GB2532061A

GB2532061A - Packaging system and method

Info

Publication number: GB2532061A
Application number: GB1419862.6A
Authority: GB
Inventors: Roger Payne Derek
Original assignee: Dubble Bubble Ltd
Current assignee: Dubble Bubble Ltd
Priority date: 2014-11-07
Filing date: 2014-11-07
Publication date: 2016-05-11
Also published as: GB201419862D0

Abstract

A pouch for containing liquid or solid contents (1) incorporates a surface or edge (3) so shaped as to form a pouring spout (6) and the corresponding portion of the pouch opposed thereto constitutes an external flap (4) of a shape corresponding to the spout (3). A second external flap (2) is located along the top of the pouch. The flaps (2, 4) are formed as wide seals. They provide a handling surface and also reduce the conduction of heat from hot products (1) contained within the pouch, thereby making it easier and safer to handle.

Description

PACKAGING SYSTEM AND METHOD

Field of the Invention

This invention concerns a flexible packaging concept that may be used for packing solid or liquid products and may be manufactured on automated packaging machinery.

Background of the Invention

Packaging of products serves several functions, including protecting the contents from contamination or deterioration, minimising mechanical damage during handling or transport and for heating to a temperature within the package.

Packages that are primarily designed for microwaveable products such as foodstuffs, are typically either packed inside a semi-rigid tray with a sealed lid, or contained within a pouch, with both being heated to high temperatures to both cook its contents and destroy any adverse microbial activity within the product. Products then being removed from microwave heating are therefore typically very hot and potentially dangerous to handle. In the case of heated products contained within semi-rigid trays such as many convenience foods, the thin tray lid (typically polyethylene terephthalate), which has been previously punctured to allow expanding hot gases to escape, has then to be cut away in order to dispense the steaming contents; again an area for potential danger, particularly for older people or those with less dexterity in their hands. Such semi-rigid tray and lid systems also use heavyweight materials that have an environmental impact in both their manufacture and disposal.

Summary of the Invention

Primarily, this invention is directed towards a pouch for containing liquid or solid contents which can be heated by microwaves (hereinafter referred to as a "microwaveable pouch") but the invention is not so limited. The invention has two key features that combine to produce a package that has clear safety benefits with the reduction of burns sustained through contact with hot products, or accidents -2 -occurring through the handling or dropping heated packages. The invention also has clearly demonstrated environmental benefits in using lower weight materials and therefore using less of the planet's resources in manufacture. Also the invention gives the benefit of increased customer convenience in the easy and safe dispensing of heated products.

In accordance with a first aspect of the invention, we provide a pouch for containing liquid or solid contents including at least one external flap which, in use, provides a handling surface. Preferably, the pouch is microwaveable.

We also provide a method of forming a pouch including: folding or shaping at least one sheet or film to form a pouch which, in use, contains a liquid or solid item; and sealing adjacent or opposed areas of the sheet or film to each other, wherein at least one seal constitutes an external flap which, in use, provides a handling surface.

We further provide a system for forming pouches on a continuous basis including:(a) wrapping a web around a former and forming a back seal from overlapping or opposing edges of the web; (b) forming a series of transverse seals so as to define a pouch between each pair of transverse seals, which pouch, in use, contains a liquid or solid item; and (c) parting individual pouches from the web by cutting or otherwise severing along each transverse seal, wherein the transverse seals constitute a wide flap external of the resultant pouch.

The pouches are normally formed by at least one plastics film or sheet.

In accordance with an aspect of the invention there is provided a package with an extended seal which forms the top of the finished pouch, that is, above the eventual contents, and creates a wide flap, normally of sealed plastic. This wide seal area may be of low thermal conductivity to reduce the conduction of heat from hot products contained within the package, therefore making it safer to handle.

In another aspect, a cross seal area is created with a particular shape, particularly curved, that fulfils two functions within the invention. The end seal shape and how it is cut via the cross seal knife firstly create an openable outlet from the pack, preferably shaped as a -3 -pouring spout, for the easy and safe dispensing of the pack's contents and, secondly, create a wide seal area at the back of the finished pouch, corresponding in shape to the outlet, that is designed to reduce the conductivity of heat from hot products contained within the package, thereby making it safer to handle. The outlet may be opened by cutting part of the pouch or the shaped portion may be provided with a tear-off strip.

In another aspect, the area created to provide an outlet also creates a convenient and safe area that can be removed prior to cooking to allow the safe venting of hot gases from the pack while it is reaching the high temperatures required to both cook and destroy any adverse microbial activity within the product.

Although the invention has been described with reference to microwaveable packs, the above configuration of a pouring spout with a correspondingly shaped flap on the opposed edge of the pouch is also applicable to the dispensing of unheated products, particularly liquids or pastes.

Optionally, the pouch may include a second external flap, preferably positioned above the contents of the pouch, serving as a further handling surface, as illustrated, for example, in Fig 12. Where two flaps are provided, they are normally located on different external surfaces of the pouch.

Embodiments of the invention can thus be seen to provide a pack that protects the product, while reducing the need for heavyweight packaging materials. The pack can be produced on a range of packaging machinery or from pre-made pouches.

Some embodiments of the invention may enable continuous assembly of packages by modifying existing machines.

The term "pouch" as used herein is intended to include any receptacle, cavity or wrapping surrounding and containing a liquid or solid item.

In order to incorporate the invention into quad packs, a pouch may be formed from a flat sheet that is drawn from a reel and made into a tubular sleeve by means of a hermetic back seal. Where the folded material meets, the sealing station on the machine is moved to the side of the pack where a wide seal is made to create what becomes the top of the final pouch, forming an area for easy handling of the -4 -pack. At the same time as this seal is made, three additional longitudinal welded pinches are made forming cusps seals to the other three corners of the package.

In another aspect of this embodiment, a cross seal area is created with a particular shape that fulfils two functions within the invention, as described above. The end seal shape and how it is cut via the cross seal knife firstly create a pouring spout for the easy and safe dispensing of the pack's contents and secondly create a wide seal area at the back of the finished pouch, corresponding in shape to the pouring spout, that is designed to reduce the conductivity of heat from hot products contained within the package, thereby creating a second area for the package to be picked up. The finished package therefore has two areas of the package with wide seals from which to both pick up and handle the heated package, making it a safer pack to handle.

As above, the area created to provide a pouring spout also creates a convenient and safe area that can be removed prior to cooking to allow the safe venting of hot gases from the pack while it is reaching the high temperatures required to both cook and destroy any adverse microbial activity within the product.

Our British patent GB 2475770 B and equivalents elsewhere describe and claim a package for an article comprising a pressurised outer bag having gas tight seals at opposite ends and an inner pouch for supporting the article within the outer bag, wherein the pouch extends along the length of the outer bag and is secured to the outer bag only at the gas tight seals, and wherein the pouch is maintained under sufficient tension by the pressure within the outer bag to suspend the article within the bag and to maintain a space between the article and the outer bag on all sides of the article; characterised in that back seals closing the inner pouch and the outer bag respectively are laterally offset from one another. Thus, the packaged product is held in suspension within a sealed inflated bag and in this way is protected against mechanical impact. A further advantage is that the pouch and the outer bag may be gas-flushed with an inert gas or combination of gases, such as N-or CO, to prolong the shelf life of certain products such as foodstuffs. -5 -

When this invention is incorporated into the packages of GB 2475770 B, the outer bag may be formed from a flat sheet that is drawn from a reel and made into a tubular sleeve by means of a hermetic back seal. Where the folded material meets, the sealing station on the machine is moved to the side of the pack where a wide seal is made to create what becomes the top of the final package, forming an area for easy handling of the pack. At the same time as this seal is made, three additional longitudinal welded pinches are made forming cusps seals to the other three corners of the package.

In another aspect of this embodiment, a cross seal area is created with a particular shape that fulfils two functions within the invention, as described above. The end seal shape and how it is cut via the cross seal knife, firstly create a pouring spout for the easy and safe dispensing of the packs contents and secondly create a wide seal area at the back of the finished pouch, corresponding in shape to the pouring spout, that is designed to reduce the conductivity of heat from hot products contained within the package, thereby creating a second area for the package to be picked up. The finished package therefore has two areas of the package with wide seals from which to both pick up and handle the heated package, making it a safer pack to handle.

In order to incorporate the invention into stand-up pouches, a pouch may be formed from a flat sheet of material that is drawn from a reel and folded in half. Where the folded material meets, the sealing station on the machine creates a wide seal that eventually becomes the top of the final pouch. The additionally wide seal forms an area for easy and safe handling of the pack. A second web of material is folded in half and positioned to form the eventual bottom of the pouch. The two materials are then joined together by means of a hermetic seal that is shaped to create the pack base and allow the package to stand on its end. -6 -

In another aspect of this embodiment, a cross seal area is created with a particular shape that fulfils two functions within the invention. The end seal shape and how it is cut via the cross seal knife, firstly create a pouring spout for the easy and safe dispensing of the pack's contents and secondly creates a wide seal area at the back of the finished pouch, corresponding in shape to the pouring spout, that is designed to reduce the conductivity of heat from hot products contained within the package, thereby creating a second area for the package to be picked up. The finished package therefore has two areas of the package with wide seals from which to both pick up and handle the heated package, making it a safer pack to handle.

Brief Description of the Drawings

The invention will now be described further, by way of example, with reference to the accompanying drawings.

(Note, references to side seals and end seals relate to seal positioning from a production perspective and not as the finished package stands or is viewed): Fig 1 is a drawing of the finished package viewed from the front for the quad pack production method.

Fig 2 shows the same package viewed from the side of the pack to highlight the feature of an extended offset side seal.

Fig 3 is a drawing viewed from the front of a finished package incorporating the suspended inner pouch of GB2475770.

Fig 4 shows the same package viewed from the side of the pack to highlight the feature of an extended offset side seal.

Fig 5 is a drawing of a stand-up-pouch type pack viewed from the front. -7 -

Fig 6 shows the same package viewed from the side of the pack to highlight the feature of an extended side seal.

Fig 7 is a schematic of a vertical form fill and seal machine showing the positioning of the extended offset side seal and end seal jaws, with finished packages coming from the machine.

Fig 8 shows the principle of a vertical form fill and seal machine that would be used to manufacture packages incorporating the suspended inner pouch of GB2475770. The drawing shows how the inner pouch is formed prior to the outer bag and the positioning of the extended offset side seal and end seal jaws, with finished packages coming from the machine.

Fig 9 is a schematic of one section of the cross seal jaws (see Fig 10), showing the shaped heating profile and knife that produces the shaped end seal.

Fig 10 shows a cross sectional view of the end seal sealing jaws at one point of its profile.

Fig 11 shows a helicopter view of a forming Lube where Lhe material from the reel is formed around the tube to form one wide cusped seal and three narrower seals.

Fig 12 illustrates how the wide flaps of material at the top and back of the package can be safely held away from hot contents, with the pack tilted to dispense its contents through the pouring spout created by the pack profile.

Detailed Description of the Preferred Embodiments

In Fig 1, the product to be packaged is shown as 1. A pouch is formed by wrapping a web of material around the product 1, and forming longitudinal cusped seals in three corners shown at 5. Where the web of material folds around to meet itself, an extended seal 2 is formed where the edges of the web meet. This formed a deliberately extended cusped seal as an area for handling the package when lifting it in and out of the microwave. A shaped end seal 3 is produced with a specific contour to allow for easy removal (just prior to heating) of the section shown as 6. The area marked 6 forms a pouring spout for the easy and safe dispensing of the heated contents. A contoured end seal shown as 4 is also formed, and deliberately extended to give a wider area of -8 -sealed plastic for safe and cool handling and dispensing of hot products 1.

In Fig 2, the package is shown from another angle, where 1 is the product and 2 shows the extended cusped seal that allows for easier handling of a heated package. 4 shows the profile of the end seal viewed from from the back of the package and 5 are the three cusped longitudinal seals.

In Fig 3, an alternative embodiment of the invention is shown, where an inner pouch 7 is formed by wrapping an inner web around the product 1, and creating a back seal 8. An outer material 7A (Fig 4) is wrapped around the inner pouch 7 with an overpressure being trapped inside the pack by virtue of the outer bag back seal 2 and end seals 3 and 4 hermetically sealing the outer material together. The outer bag end seals 3 and 4 seals the outer material to the inner pouch 7, thus allowing the product 1 to be held in suspension within a cushion of air or mixed gases. The end seal 3 is produced with a specific contour to allow for easy removal (just prior to heating) of the section shown as 6.

The area marked 6 forms a pouring spout for the easy and safe dispensing of the heated contents.

In Fig 4, the package is shown from another angle, where 1 is the product and 2 shows the extended cusped seal that allows for easier handling of a heated package. 4 shows the profile of the end seal from the back of the package and 5 are the three cusped longitudinal seals. 7 shows the inner pouch encapsulated within the outer bag and suspended from the end seals but otherwise free of contact with the outer package 7A by virtue of an overpressure being trapped inside the pack.

In Fig 5, an alternative embodiment of the invention is shown, where a stand-up-pouch is formed but specifically modified in accordance with invention. 1 is the product. A shaped end seal 3 is produced with a specific contour to allow for easy removal (just prior to heating), of the section shown as 6. A contoured end seal shown as 4 is also formed, and deliberately extended to give a wider area of sealed plastic for safe and cool handling and dispensing of hot products 1. A web of material 10 is sealed into the package thus allowing the package to stand supported by a bottom gusset (not shown) sealed in the area 10. The area marked 6 forms a pouring spout for the easy and safe dispensing of the heated contents. -9 -

In Fig 6, the package is shown from another angle with the productshown as 1 and a single extended end seal that forms an area of sealed plastic that will reduce the conductivity of heat from a hot product shown as 2A. 4 shows the profile of the end seal seen from the back of the package and 10 is the web of material sealed into the package to form a bottom gusset.

In Fig 7, 1 is the product being dropped vertically. 11 shows a reel of material to form the package being formed around a forming collar 12. The material is then pulled or driven downwards by conventional methods, such as a moving belt (not shown) or reciprocating jaws 15. Three cusped longitudinal (back) seals are formed at 13 and an extended cusped back seal is formed where the two edges of the material meet at 14, where the web of material is formed around the forming tube 21. End (transverse) seals are applied at 15 and each package is parted from the web by cutting or otherwise severing along the end seal in conventional manner. 16 shows an impression of the contour seal and knife shown in more detail in Fig 9. 17 shows the final cut packages leaving the machine.

In Fig 8, 1 is the product being dropped vertically. 11 shows a reel of material to form the inner pouch being formed around a forming collar 12. The material is formed around a forming tube 21 and a back-seal is applied at 18, sealing the material together to form a tube. A wider reel of material that forms the outer bag is shown as 11A. This is pulled around a second forming collar shown as 12A and down a forming tube 22. Three cusped longitudinal (back) seals are formed at 13 and an extended cusped (back) seal is formed where the two edges of the material meet at 14, where the web of material is formed around the forming tube 22. End (transverse) seals are applied at 15 and each package is parted from the web by cutting or otherwise severing along the end seal in conventional manner. 16 shows an impression of the contour seal and knife shown in more detail in Fig 9. 17 shows the final cut packages leaving the machine.

Fig 9 shows the inner view of the male section of sealing jaws 15. (A profile of both sections is shown in Fig 10).

In Fig 9, 18 shows the raised heated area that forms the shaped end seal shown as 4 on the finished package. 19 is the raised heated area that forms the shaped end seal shown as 3 on the finished package. 20 shows the contour knife -10 - (retracted), that is used to cut the forms into individual packages.

In Fig 10, the side profile of the end sealing jaws is shown, where 18 is the heated sealing area that forms area 4 on the package and 19 is the heated sealing area that makes the seal area 3. The contour knife is shown at 20, where it is shown in the cutting position to produce the individual packages.

Fig 11 shows a cross section of the machine forming tube viewed from above the machine, with the material from the reel of material (11 or 11A, not shown) wrapped around the tube (which may be rectangular or circular) and brought together at 2 to form a wide seal. The two edges of material are welded together by heated jaws 14. Three further cusped longitudinal seals are made at 5, the folded material being welded to the cusps seals by heated jaws shown at 13.

Fig 12 demonstrates how the back seal 2 and the end seal 4, form convenient and low temperature flaps of material by which to safely remove the package from the microwave and dispense its contents 1, through the pouring vent shown at 6.

Claims

CLAIMS1. A pouch for containing liquid or solid contents including at least one external flap which, in use, provides a handling 5 surface.
2. A pouch as claimed in Claim 1 including two external flaps providing handling surfaces.
3. A pouch as claimed in Claim 2 wherein the two flaps are located on different external surfaces of the pouch.
4. A pouch as claimed in any one of the preceding claims formed by at least one plastics film or sheet.
5. A pouch as claimed in Claim 4 wherein the or each flap is formed as a wide seal.
6. A microwaveable pouch as claimed in any one of the 20 preceding claims, wherein the or each flap is of low thermal conductivity.
7. A pouch as claimed in any one of the preceding claims wherein one surface or edge is so shaped as to form an 25 openable outlet from the pouch and the corresponding portion of the pouch opposed thereto constitutes an external flap.
8. A pouch as claimed in Claim 7 wherein the outlet is so shaped as to form a spout.
9. A pouch as claimed in Claim 8 wherein the spout is formed by means of a curved seal and the external flap is a corresponding shape thereto.
10. A pouch as claimed in any one of Claims 7 to 9 wherein the outlet is closed by a tear-off strip.
11. A pouch as claimed in any one of Claims 7 to 10 wherein, in use, a second external flap is positioned above the 40 contents of the pouch.
12. A pouch as claimed in any one of Claims 7 to 11 wherein, in use, the outlet forms a vent during heating of the contents of the pouch.

-12 -
13. A pack for containing liquid or solid contents comprising an inner pouch suspended within an outer pouch, which outer pouch is as claimed in any one of the preceding claims.
14. A method of forming a pouch including: * folding or shaping at least one sheet or film to form a pouch which, in use, contains a liquid or solid item; and * sealing adjacent or opposed areas of the sheet or film to each other, wherein at least one seal constitutes an external flap which, in use, provides a handling surface.
15. A method as claimed in Claim 14 wherein two seals 15 constitute two external flaps.
16. A method as claimed in Claim 15 wherein the two flaps are located on different external surfaces of the pouch.
17. A method as claimed in any one of Claims 14 to 16 wherein the sheet or film is a plastics material.
18. A method as claimed in any one of Claims 14 to 17 wherein the or each flap is formed as a wide seal.
19. A method as claimed in any one of Claims 14 to 18 wherein the or each flap is formed by heat sealing, with or without the application of pressure.
20. A method as claimed in any one of Claims 14 to 19 wherein the resultant pouch is microwaveable and, in use, the or each flap provides a low-temperature handling surface.
21. A method as claimed in any one of Claims 14 to 20 wherein one surface or edge of the resulting pouch is so shaped as to form an openable outlet from the pouch and the corresponding portion of the pouch opposed thereto constitutes an external flap.
22. A method as claimed in Claim 21 wherein the outlet is so shaped as to form a spout.
23. A method as claimed in Claim 22 wherein the spout is formed by means of a curved seal and the external flap is a 45 corresponding shape thereto.-13 -to 23 wherein to 24 wherein, in use, a second external flap is positioned above the contents of the pouch.26. A method as claimed in any one of Claims 21 to 25 10 wherein, in use, the outlet forms a vent during heating of the contents of the pouch.27. A system for forming pouches on a continuous basis including: (a) wrapping a web around a former and forming a back seal from overlapping or opposing edges of the web; (b) forming a series of transverse seals so as to define a pouch between each pair of transverse seals, which pouch, in use, contains a liquid or solid item; and (c) parting individual pouches from the web by cutting or otherwise severing along each transverse seal, wherein the transverse seals constitute a wide flap external of the resultant pouch.28. A system as claimed in Claim 27 wherein the transverse seal is so shaped as to form a spout through which the contents of the pouch may be discharged and the corresponding seal on the opposed edge of the resultant pouch constitutes the wide flap external of the pouch.29. A system as claimed in Claims 27 or 28 wherein a back seal constitutes a second wide flap.30. A system as claimed in Claim 29 wherein, in use, such 35 second flap is positioned above the contents of the pouch.31. A system as claimed in any one of Claims 27 to 30 wherein Lhe resultant pouches are microwaveable and Lhe or each flap is of low thermal conductivity.32. A pouch substantially as described and with reference to the accompanying drawings.33. A method of forming a pouch substantially as described 45 and with reference to the accompanying drawings.
24. A method as claimed in any one of Claims 21 the outlet is closed by a tear-off strip.
25. A method as claimed in any one of Claims 21 -14 - 34. A system for forming pouches on a continuous basis substantially as described and with reference to the accompanying drawings.