GB2580632A

GB2580632A - Refill products

Info

Publication number: GB2580632A
Application number: GB1900685.7A
Authority: GB
Inventors: Richard John Dunham Alexander
Original assignee: Peartree Chemicals Ltd
Current assignee: Peartree Chemicals Ltd
Priority date: 2019-01-17
Filing date: 2019-01-17
Publication date: 2020-07-29
Also published as: GB202000750D0; GB201900685D0; GB2598531A

Abstract

A concentrated refill product 10 for dilution into a solution comprises a sachet 20 encasing a volume of concentrated liquid. The sachet is tubular with a diameter of less than 25mm, and has a water soluble casing. This allows the sachet to be used to form the solution. The volume of the concentrated product is preferably between 2.5ml and 20ml. A method of diluting the concentrated product comprises: providing an empty container with an opening of 19mm or greater; placing the refill product inside the container; filling the container with water; waiting until the sachet ruptures due to dissolution of the casing; and optionally agitating the container to ensure an even solution. A method of manufacturing a sachet comprises: providing a sheet of water soluble film; wrapping the sheet around a mandrel; heat sealing the edges to form a tubular roll; removing the mandrel; filling the roll with product; and heat sealing a base and a top of the roll to form a sealed sachet.

Description

DESCRIPTION

REFILL PRODUCTS

Field

This invention relates to improvements in refill products for dilution into a solution, in particular concentrated cleaning products provided in a water soluble casing.

Background

Plastics pollution is a major current ecological concern. A recent drive amongst 10 consumers has been to reduce plastics usage, leading to an increased awareness and demand for products that reduce or eliminate plastics usage.

One major source of household and commercial plastics waste are containers for storage of cleaning products such as household kitchen and bathroom cleaners.

Such products are typically sold in containers of between 500m1 -750m1, although alternative container sizes are available. As noted above, commercial cleaning products used by retail and leisure industries generate a large amount of empty plastic container waste.

Refills that allow a consumer or cleaning company to reuse the original plastic container are available, allowing a consumer to replenish the contents of the original container. Such refills are typically either supplied as standard strength products or in concentrated form that must be diluted by the end user prior to use. Such refills often come as plastics pouches or smaller plastic bottles that contain the refill product and must be decanted into the original container prior to subsequent dilution (as necessary). However, the use of such refills merely mitigated the plastics problem, reducing the plastics use but not eliminating it. Furthermore such refills typically require decanting or a measured amount that is less than the full amount of the refill, leading to concentration issues with concentrated refills.

There therefore exists a need for a refill product that at least ameliorates the above mentioned issues.

Summary

According to a first aspect of the present invention, there is provided a concentrated refill product for dilution into a solution, said product comprising a sachet; a volume of concentrated liquid product, said volume encased by the sachet; and wherein the sachet is substantially tubular in shape, having a diameter of less than 25mm, and wherein the sachet comprises a water soluble casing.

The present disclosure allows for easy insertion of a sachet into a suitable container for subsequent dilution. The present disclosure provides a convenient, plastics-free product that can be used to refill existing product containers, or to make new product containers from alternative containers, such as spray bottles, flip-top bottles and jars.

The diameter of the sachet allows the product to be easily placed through the necks of such containers, which typically have an opening of 19mm or larger. The water soluble casing allows for easy product production, without leaving any waste packaging -the casing dissolves during production of the product.

The refill products are typically concentrated cleaning products or detergents, such as kitchen or household cleaners, oven or floor cleaners, window/glass cleaners or the like. It can be appreciated that although the products are primarily refill products intended to refill a similar original container, it may be used to make a new product.

In an embodiment, the volume of concentrated product may be between 2.5m1 and 20m1. Typically volumes of 5m1 or 10m1 may be used. The choice of volume is dependent, at least in part, on the product being diluted and the volume of solution required.

In examples, the water soluble casing may be at least partially dissolved to release the concentrated product into water to form the solution within, 5 minutes, with typical timings of, for example, 4 minute or less after submersion into the water at 15 degrees Celsius or warmer. It can be appreciated that rupture of the casing is only required to release the concentrated liquid product and allow dilution. Accordingly, the solution is typically formed quicker than the complete dissolution of the casing. The timings and temperatures are typical values -warmer water will reduce the dissolution time and vice-versa.

Typically the water soluble casing is made from a poly vinyl alcohol, although other suitable films may be used, such as starch or other dissolvable films. The sachet may be flexible and compressible for insertion within an opening of a bottle having diameter of 19mm or larger.

Typically the volume of concentrated product is coloured to allow identification of the concentrated product. Additionally or alternatively, the sachet may have writing on an exterior surface of the casing, again for identification and/or instructions or warnings.

According to a second aspect of the present invention, there is provided a method of diluting a concentrated product, said method comprising the steps of: a) providing an empty container, said container comprising an opening of 19mm or greater; b) placing a product according to the first aspect within the container through the opening; c) filling the container with water; and d) waiting until the sachet ruptures due to dissolution of the water soluble casing; e) optionally agitating the container to ensure an even solution; and wherein steps b) and c) are interchangeable.

In examples, the temperature of the water may be directed to the user. The temperature of the water may be 15 degrees Celsius.

In a further embodiment, the method may comprise the step of placing one or more additional products according to the first aspect within the container through the opening. Accordingly, the concentrated refill product may be components used to produce the desired solution. For example, each refill product may comprise a concentratedconstituent of a cleaning product that combines to produce the cleaning product.

According to a third aspect of the present invention, there is provided a method of manufacturing a sachet for a concentrated liquid product, said method comprising the steps of: i) providing a sheet of water soluble film; ii) wrapping the sheet around a mandrel; iii) heat sealing edges of the sheet to form a tubular roll; iv) removing the mandrel; v) filling the tubular roll with a liquid concentrated product; and vi) heat sealing a base and a top of the tubular roll to form a sealed sachet comprising the liquid concentrated product.

In an embodiment, step iii) may comprise the step of heat sealing the edges of the sheet against the mandrel. Additionally or alternatively, one or more sealing jaws may be used to heat seal the edges of the sheet either together or against the sheet held by the mandrel.

Steps iv) and v) may occur simultaneously, with the tubular roll filled as the mandrel is removed from the tubular roll. In this embodiment, the tubular roll may be filled from below. Filling may be by using a filling tube that runs within the mandrel.

In embodiments of this aspect, the sheet may comprise a polyvinyl alcohol film.

The method may further comprise the step of adjusting a local temperature and humidity prior to performing any of the method steps to provide a desired physical property for the casing. The behavior of such water soluble films varies according to the relative temperature and humidity -in one embodiment the humidity may be above 80% and the temperature may be above 25 degrees Celsius. The use of different temperature and humidity conditions can lead to poor sealing.

The sheet may be tensioned prior to step iii). This tensioning ensures that the film is taught and seats properly around the mandrel and within sealing jaws. Over tensioning should be avoided -elongation of the sealed tubular roll caused by over tensioning may negatively affect reproducibility in size and weakens the seal, conversely limited tension helps the film run true and seat properly around the mandrel and within the sealing jaws.

The method may also comprise the step of printing onto the sealed sachet or onto the sheet. The printing may be used to identify the contents of the sachet and/or provide warnings, branding or other information.

It can be appreciated that features described in relation to one aspect may be equally applied to alternative complimentary aspects.

Brief description of Drawings

Embodiments will be described, by way of example only, with reference to the drawing, in which figure 1 shows a diagram of a concentrated liquid product according to at least one embodiment of at least one aspect of the present disclosure.

It should be noted that the Figure is diagrammatic and not drawn to scale. Relative dimensions and proportions of parts of the Figure has been shown exaggerated or reduced in size, for the sake of clarity and convenience in the drawings. The same reference signs are generally used to refer to corresponding or similar feature in modified and different embodiments.

Detailed description of embodiments

According to one aspect of the present disclosure, a concentrated liquid product 10 is shown. In particular, the product 10 comprises a generally tubular sachet 20, having a top seal 24 and a bottom seal 26. A side seam or seal 28 runs along the length of the sachet 20. The seals 24-28 provide a liquid-tight seal around the sachet 20. The sachet 20 is made from a water soluble casing, such as polyvinyl alcohol. Other water soluble casings such as starch based casings may be used.

The sachet 20 is flexible, allowing the sachet to be deformed.

The sachet 20 is filled with a concentrated solution of typically cleaning product, such as kitchen degreaser, bathroom cleaner, floor cleaner, oven cleaner or other similar product. Typical volumes of cleaning products include 5m1 or 10m1 depending on the product used and solution desired. The concentration of the liquid cleaning product within the sachet 20 is typically above 95%. By liquid cleaning product we refer to the combination of liquid cleaning concentrate, including surfactants, fragrance, dye and the like. Intended dilution concentrations include 1:25 or 1:100, with a typical container of between 250m1 and 750m1 used to dilute the concentrated solution. The concentrated solutions are usually coloured, for identification. Markings may also be placed on the exterior surface of the sachets, again to provide identification or other information.

The sachet 20 is typically less than 25mm in diameter. Typically a diameter of 22mm is used for the sachet, but ranges include 15-25mm diameters. The height of the sachet is typically around 4-13 or 15cm. In some examples the height is 12cm, but this can be varied depending upon the volume of concentrated liquid.

In use, a sachet 20 is typically placed within an empty container, such as a spray bottle, flip-top bottle or standard jar. Such containers which are recommended for use are between 250-750m1 in volume. Spray bottles and flip-top bottles typically have an opening diameter of 19mm or more. The sachet, if the diameter is greater than the diameter of the opening, can be deformed to fit within and through the opening. In some examples, two or more sachets 20 may be used depending on the concentration required or to create a desired combined solution.

Water is then added to the container (or the water may already be within the container) up to a desired amount, typically 500m1. The temperature of the water broadly determines the speed at which the water soluble casing of the sachet 20 dissolves. However, within approximately 4 or 5 minutes enough of the casing has dissolved to rupture the sachet 20 and allow the concentrated product to be diluted with the water. Shaking or other agitation may be used to ensure an even dilution.

Once diluted, the solution can be used as directed. Labels will be provided, where appropriate, to provide an indication to the user of the cleaning product within the reused container.

The sachets 20 are made by providing a sheet of water soluble film (such as polyvinyl alcohol), which is then wrapped around a mandrel or the like to form a tubular shape having open ends and an open seam from overlapping film. The overlapping film is then heat sealed either against the mandrel or between sealing jaws to form the side seam 28.

The tubular shaped film is then heat sealed at a bottom portion to form bottom seal 26 as well as top seal 24 of the previous sachet. The sachet 20 is then filled through the mandrel to the desired amount as the sachet is pulled down by rollers that clamp to the side seal 28. Once the desired amount is reached, the sachet is sealed at the top to form top seal 24 as well as bottom seal 26 of the next sachet. The sealed sachet 20 is then separated from the film. Desired amounts are typically 10m1 or 5m1. Heights of the sachets are approximately 4-13cm. Diameters of the sachets are approximately 15-25mm, more particularly 22mm.

The temperature and humidity at which the sachet 20 is formed plays a role in ensuring that the properties of the water soluble casing are consistent and suitable for both ensuring that the seal doesn't leak and that the flexibility of the sachet 20 is maintained. In one example the temperature used is at or above 25 degrees Celsius, with a relative humidity of 80% or higher.

The use of the sachets of the present disclosure allows for the reuse of a wider variety of containers than previously possible. The sachets are ecologically friendly and are easy to store and deliver by post.

From reading the present disclosure, other variations and modifications will be apparent to the skilled person. Such variations and modifications may involve equivalent and other features which are already known in the art of design realisation and extrusion and which may be used instead of, or in addition to, features already described herein.

Although the appended claims are directed to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention.

Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination. The applicant hereby gives notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.

For the sake of completeness it is also stated that the term "comprising" does not exclude other elements or steps, the term "a" or "an" does not exclude a plurality, and reference signs in the claims shall not be construed as limiting the scope of the 10 claims.

Claims

CLAIMSA concentrated refill product for dilution into a solution, said product comprising: a sachet; a volume of concentrated liquid product, said volume encased by the sachet; and wherein the sachet is substantially tubular in shape, having a diameter of less than 25mm, and wherein the sachet comprises a water soluble casing.
2. The product of claim 1, wherein the volume of concentrated product is between 2.5m1 and 20m1.
3. The product of claim 1 or claim 2, wherein the water soluble casing is at least partially dissolved to release the concentrated product into water to form the solution within 4 minutes after submersion into the water at 15 degrees Celsius or warmer.
4. The product of claim 1 or claim 2 or claim 3, wherein the water soluble casing is made from a poly vinyl alcohol.
5. The product of claim 4, wherein the sachet is flexible and compressible for insertion within an opening of a bottle having diameter of 19mm or larger.
6. The product of any preceding claim wherein the volume of concentrated product is coloured.
The product of any preceding claim wherein the sachet comprises writing on an exterior surface of the casing.
8. The product of any preceding claim wherein the concentrated product is a concentrated cleaning product.
9. A method of diluting a concentrated product, said method comprising the steps of: a) providing an empty container, said container comprising an opening of 19mm or greater; b) placing a product according to any preceding claim within the container through the opening; c) filling the container with water; and d) waiting until the sachet ruptures due to dissolution of the water soluble casing; e) optionally agitating the container to ensure an even solution; and wherein steps b) and c) are interchangeable.
10. A method of manufacturing a sachet for a concentrated liquid product, said method comprising the steps of: i) providing a sheet of water soluble film; ii) wrapping the sheet around a mandrel; iii) heat sealing edges of the sheet to form a tubular roll; iv) removing the mandrel; v) filling the tubular roll with a liquid concentrated product; and vi) heat sealing a base and a top of the tubular roll to form a sealed sachet comprising the liquid concentrated product.
11. The method of claim 10, wherein the sheet comprises a polyvinyl alcohol film.
12. The method of claim 10 or claim 11, where steps iv) and v) occur simultaneously.
13. The method of any one of claims 10 to 12, wherein step iii) further comprises the steps of heat sealing the edges of the sheet against the mandrel; and optionally or preferably wherein one or more sealing jaws are be used to heat seal the edges of the sheet either together or against the sheet held by the mandrel.
14. The method of any one of claims 10 to 13, further comprising the step of adjusting a local temperature and humidity prior to performing any of the method steps to provide a desired physical property for the casing.
15. The method of any one of claims 10 to 14, wherein the sheet is tensioned prior to step iii).
16. The method of any one of claims 10 to 15, further comprising the step of printing onto the sealed sachet or onto the sheet.