GB2573779A

GB2573779A - Multi-pack and method of making a multi-pack

Info

Publication number: GB2573779A
Application number: GB1807964.0A
Authority: GB
Inventors: Mann David; Wright Lee
Original assignee: Intersnack Group & Co KG GmbH
Current assignee: Intersnack Group & Co KG GmbH
Priority date: 2018-05-16
Filing date: 2018-05-16
Publication date: 2019-11-20
Also published as: GB201807964D0

Abstract

A multi-pack 1 comprising a plurality of primary packets 2, containing food, folded within a flexible secondary packet 3 that is sealed or partially sealed at opposite ends 7. A further seal 6 extends between the end seals 7, which may be on the rear face of the secondary packet 3. The primary packets 2 have a main face 5 perpendicular to a front face 9 of the secondary packet 3. An edge of the primary packet 2 may be parallel or perpendicular to the front face of the secondary packet 3 and the rows may be interleaved (figures 1 and 2). The primary packets 2 may be bags and/or may comprise flexible material. The seals may be heat seals. A method of manufacturing the multi-pack 1 comprises flow wrapping the rows of primary packets 2 inside secondary packet 3 using a flow wrapper, which may comprise one or more conveyors that may be inclined at an angle of 20 to 45º and may run at different speeds. Robot arms may control the orientation of the primary packs 2.

Description

MULTI-PACK AND METHOD OF MAKING A MULTI-PACK

Field of the invention

The present invention relates to a multi-pack, in which a plurality of primary packets containing food are packed inside a secondary packet. The present invention also relates to a method of making a multi-pack.

Background of the invention

Processed food, especially sweets, snacks, ready meals or bread is sold in packages. These packages are usually made from paper, cardboard or plastic. Some of the most common types of packaging include blister packs, clamshell packaging, shrink-wrapping, flow wrapping and paperboard packaging. The primary function of the packaging is to preserve and protect the quality of the food. To ensure a safe and hygienic delivery to the customer the food is typically packaged directly after it is produced in the factory. Usually the packaging is part of the production process in the factory.

It is common to package food in bite size or small food portions. For logistic reasons typically several primary packets are included in a secondary packet. The secondary packet makes it possible to safely transport and store larger quantities of the primary packets. This type of packaging is particularly common for snack foods, for example crisps (alternatively referred to as chips in the US and some other countries ) .

If a secondary packet is used, separate packaging steps are necessary. A first step is to pack the food into the primary packets and a second step is to pack the primary packets in a secondary packet.

A package comprising a secondary packaging and a plurality of snack food packs is disclosed in EP 2 704 963 Bl.

The secondary packaging comprises a folded layer of paper with a mechanical seal. The secondary packaging has a pillow like shape which surrounds several primary packs that have no specific place within the secondary pack but can move easily within the packaging.

GB 2 454 748 A describes a method for packaging snack food products such as potato crisps. The snack food products are delivered into single primary bags, a plurality of the filled primary bags are packed in a vertical form fill and seal unit to form a multipack bag containing a plurality of the primary bags. The secondary packaging can be a box such as a cardboard box.

A typical known method of making a multi-pack in which a plurality of primary packets containing food are packed inside a secondary packet includes making and filling both the primary packets and the secondary packet using vertical form filling .

Firstly, a flexible material is folded into a tube and a longitudinal seal is provided along a length direction of the tube to close the tube. Then, a lateral seal is provided to form an open pouch above the lateral seal. Food, for example snack food such as crisps, is then dropped vertically into the open pouch. Then, a further lateral seal is provided vertically above the food to close the open pouch to form the primary packet. The seals are typically crimp seals formed by applying heat and pressure to the folded flexible material. The primary packet typically has a pillow-shape. The seals are typically air-tight seals to prevent the food contained in the primary packets from being exposed to the surrounding air.

Similarly, to form the secondary packet a flexible material is folded into a tube and a longitudinal seal is provided along a length direction of the tube to close the tube. Then, a lateral seal is provided to form an open pouch above the lateral seal. The primary packets are then dropped vertically into the open pouch. Then, a further lateral seal is provided vertically above the primary packets to close the open pouch to form the secondary packet. Again, the seals are typically crimp seals formed by applying heat and pressure to the folded flexible material. The secondary packet typically has a pillow shape. In the secondary packet, the end seals may be air tight seals. However, it is preferable to allow air to escape from the secondary packet once the secondary packet has been produced, to minimise a size of the secondary packet, for example when packing multiple secondary packets in a case. Therefore, the end seals may instead be partial seals, which either do not extend all the way along the ends of the secondary packet, or which comprise lengths where a seal is formed interspersed with lengths where there is no seal. This allows air to escape from the secondary packet after it has been formed, for example when packing multiple secondary packets in a case.

Since the primary packets are merely dropped vertically into the open pouch when filling the secondary packet, the primary packets are not arranged in the secondary packet in any specific predefined arrangement. Instead, the primary packets may be randomly or irregularly located inside the secondary packet.

Summary of the invention

It is desirable to reduce an amount of packaging used in multi-packs. In particular, reducing an amount of packaging can reduce negative environmental impacts relating to the production and disposal of the packaging, and can also reduce a cost of producing the packaging. Furthermore, reducing an amount of packaging can reduce an overall size of the multipack, making the multi-pack easier and cheaper to transport and store.

The present invention therefore aims to provide a multipack in which an amount of packaging is reduced relative to the typical known method of making a multi-pack discussed above .

Other advantages of the present invention are discussed below.

The present inventors have realised that a reduction in packaging can be achieved by using flow wrapping to provide the secondary packet in which the primary packets are packed, instead of vertical form filling.

Furthermore, the present inventors have realised that an advantageous configuration (i.e. shape) of the multi-pack can be provided by arranging the primary packets in a specific arrangement inside the secondary packet.

At its most general, therefore, the present invention relates to a multi-pack in which a plurality of primary packets containing food are flow wrapped inside a secondary packet. The primary packets are flow wrapped inside the secondary packet with the primary packets stacked in one or more rows and with primary planes of the primary packets being substantially perpendicular to a primary plane of the secondary packet.

Flow wrapping the primary packets with the primary packets stacked in one or more rows significantly reduces an amount of packaging material used, relative to using vertical form filling to produce an eguivalent multi-pack. In addition, it also minimises a size of the multi-pack, providing a multi-pack that is smaller than a multi-pack formed by vertical form filling that contains the same number of primary packets .

Furthermore, the specific arrangement of the primary packets, with the primary planes of the primary packets being substantially perpendicular to a primary plane of the secondary packet, can provide a more stable multi-pack while also maximising a size of a main face of the secondary packet. This is particularly, but not exclusively, the case when dealing with larger numbers of primary packets in the, or each of the, one or more rows of primary packets.

Since the main face of the secondary packet is typically used to identify the product and/or to provide information about the product, it is advantageous for the size of the main face to be maximised.

Flow wrapping is a known process in which articles being wrapped (in the present case the arranged primary packets) are wrapped in a flexible material such as a plastic sheet to form a flexible packaging containing the articles. Typically, both the articles being wrapped and the flexible material are moved horizontally along a flow wrapping machine that wraps the flexible material around the article in the horizontal direction. A first seal is provided along the wrapped flexible material to form a tube of flexible material around the articles. Then, end seals are provided at opposite ends of the tube of flexible material to seal the articles being wrapped in the flexible material. Thus, the articles being wrapped are sealed in a pack of the flexible material. Typically the articles are tightly wrapped in the flexible material with a minimum of wasted material, such that the articles are substantially restricted from moving within the flexible material.

Advantages of flow wrapping over vertical form filling include that an orientation of the article being wrapped can be better controlled, an amount of packaging can be reduced, and an overall size of the packaged product can be reduced. In particular, forming the secondary packet by tightly wrapping a flexible material around an ordered arrangement of the primary packets can minimise an amount of material needed to form the secondary packet, and can minimise a size of the secondary packet.

According to a first aspect of the present invention there is provided a multi-pack comprising:

a plurality of primary packets, each of which contains food; and a secondary packet, wherein the primary packets are packed inside the secondary packet;

wherein:

the secondary packet comprises flexible material folded about the primary packets and sealed or partially sealed by at least end seals or partial end seals at opposite ends of the secondary packet and a further seal or partial seal that extends along the secondary packet between the end seals or partial end seals; and the primary packets are packed inside the secondary packet in one or more rows, wherein each of the primary packets is arranged with a main face of the primary packet substantially perpendicular to a front face of the secondary packet, the front face of the secondary packet being a face that extends along a same direction as the end seals or partial end seals of the secondary packet.

The first aspect of the present invention may have any one, or, to the extent that they are combinable, any combination of the following optional features.

Typically the further seal or partial seal is formed before the end seals or partial end seals.

The end seals and/or the further seal may be continuous seals and/or substantially air-tight seals.

However, one, more than one, or all of these seals may be partial seals that are not air-tight.

A partial seal means a seal that does not fully close the secondary packet, therefore allowing air to escape from the secondary packet. However, the partial seal prevents primary packets from leaving the secondary packet. The partial seal therefore seals the primary packets inside the secondary packet, but allows air to leave the secondary packet.

The term partial seal may be replaced throughout with the term non-airtight seal.

For example, a partial seal may not extend all the way along the gap being sealed, or a partial seal may have one or more gaps where the seal is not formed and there is an opening into the secondary packet from which air can escape. These openings are smaller (significantly smaller) than a size of the primary packets, so that the primary packets are securely contained inside the secondary packet.

A partial seal may comprise areas in which a seal is formed interspersed with areas in which no seal is formed and instead there is an opening into the secondary packet. The areas in which the seal is formed and the areas in which no seal is formed may alternate along a length of the seal.

A partial seal may have a castellated arrangement of sealed areas and non-sealed areas.

One of the end seals may be a partial seal, or both of the end seals may be a partial seal.

Alternatively, all of the end seals and the further seal may be continuous seals, which may be substantially air-tight, and one or more other openings/holes may be provided in a surface of the secondary packet to allow air to escape from the secondary packet. For example, the one or more other openings/holes may be punch holes in a surface of the secondary packet.

More generally, the secondary packet may not be an airtight packet, and instead may have one or more openings from which air can escape from the secondary packet.

Allowing air to escape from the secondary packet helps to minimise the size of the secondary packet, particularly when a plurality of the secondary packets are packed in a box or other container.

However, it is not essential for air to be able to escape from the secondary packet.

The term multi-pack means a combination of a secondary packet and a plurality of primary packets containing food packaged inside the secondary packet.

The term packet may mean a flexible container. For example, the term packet may alternatively be replaced with any of the terms pack, packaging, sachet, bag or container.

The term primary packet means a packet that is in immediate contact with the food, and that contains the food.

The term secondary packet means a packet that is not in immediate contact with the food, and that instead contains the primary packets .

The main face of the primary packet being substantially perpendicular to a front face of the secondary packet means that a normal to the main face of the primary packet is at substantially 90 degrees to a normal to the front face of the secondary packet.

Substantially perpendicular may mean that the main faces of the primary packets are within ±20°, or ±15°, or ±10°, or ±5°, or ±1° of being perpendicular to the front face of the secondary packet.

Equivalently, this may mean that the normal to the main face of the primary packet is within ±20°, or ±15°, or ±10°, or ±5°, or ±1° of being perpendicular to the normal to the front face of the secondary packet.

The main face of the primary packet may alternatively be considered to be a main plane or a primary plane of the primary packet. The term main face may therefore be replaceable with the term main plane or primary plane.

The main face of the primary packet typically has a curved surface that curves outwards around the food contained in the primary packet.

The main face of the primary packet may be a front face of the primary packet. The front face of the primary packet may have printed material thereon.

Typically the primary packet has two equally sized main faces which are opposite to each other. In that case, either of the main faces may be considered to be the front face of the primary packet. However, typically one of the main faces has a seal thereon, and this face is typically considered to be the rear face of the primary packet. The other opposite face is then considered to be the front face of the primary packet.

Typically the primary packet is substantially air-tight, so that the food contained in the primary packet is protected from the atmosphere .

Typically the end seals or partial end seals of the secondary bag are linear and are substantially parallel to each other.

A distance between the two end seals or partial end seals may be considered to be a length of the secondary packet.

A length of the end seals or partial end seals may be considered to be a width of the secondary packet.

In that case, the front face of the secondary packet extends in both the length and width directions of the secondary packet.

Typically the secondary packet has a rear face that is opposite to the front face, and the rear face also extends in both the length and width directions of the secondary packet.

A direction perpendicular to the length and width of the secondary packet may be considered to be a depth of the secondary packet.

The terms length, width and depth will be used accordingly in the following.

The term main face may mean a largest face. Typically the primary packets or secondary packet will have two substantially equally sized largest faces. Therefore the term main face may mean either of the largest faces.

The term main face may be replaced with the term primary face.

The front face of the secondary packet may be a main face of the secondary packet. The term front face in relation to the secondary packet may alternatively be replaced with the term primary plane or main plane.

The front face of the secondary packet may have a curved, bent or folded surface. In particular, the front face of the secondary packet may have a curved, bent or folded surface that curves, bends or is folded around the primary packets contained in the secondary packet.

Typically the secondary packet has two opposite faces that extend along a same direction as the end seals or partial end seals of the secondary packet. In that case, either of the two opposite faces may be considered to be the front face. However, typically the further seal or further partial seal extends along one of the two faces. In that case, the face that includes the further seal or further partial seal is considered to be a back face and the other of the two faces is considered to be the front face.

The term folded may alternatively mean bent or curved.

The term flexible means that the material is capable of being wrapped around the food (for the primary packets) or the primary packets (for the secondary packet).

The term flexible may mean that the material deforms when a pressure is applied to the material.

The seals or partial seals may be formed by applying heat and/or pressure to the flexible material.

Alternatively the seals or partial seals may be formed by applying pressure without applying heat, which may be referred to as cold sealing.

The seals or partial seals may be crimp seals formed by applying heat and pressure to the flexible material, or formed by applying pressure to the flexible material without applying heat.

Typically the further seal or partial seal is substantially perpendicular to the end seals or partial end seals and extends in a substantially straight line along the length of the secondary packet. The further seal or further partial seal may therefore be considered to be a longitudinal seal or longitudinal further seal, and the end seals or partial end seals may therefore be considered to be transverse seals or transverse partial seals.

The primary packets are arranged in a row by adjacent primary packets being stacked substantially one in front of the other in a line with the main faces of the primary packets facing along the line. The primary packets in a row are in contact with each other.

The configuration of the present invention may significantly reduce an amount of material required for the secondary packet relative to using vertical form filling, in which the primary packets do not have a predetermined arrangement inside the secondary packet. For example, reductions in material usage of up to 30% may be achievable, and reductions of the order of 20% have been practically achieved. Such a reduction can provide significant environmental and financial benefits.

Furthermore, reducing a size of the secondary packet means that the overall size of the multi-pack is reduced relative to using vertical form filling. This means that the multi-pack may be easier and/or less expensive to transport and/or store.

The specific arrangement of the primary packets inside the secondary packet in the present invention, wherein each of the primary packets is arranged with a main face of the primary packet substantially perpendicular to a front face of the secondary packet, the front face of the secondary packet being a face that extends along a same direction as the end seals or partial end seals of the secondary packet, can improve the handling and shelving of the multi-pack. In particular, the arrangement of the primary packets preferably means that the multi-pack is shorter in the length direction, narrower in the width direction, and has a depth that is on average deeper and more consistent than an equivalent multi pack formed by vertical form filling. This improves the ease of handling and shelving, and means that the multi-pack can more easily be handled by distributors and consumers.

For example, the multi-pack of the present invention may be more uniform in appearance than a multi-pack made using vertical flow forming, which typically has a pillow shape. For example, the multi-pack of the present invention typically has a square or rectangular base, which provides more stability for the multi-pack when stacked on a shelf.

Typically the front face of the secondary packet is used for branding and information purposes. In that case, the front face of the secondary packet has printing thereon.

More generally, one or more surfaces of the secondary packet may have printing thereon.

Each of the primary packets may be arranged with the main face of the primary packet substantially aligned along a length direction of the secondary packet, the length of the secondary packet being a distance between the end seals or partial end seals of the secondary packet.

The main faces of the primary packets may substantially extend along the length direction or be substantially parallel to the length direction.

Each of the primary packets may be arranged with an edge of the primary packet substantially parallel to the front face of the secondary packet. The edge of the primary packet may be along an edge of the main face of the primary packet.

Each of the primary packets may comprise flexible material folded about the food and sealed by at least end seals at opposite ends of the primary packet.

In that case, where an edge of the primary packet is substantially parallel to the front face of the secondary packet, this is typically an edge at which the end seals of the primary packet are not formed.

The main face of the primary packets may therefore be a face that extends along a same direction as end seals of the primary packets .

Substantially parallel may mean within ±20°, ±15°, ±10°, ±5° or ±1° of being parallel

The end seals of the primary packets may be continuous seals which may be substantially air-tight.

As for the secondary packet, a distance between the end seals of the primary packets may be considered to be a length of the primary packets, a length of the end seals may be considered to be a width of the primary packets, and a direction perpendicular to both the length and the width may be considered to be a depth of the primary packets.

Each of the primary packets may further comprise a further seal that extends along a surface of the primary packet between the two end seals.

The further seal of the primary packets may be a continuous seal which may be substantially air-tight.

The further seal of the primary packet may extend in a substantially straight line along a length direction of the primary packet.

The further seal of the primary packet may be located on a rear face of the primary packet, and an opposite face may be the front face.

The primary packets may be formed by vertical form filling .

Each of the primary packets may be arranged with the end seals of the primary packet substantially perpendicular to the front face of the secondary packet.

Each of the primary packets may be arranged with the end seals of the primary packet substantially perpendicular to the end seals of the secondary packet. This may prevent the end seals of the primary packets from being caught in the end seals of the secondary packet when the end seals of the secondary packet are formed, which may lead to fewer consumer complaints and also a lesser percentage of waste from an operational perspective.

As mentioned above, typically the further seal or further partial seal of the secondary packet is substantially perpendicular to the end seals or partial end seals of the secondary packet and extends in a substantially straight line along the length of the secondary packet. In that case, each of the primary packets may be arranged with an edge of the primary packet substantially parallel to the further seal or partial further seal of the secondary packet. Typically the edge is an edge at which end seals of the primary packet are not provided. Thus, an edge of the primary packet may be parallel to a longitudinal direction of the secondary packet. The edge of the primary packet may be along an edge of the main face of the primary packet.

The further seal or further partial seal of the secondary packet may be on a rear face of the secondary packet that is opposite to the front face of the secondary packet. Thus, the further seal or further partial seal does not interfere with any branding or information on the front face of the secondary packet.

The secondary packet may contain any number of primary packets, for example a number between 6 and 32.

The secondary packet may contain 8 or more primary packets .

In specific examples, the secondary packet may contain 8, 10, 12, 14, 16, 18, 21, 24, 28 or 32 primary packets.

The multi-pack may contain an even or an uneven number of primary packets .

Multi-packs including 10 to 16 primary packets may include two rows of primary packets, while multi-packs including more than 16 primary packets may be include three or more rows. For example, multi-packs including 18 to 24 primary packets may include three rows of primary packets and multi-packs including 32 primary packets may include four rows of primary packets .

The one or more rows of primary packets typically extend along the width direction of the secondary packet.

The primary packets may be packed inside the secondary packet in a plurality of adjacent rows.

Adjacent means that the rows are side-by-side.

Typically the rows are side by side along the length direction of the secondary packet.

Typically the rows include the same number of primary packets .

There may be between 2 to 4 rows of primary packets in the secondary packet.

Primary packets in adjacent rows may be interleaved with each other. This means that parts of primary packets in one row extend into the adjacent row, so that there is partial overlap of primary packets in adjacent rows.

Alternatively, primary packets in adjacent rows may not be interleaved with each other, and for example instead the adjacent rows may merely be arranged immediately side-by-side or spaced apart.

Each of the primary packets may comprise flexible material folded about the food and sealed by at least end seals at opposite ends of the primary packet; and end seals of primary packets in each row may be interleaved with end seals of primary packets in the, or each, adjacent row. Thus, the end seals of primary packets in one row may overlap, or partially overlap, with end seals of primary packets in an adjacent row.

Typically the secondary packet is sufficiently tight around the primary packets to substantially hold the primary packets in position within the secondary packet. In other words, the secondary packet may provide sufficient pressure on the primary packets to prevent significant relative movement between the primary packets.

The secondary packet is a flow wrap packet. This means that the secondary packet is made by flow wrapping.

The secondary packet and/or each of the primary packets may be a bag.

The secondary packet and/or each of the primary packets may be made of plastic. For example, the plastic may comprise polypropylene .

The secondary packet and/or each of the primary packets may be made of a laminate, for example a laminate of a plurality of different layers of plastic. For example, a laminate of a plurality of different layers of polypropylene may be used, or a laminate of a plurality of different layers of polypropylene and PET may be used.

Alternatively, the secondary packet and/or each of the primary packets may be made of a single sheet of material, for example a single sheet of polypropylene. In other words, the secondary packet and/or each of the primary packets may not be made of a laminate.

The secondary packet and/or each of the primary packets is typically formed from a wrapper or sheet of flexible material.

The wrapper or sheet may be a single layer of material, or may be a laminate of more than one layer of material or materials .

The end seals or partial end seals and/or the further seal or further partial seal of the secondary packet may be heat and/or pressure seals, for example crimp seals.

Alternatively, the seals or partial seals may be formed by applying pressure without also applying heat.

The first aspect of the present invention may alternatively be expressed as a multi-pack comprising:

wherein:

the secondary packet comprises flexible material folded about the primary packets and sealed by at least end seals or partial end seals at opposite ends of the secondary packet and a further seal or further partial seal that extends along the secondary packet between the end seals; and the primary packets are packed inside the secondary packet in one or more rows, wherein each of the primary packets is arranged with a primary plane of the primary packet substantially perpendicular to a primary plane of the secondary packet.

This alternative first aspect of the present invention may have any one, or, to the extent they are combinable, any combination of the optional features of the first aspect of the present invention discussed above.

wherein:

the secondary packet comprises flexible material flow wrapped around the plurality of primary packets; and the primary packets are packed inside the secondary packet in one or more rows, wherein each of the primary packets is arranged with a primary plane of the primary packet substantially perpendicular to a primary plane of the secondary packet.

According to a second aspect of the present invention there is provided a method of manufacturing a multi-pack comprising :

arranging a plurality of primary packets, each of which contains food, in one or more rows; and flow wrapping the one or more rows of primary packets inside a secondary packet using a flow wrapper;

wherein the one or more rows of primary packets are flow wrapped inside the secondary packet with each of the primary packets arranged with a main face of the primary packet substantially perpendicular to a front face of the secondary packet, the front face of the secondary packet being a face that extends along a same direction as end seals or partial end seals of the secondary packet.

As discussed above, flow wrapping the one or more rows of primary packets comprises wrapping the one or more rows of primary packets in a flexible material such as a plastic sheet to form a flexible secondary packet containing the one or more rows of primary packets.

Typically, both the one or more rows of primary packets and the flexible material are moved horizontally along a flow wrapping machine that wraps the flexible material around the one or more rows of primary packets in the horizontal direction.

A first seal or first partial seal is provided along the wrapped flexible material to form a tube of flexible material around the one or more rows of primary packets. Then, end seals or partial end seals are provided at opposite ends of the tube of flexible material to seal or partially seal the one or more rows of primary packets inside the flexible material.

Thus, the one or more rows of primary packets are sealed or partially sealed in a secondary packet of the flexible material.

Typically the one or more rows of primary packets are tightly wrapped in the flexible material with a minimum of wasted material, such that the articles are substantially restricted from moving within the flexible material.

The advantages of this method are the same as the advantages discussed above in relation to the first aspect of the present invention, so are not repeated here.

The method may be a method of manufacturing a multi-pack according to the first aspect of the present invention, optionally with any of the optional features of the first aspect of the present invention.

The one or more rows of primary packets are typically transported to the flow wrapper on a first conveyor belt

The first conveyor belt may inclined at an angle of 20° to 45° relative to the horizontal floor. In one example, the first conveyor belt may be inclined at an angle of 30° relative to the horizontal floor.

There may be a support surface along a lower edge of the angled surface of the first conveyor belt for supporting a pile of primary packets on the first conveyor belt. The support surface moves with the first conveyor belt as part of the first conveyor belt.

The first conveyor belt may be an L-shaped conveyor belt with an L-shaped moving surface.

Alternatively, the first conveyor belt may comprise two conveyor belts arranged in an L-shaped arrangement and having the same speed, to provide an L-shaped moving surface.

Thus, the one or more rows of primary packets may be formed by stacking a plurality of primary packets on the angled conveyor belt in one or more stacks, the one or more stacks being supported by the support surface

Angling the first conveyor belt in this manner may improve the stability of the one or more rows of primary packets on the first conveyor belt, to prevent them from falling over.

The method may comprise using one or more robot arms to pick up the primary packets and to stack the primary packets in the one or more rows. The primary packets may be stacked on the angled conveyor belt by the robot arms.

The method may comprise using the one or more robot arms to control a rotational orientation of the main faces of the primary packets in the one or more rows. For example, the front faces of the primary packets may have printed information on, and the primary packets may be arranged with the printed information of each primary packet being in the same orientation.

The primary packets may be transported to the one or more robot arms by one or more further conveyor belts.

The one or more rows of primary packets may be transported to the flow wrapper on a first conveyor belt; and the one or more further conveyor belts may have a faster speed than the first conveyor belt. The speed differential between the first conveyor belt and the further conveyor belts may depend on the number of primary packets being included in the secondary packet.

In any of the aspects of the present invention, the food may be snack food, for example fried or baked snack food, for example crisps. Alternatively, the food may be nuts, for example .

In any of the aspects of the present invention, any of the end seals, partial end seals, further seals or further partial seals may be linear.

In any of the aspects of the present invention, any of the end seals, partial end seals, further seals, or further partial seals may be elongate.

In any of the aspects of the present invention, any of the end seals, partial end seals, further seals or further partial seals may be substantially planar.

In any of the aspects of the present invention, any of the end seals, partial end seals, further seals or further partial seals may be in the form of a strip.

Brief description of the drawings

Embodiments of the present invention will now be discussed, by way of example only, with reference to the accompanying Figures, in which:

FIGS. 1(a) to 1(d) are schematic drawings showing examples of multi-packs according to embodiments of the present invention;

FIGS. 2(a) to 2(c) are schematic drawings showing further examples of multi-packs according to embodiments of the present invention; and

FIG. 3 is a schematic drawing shown different stages of the process of producing a multi-pack according to an embodiment of the present invention.

Detailed description of the preferred embodiments and further optional features of the invention

Embodiments of the present invention will now be described with reference to FIGS. 1 to 3.

Embodiments of the present invention relate to multipacks 1, in which primary packets 2 containing food are packed inside a secondary packet 3.

In embodiments of the present invention the food is snack food, for example crisps or nuts. However, other types of food, such as other types of fried, roasted or baked foods, may be used instead.

The primary packets 2 are primary bags 2 formed by vertical form filling. Specifically, a vertical form filling machine (not shown) is used to form a sheet of flexible plastic into a tube which is then closed by a longitudinal seal extending along a side of the tube. A lateral end seal 4 is then provided at a bottom end of the closed tube to form an open pouch above the lateral end seal. Then, food is dropped vertically into the open pouch to fill or partially fill the open pouch with food. Then, a further lateral end seal 4 is provided above the food to seal the pouch to form the sealed primary bag 2. The seals are crimp seals formed by applying heat and pressure to the flexible plastic. However, alternatively the seals may be formed by applying pressure without also applying heat.

The seals of the primary packets are typically continuous and substantially air-tight seals, so that the primary packet is substantially air-tight and the food in the primary packets is therefore protected from the surrounding atmosphere.

The plastic in some embodiments may be polypropylene.

For example, the flexible plastic may comprise a laminate of a plurality of different layers of plastic. For example, a laminate of a plurality of different layers of polypropylene may be used, or a laminate of a plurality of different layers of polypropylene and PET.

Alternatively, the flexible plastic may be a single sheet of plastic, for example a single sheet of polypropylene.

The resulting primary bag 2 has a pillow shape, as shown in FIG. 3. In particular, the bag 2 may be substantially planer, but with a depth that increases towards a centre of the plane .

As shown in FIG. 3, the primary bag 2 has a primary plane and opposite main faces that extend in a same direction as the lateral end seals of the primary bag 2. The main faces of the primary bag 2 are curved outwards around the food contained in the primary bag 2.

A distance between the lateral end seals 4 of the primary bag 2 may be considered to be a length of the primary bag 2, a length of the end seals 4 may be considered to be a width of the primary bag 2, and a direction perpendicular to both the length and the width may be considered to be a depth of the primary bag 2.

The primary plane and opposite main faces of the primary bag 2 therefore extend in both the length and width directions of the primary bag 2.

The longitudinal seal of the primary bag 2 extends along one of the main faces of the primary bag 2, which is referred to as the rear face of the primary bag 2, in a straight line in the length direction between the end seals 4. The opposite main face of the primary bag 2 is referred to as the front face 5 of the primary bag 2.

The front face 5 of the primary bag 2 typically has printed material thereon, for example branding and information about the product.

The secondary packet 3 is a secondary bag 3 that is formed by flow wrapping an arrangement of the primary bags 2.

Flow wrapping the arrangement of the primary bags 2 involves wrapping the arrangement of the primary bags 2 in a sheet of flexible plastic to form a flexible secondary bag 3 containing the arrangement of the primary bags 2. The arrangement of the primary bags 2 in embodiments of the present invention is discussed in more detail below.

In the flow wrapping process, the arrangement of the primary bags 2 and the sheet of flexible plastic are moved horizontally along a flow wrapping machine (not shown) that wraps the flexible plastic around the arrangement of the primary bags 2 in the horizontal direction. A longitudinal seal 6 or longitudinal partial seal 6 is provided along the wrapped flexible plastic to form a tube of flexible plastic around the arrangement of the primary bags 2.

Then, lateral end seals 7 or lateral partial end seals 7 are provided at opposite ends of the tube of flexible plastic to seal or partially seal the arrangement of the primary bags 2 inside the flexible plastic. Thus, the arrangement of the primary bags 2 are sealed or partially sealed in a secondary bag 3 of the flexible plastic.

In this embodiment, lateral partial end seals 7 are provided in which areas where the seal is formed are interspersed or alternated with areas where the seal is not formed along the lengths of the lateral partial end seals. Therefore, air can escape from the secondary bag 3 through the lateral partial end seals 7 when the secondary bag 3 is packed with other secondary bags 3 in a container, thus minimising a size of the secondary bag 3.

However, in other embodiments, one continuous lateral end seal 7 and one lateral partial end seal 7 may be provided. Alternatively, both end seals 7 may be continuous, and instead a longitudinal partial seal 6 may be provided, or other holes may be provided in a surface of the secondary bag 3.

More generally, one of more of the longitudinal seal 6 or lateral end seals 7 may be a partial seal that prevents the primary bags 2 from leaving the secondary bag 3, but which allows air to leave the secondary bag 3.

The term partial seal may be replaced with the term non-airtight seal.

Alternatively, all of the seals of the secondary bag may be continuous seals that are substantially air-tight, and the secondary bag may be substantially air-tight.

The flexible plastic of the secondary bag 3 is tightly wrapped around the arrangement of the primary bags 2, so that the primary bags 2 are maintained in a substantially fixed position and orientation within the secondary bag 3. This also minimises an amount of plastic material necessary to form the secondary bag 3.

The flexible plastic in some embodiments may comprise polypropylene. For example, the flexible plastic may comprise a laminate of a plurality of different layers of plastic. For example, a laminate of a plurality of different layers of polypropylene may be used, or a laminate of a plurality of different layers of polypropylene and PET.

As shown in FIG. 3, the secondary bag 3 has a primary plane and opposite primary faces that extend in a same direction as the lateral partial end seals 7 of the secondary bag 2 .

A distance between the lateral partial end seals 7 of the secondary bag 3 may be considered to be a length of the secondary bag 3, a length of the lateral partial end seals 7 may be considered to be a width of the secondary bag 3, and a direction perpendicular to both the length and the width may be considered to be a depth of the secondary bag 3.

The primary plane and opposite primary faces of the secondary bag 3 therefore extend in both the length and width directions of the secondary bag 3.

The primary faces of the secondary bag 3 are typically the largest faces of the secondary bag 3, and may be referred to as front and rear faces of the secondary bag 3. In practice, either of the primary faces may be considered to be the front face.

However, typically the longitudinal seal 6 or longitudinal partial seal 6 of the secondary bag 3 extends along one of the primary faces of the secondary bag 3, which is referred to as the rear face 8 of the secondary bag 3, in a straight line in the length direction between the end seals 7. The opposite main face of the secondary bag 3 is referred to as the front face 9 of the secondary bag 3.

The front face of the secondary bag 3 typically has printed material thereon, for example branding and information about the product.

The front face of the secondary bag 3 may be a curved, bent or folded surface that is curved, bent or folded around the primary bags 2 contained in the secondary bag 3.

As shown in FIGS. 1 to 3, the primary bags 2 are packaged inside the secondary bag 3 arranged in one or more rows. In a given row, the primary bags 2 are stacked in a line with the main faces of the primary bags facing along the line. The primary bags 2 in a row are in contact with each other.

The primary bags 2 are arranged with their front faces facing in the same direction down the row. Therefore, each of the primary bags 2 (except for the two end bags in each row) has its front face in contact with a rear face of the primary bag 2 in front and its rear face in contact with the front face of the primary bag 2 behind.

This arrangement is illustrated for two rows of primary bags 2 in FIG. 3.

As shown in FIGS. 1 to 3, the one or more rows of the primary bags 2 are packed inside the secondary bag 3 with the primary planes of the primary bags 2 being substantially perpendicular to the primary plane of the secondary bag 3.

In other words, the primary bags 2 are arranged sideways on to a front face 9 of the secondary bag 3

This means that front faces 5 of the primary bags 2 are substantially perpendicular to the front face 9 of the secondary bag 3.

Put another way, a normal to the front face 5 of each of the primary bags 2 is arranged at substantially 90 degrees to a normal to the front face 9 of the secondary bag 3.

Of course, it is not essential for the orientation to be exactly perpendicular/90 degrees, and instead may be within ±20°, or ±15°, or ±10°, or ±5°, or ±1° of being perpendicular/90 degrees.

As shown in FIGS. 1 to 3, typically the one or more rows of primary bags 2 extend along the width direction of the secondary bag.

In embodiments of the present invention, each of the primary bags 2 is arranged inside the secondary bag 2 with the end seals 4 of the primary bag 2 perpendicular to the front face 9 of the secondary bag 3 and perpendicular to the partial end seals 7 of the secondary bag.

In embodiments of the present invention, each of the primary bags 2 is arranged inside the secondary bag 3 with the front face 5 of the primary bag substantially aligned along a length direction of the secondary bag 3.

In embodiments of the present invention, each of the primary bags 2 is arranged inside the secondary bag 3 with the front face 5 of the primary bag 2 arranged parallel to the longitudinal seal 6 or longitudinal partial seal 6 of the secondary bag 3.

As shown in FIGS. 1 to 3, typically embodiments of the present invention include more than one row of primary bags 2 inside the secondary bag 3. In these embodiments, the two or more rows of primary bags 2 are arranged side by side along the length direction of the secondary bag 3.

As shown in FIGS. 1 to 3, in specific embodiments of the present invention the number of rows may be between 2 and 4, and the number of primary packets inside the secondary packet may be between 10 and 32.

As shown most clearly in FIGS. 1 and 2, where there are multiple rows of primary bags 2, the primary bags 2 in each row are arranged so as to interleave with the primary bags in adjacent rows. In particular, the primary bags 2 in adjacent rows may be in a staggered arrangement, wherein the positions of the primary bags 2 in one row are offset (along the row) relative to the positions of the primary bags 2 in the adjacent rows.

In alternative embodiments, primary bags 2 in each row may not interleave with the primary bags 2 in adjacent rows.

In some embodiments, the end seals 4 of the primary bags 2 in each row overlap with, and may contact, the end seals 4 of the primary bags 2 in adjacent rows.

This may further reduce a size of the secondary bag 3, and thus reduce an amount of material required for the secondary bag 3.

As discussed above, the secondary bag 3 in the present invention is formed by flow wrapping.

In a typical embodiment, individual primary bags 2 are transported by one or more first conveyor belts.

The individual primary bags 2 are picked up off the one of more first conveyor belts by one or more robot arms and positioned in one or more stacks on a second conveyor belt. This arrangement of the primary bags 2 is illustrated in the second part of FIG. 3.

The second conveyor belt may be substantially parallel to the one or more first conveyor belts.

The one or more robot arms may therefore have at least three axes of rotation, for positioning the primary bags 2 in the one or more stacks.

The robot arms may have further axes of rotation, for example for rotating the front face 5 of the primary bag 2 around a normal to the front face 5 so as to control a rotational orientation of the front face 5. This may enable all of the primary bags 2 in a row to have front faces 5 in the same orientation, for example the same way up.

The speed of the one or more first conveyor belts may be different to the speed of the second conveyor belt. For example, the speed of the one or more first conveyor belts may be greater than the speed of the second conveyor belt.

The stacks of primary bags 2 are then conveyed by the second conveyor belt to a flow wrapper, where the one or more stacks of primary bags 2 are flow wrapped in a flexible plastic sheet in the specific arrangement discussed above.

The second conveyor belt may be arranged at an angle to the horizontal, for example an angle of 20° to 45°, preferably 25 to 35°, most preferably 30°. The surface of the conveyor belt may be L shaped, such that there is a support surface at the lower end of the surface of the conveyor belt that moves with the conveyor belt. Alternatively, the second conveyor belt may comprise two conveyor belts arranged in an L-shaped arrangement and having a same speed, to provide an L-shaped moving conveyor surface.

Such a conveyor belt may improve the stability of the stacks of primary bags 2, particularly when dealing with larger numbers of primary bags 2 (for example more than 6 bags) .

There is then direct transfer from the second conveyor belt to the flow wrapper where the flow wrapping is then performed on the arranged primary bags 2.

As shown in FIGS. 1 to 3, the multi-pack of the present invention is typically shorter in the length direction and narrower in the width direction than a multi-pack containing the same number of primary packets formed by vertical form filling .

Furthermore, the multi-pack of the present invention typically has a greater depth than a multi-pack containing the same number of primary packets formed by vertical form filling, and the depth is more uniform or consistent across the multi-pack. This means that the shape of the multi-pack of the present invention is more square or rectangular than the pillow shape of a multi-pack formed by vertical form filling. This means that the ease of handling, storing and displaying (for example on a shelf) of the multi-pack is improved in the present invention.

As shown in FIGS. 1 to 3, increasing the number of primary packets in a row in embodiments of the present invention increases the size of the front face of the secondary packet. This means that size of the main face is maximised, particularly for larger numbers of primary packets in each row, therefore providing a suitable space for branding and/or information.

As shown in FIGS. 1 to 3, in embodiments of the present invention the substantially square or rectangular shape of the multi-pack provides a number of substantially flat surfaces that can aid packing and storing of the multi-pack, therefore making more efficient use of storage space, for example on a shelf .

As shown in FIGS. 1 to 3, in embodiments of the present invention the end seals and longitudinal seals of the primary bags 2 and secondary bag 2 are each linear seals that are elongate, substantially planar and in the form of a strip.

Claims

1. A multi-pack comprising:

wherein:

the secondary packet comprises flexible material folded about the primary packets and sealed or partially sealed by at least end seals or partial end seals at opposite ends of the secondary packet and a further seal or further partial seal that extends along the secondary packet between the end seals or partial end seals; and the primary packets are packed inside the secondary packet in one or more rows, wherein each of the primary packets is arranged with a main face of the primary packet substantially perpendicular to a front face of the secondary packet, the front face of the secondary packet being a face that extends along a same direction as the end seals or partial end seals of the secondary packet.

2. The multi-pack according to claim 1, wherein each of the primary packets is arranged with the main face of the primary packet substantially aligned along a length direction of the secondary packet, the length of the secondary packet being a distance between the end seals or partial end seals of the secondary packet.

3. The multi-pack according to claim 1 or claim 2, wherein each of the primary packets is arranged with an edge of the primary packet substantially parallel to the front face of the secondary packet.

4 . The multi-pack according to any one of the previous claims, wherein each of the primary packets comprises flexible material folded about the food and sealed by at least end seals at opposite ends of the primary packet.

5. The multi-pack according to claim 4, wherein each of the primary packets is arranged with the end seals of the primary packet substantially perpendicular to the front face of the secondary packet.

6. The multi-pack according to any one of the previous claims, wherein each of the primary packets is arranged with an edge of the primary packet substantially parallel to the further seal or further partial seal.

7 . The multi-pack according to any one of the previous claims, wherein the further seal or further partial seal is on a rear face of the secondary packet that is opposite to the front face of the secondary packet.

8 . The multi-pack according to any one of the previous claims, wherein the primary packets are packed inside the secondary packet in a plurality of adjacent rows.

9. The multi-pack according to claim 8, wherein primary packets in adjacent rows are interleaved with each other.

10. The multi-pack according to claim 8 or claim 9, wherein: each of the primary packets comprises flexible material folded about the food and sealed by at least end seals at opposite ends of the primary packet; and end seals of primary packets in each row are interleaved with end seals of primary packets in the, or each, adjacent row.

11. The multi-pack according to any one of the previous claims, wherein the secondary packet is sufficiently tight around the primary packets to substantially hold the primary packets in position within the secondary packet.

12 .

The multi-pack according to any one of the previous claims, wherein the secondary packet is a flow wrap packet.

13. The multi-pack according to any of the previous claims, wherein the secondary packet and/or of the primary packets is a bag.

14. The multi-pack according to any the previous claims, wherein the secondary packet and/or each of the primary packets is made of plastic.

15. The multi-pack according to any one of the previous claims, wherein the end seals or partial end seals and/or the further seal or partial further seal of the secondary packet are heat seals .

16. A method of manufacturing a multi-pack comprising:

17. The method according to claim 16, wherein the method is a method of manufacturing the multi-pack according to any one of claims 1 to 15.

18. The method according to claim 16 or claim 17, wherein the one or more rows of primary packets are transported to the flow wrapper on a first conveyor belt.

19. The method according to claim 18, wherein the first conveyor belt is inclined at an angle of 20° to 45° relative to the horizontal floor.

20. The method according to any one of claims 16 to 19, wherein the method comprises using one or more robot arms to pick up the primary packets and to stack the primary packets in the one or more rows.

21. The method according to claim 20, wherein the method comprises using the one or more robot arms to control a rotational orientation of the main faces of the primary packets in the one or more rows.

22. The method according to claim 20 or claim 21, wherein the primary packets are transported to the one or more robot arms by one or more further conveyor belts.

23. The method according to claim 22, wherein:

the one or more rows of primary packets are transported to the flow wrapper on a first conveyor belt; and the one or more further conveyor belts have a different speed to the first conveyor belt.

24. The multi-pack according to any one of claims 1 to 15 or the method according to any one of claims 16 to 23, wherein 8 or more primary packets are packed inside the secondary packet, wherein the number of primary packets packed inside the secondary packet is optionally 8, 10, 12, 14, 16, 18, 21 24, 28 or 32 primary packets.