesive, the connecting tabs 34 are folded towards the side walls 16' and connected to the side walls 16' by collage.

[057] Second, the side panels 30' are provided with a layer of adhesive, or glue, provided in an adhesive area 33. Side panels 30' are then folded towards the side walls 16' of the reservoir 2 and connected to both connecting tabs 34 and reservoir 2 by gluing. Upon folding the side panels 30, the corner sections 32 fold around the rounded corners of the reservoir 2. The void 28 is now formed in a sleeve 4 that surrounds the reservoir 2 by covering the side walls 16 and the base 14 and which supports the relatively thin walls of reservoir 2. The adhesive is a hot melt adhesive, available as TECHNOMELTTM SUPRA 325 HT from Henkel AG and having an application temperature between 160°C and 190°C. It will be understood that although it is indicated that the adhesive is applied to the designated adhesive areas 31, 33, it can be applied in any desired location using a suitable robotic glue driver and it can even be applied to the walls of the reservoir itself.

[058] Thus, the invention has been described by reference to certain embodiments discussed above. It will be recognized that many modifications, in addition to those described above, can be made to the structures and techniques described herein, without departing from the spirit and scope of the invention. Likewise, although specific embodiments have been described, they are only examples and are not limiting of the scope of the invention. PARTS LIST 1. Final packaging 1’. Semi-finished package 2. Reservoir 3. Cover assembly 4. Sleeve 6. Membrane 8. Lower rim 10. Top rim 12. Cover 14. Base 15. Open mouth 16. Peripheral wall 18. Upper rim 19. Flange 20. Space of product containment 21. Powder product 22. Serrated line 24. Opening region 26. Pull tab 28. Empty space 30. Side panel 31. Adhesive area 32. Corner section 33. Adhesive area 34. Connecting tabs 40 Production Line 41. First Low Caution Zone 42. High Caution Zone 43. Second Low Caution Zone 44. Third Low Caution Zone

Claims (15)

1. METHOD OF MANUFACTURING AND FILLING A PACKAGE (1) WITH A POWDERED NUTRITIONAL PRODUCT, characterized in that it comprises: a) provision of a thermoformed reservoir (2) having side walls (16) and a base (14) that defines a space product receiving (20), filling the product receiving space with the powdered nutritional product and sealing a membrane (6) by an open mouth of the reservoir to seal the product therein; b) folding a box void (28) with a plurality of panels around the filled reservoir to form a box sleeve (4), wherein the box void comprises a bottom panel and side wall panels (30 ) and wherein, after folding the empty space of the box into a sleeve, the box sleeve comprises a peripheral wall surrounding the side walls and at least a part of the base of the reservoir. 2. METHOD, according to claim 1, characterized in that step b) further comprises one or more of: - gluing the panels to the reservoir; - connecting the panels to each other; - bonding the lower panel to the base of the reservoir; - applying a lateral displacement to the panels to place them in engagement with the side walls of the reservoir after folding towards the side walls of the reservoir; - - provision of the box empty space of a box empty space compartment that holds multiple box empty spaces; and - centralization of the empty space of the box and the thermoformed reservoir in relation to each other. 3. METHOD, according to any one of claims 1 or 2, characterized in that step a) further comprises the adjustment of a lower rim (8) to an upper edge (18) of the reservoir. 4. METHOD, according to any one of claims 1 to 3, characterized in that step a) further comprises the adjustment of a cover assembly (3) to the reservoir, the cover assembly comprising an upper rim (10) and a cover opens and closes (12). 5. METHOD, according to any one of claims 3 or 4, characterized in that the upper rim and the lower rim are mechanically connected together in an interference fit. 6. METHOD, according to any one of claims 1 to 5, characterized in that step a) occurs in a high-care zone defined by a supra-atmospheric pressure and a filtered atmosphere, and step b) occurs outside the high-care zone . 7. METHOD, according to any one of claims 1 to 6, characterized in that the product reception space is filled with powdered nutritional product in a low oxygen atmosphere, preferably in a carbon dioxide atmosphere. 8. METHOD, according to any one of claims 1 to 7, characterized in that the reservoir has a wall thickness between 0.10 mm and 0.50 mm, preferably between 0.15 mm and 0.40 mm. 9. METHOD according to any one of claims 1 to 8, characterized in that the empty space of the box has a weight between 50 g/m2 and 400 g/m2, preferably from 100 g/m2 to 300 g/m2. 10. METHOD, according to any one of claims 1 to 9, characterized in that the reservoir and the sleeve have conical side walls, with a taper between 1° and 7°, preferably about 3°. A METHOD according to any one of claims 1 to 10, characterized in that the membrane comprises a weakened serrated line (22) defining an opening region and a pull tab (26). 12. PACKAGING FOR A POWDERED NUTRITIONAL PRODUCT, manufactured according to the method, as defined in any one of claims 1 to 11, characterized in that it comprises: a thermoformed reservoir having side walls and a base that defines a single product reception space filled with the powdered nutritional product and a membrane sealed by the mouth of the reservoir; and a box sleeve comprising a peripheral wall snugly surrounding the side walls and at least a portion of the base of the reservoir, the box sleeve comprising a box void having a bottom panel and side wall panels folded over onto the bottom panel and glued to each other and/or to the reservoir. 13. PACKAGING, according to claim 12, characterized in that the powdered nutritional product comprises a powdered milk formula for babies. PACKAGING, according to any one of claims 12 or 13, characterized in that the reservoir is, in general, rectangular and has a capacity between 800 and 3000 ml. 15. PACKAGING according to any one of claims 12 to 14, characterized in that it further comprises a lid assembly fitted to the reservoir, the lid assembly comprising an upper rim and an open and close lid.

Images