Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B51/00—Devices for, or methods of, sealing or securing package folds or closures; Devices for gathering or twisting wrappers, or necks of bags
  • B65B51/10—Applying or generating heat or pressure or combinations thereof
  • B65B51/26—Devices specially adapted for producing transverse or longitudinal seams in webs or tubes
  • B65B51/30—Devices, e.g. jaws, for applying pressure and heat, e.g. for subdividing filled tubes
  • B65B51/303—Devices, e.g. jaws, for applying pressure and heat, e.g. for subdividing filled tubes reciprocating along only one axis
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
  • B65B9/00—Enclosing successive articles, or quantities of material, e.g. liquids or semiliquids, in flat, folded, or tubular webs of flexible sheet material; Subdividing filled flexible tubes to form packages
  • B65B9/10—Enclosing successive articles, or quantities of material, in preformed tubular webs, or in webs formed into tubes around filling nozzles, e.g. extruded tubular webs
  • B65B9/20—Enclosing successive articles, or quantities of material, in preformed tubular webs, or in webs formed into tubes around filling nozzles, e.g. extruded tubular webs the webs being formed into tubes in situ around the filling nozzles
  • B65B9/2042—Means for altering the cross-section of the tube filling opening prior to transversal sealing, e.g. tube spreading devices

Definitions

• the present invention relates to a method for making flexible side-gusseted pouches on a form-fill-seal machine.
• Pouches, or bags made of plastic films are used for packaging various products like creams, powders, liquids, tablets, noodles, granular detergents and pastes. Pouches enable packaging and sale of these products in small, as well as large quantities, typically in the range of 20Og to 10kg.
• the structure of the pouch is such that it does not expand during filling but has a generally similar shape and configuration, when empty or full.
• the gusset structure is advantageous, since it permits the unfilled pouch to be substantially flat when empty, and then to expand to a full depth as the pouch is filled with material.
• Side gusseted pouches are described in US 2008/137998 Al (KONINKL PHILIPS ELECTRONICS)
• WO 1995/10566 Al (DUPONT CANADA INC) describes a process for making pouches on a vertical FFS machine, which show low rate of failure in the Bag Drop-Test.
• the laminate has one layer of a blown film formed from a blend which includes a linear polymer of ethylene with at least one C4-C10 alpha-olefin, which is manufactured in a single- site catalyst polymerization process.
• the laminate also includes at least one of a linear polymer of ethylene with at least one C4-C10 alpha-olefin made by a multi-site catalyst polymerization process; a high pressure low density polyethylene; and additives selected from the group consisting of stabilizers, anti-block additives and extrusion aids.
• a limitation of this process is that one needs to have the special grade of laminated films, and the process would not work with any other material.
• JP/2006/264765A (DAINIPPON PRINTING CO LTD) describes a process to prevent a gusset bag from being broken and generating a pin-hole at its gusset part, in which the sheet forming the gussets is folded into two and inserted between the front and back panels of the pouch, so as to extend along their one side. It is said that with this type of sealing arrangement; stress that tends to be concentrated at the crossing point is dispersed and the bag is prevented from being broken.
• a drawback of this disclosure is that the extra folds of gussets mean utilisation of higher amount of packaging material. This would therefore, be a relatively -A-
• VFFS Very Form-Fill-Seal
• JP/2005/104572A (FUJITA KIKAI KK; HAYASHI SANGYO KK) describes a square-cornered pouch, in which, in addition to the lower horizontal seal, there are two additional vertical seals near the bottom of the pouch (one adjacent to each gusset) such that this extra sealing lines extend vertically to the upper end of the pouch for some distance, whereafter the sealing lines are inclined at 45 degrees with respect to the gusset folds.
• the pouches also have reinforcing seals having a circular arc which are provided by piling four films of the front face and back face of the bag and the gusset fold and bonding them integrally by fusion.
• the arcuate seals are adjacent to the inner edges of the gusset fold, and it contacts the extra sealing lines that extend vertically upward.
• a primary drawback of such pouches is that, as the entire width of the pouch is sealed in the horizontal seal, it becomes essential that either the outermost layer of the laminated film has to be of heat- sealable grade, or a special type of lacquer is used to seal the layer in case the outermost layer is not heat-sealable . This limits the use of this process.
• Japanese unexamined Patent Application No. JP/02/173149A aims to solve the same problem of pre-formed plastic pouches with side gussets, where failure occurs at the points where the horizontal seal meets the inner ends of the gussets. This has been solved by providing non-sealed curved pockets at the points of intersection. It is known that while using pre-formed pouches for filling and packaging of products, the overall speed of filling and packaging is low as the pouches are formed at one station, and then filled and sealed at a different station.
• the present invention provides a method of continuously forming, filling and sealing side-gusseted flexible pouches with product, comprising the steps of:
• the present invention provides a system for continuously forming, filling and sealing side-gusseted flexible pouches with product, comprising :
• top-sealing section and said bottom-sealing section have depressed areas, so as to form un-sealed pockets at the intersection of the horizontal seal with the inner ends of the gussets of the pouch; wherein width of each of the depressed area is in the range of 25 to 50 % of the total width of the gusset of the pouches formed.
• Width of the un-sealed pocket is in the range of 25 to 50 %, more preferably in the range of 30 to 45 %, further more preferably in the range of 30 to 40 %, and most preferably 33 % of the total width of the gusset. It is preferred that the un-sealed pocket is free of sharp corners or bends, and more preferably the corners are rounded-off. It is preferred that the un-sealed pocket is formed at least three inner corners of the pouch. It is preferred that the profile of the unsealed pocket is semi-circular, oval or ellipsoidal, more preferably semi-circular.
• the maximum shift in the centre-line of the gussets is 13.33 % of its total width.
• the ideal situation is when the centre-line of the gusset is at 30 mm, i.e. width of both gusset ears is 30 mm each.
• the present inventors have found that the maximum shift in the centre-line could be by 8 mm, which amounts to 13.33 % of the total gusset width.
• the centre-line of the gussets could be anywhere between 22 to 38 mm, when measured from one end of the gusset. In this case, the width of the individual gussets would be different and not 30 mm each.
• the width of the un-sealed pocket is more than 200 % of the maximum shift in the centre-line of the gussets, more preferably at least 250 % and upto 300 % of the shift in the centre-line of the gusset. It is highly preferred that the width is 250 % of the maximum shift in the centre-line of the gussets.
• the width of the un-sealed pocket is more than 16 mm, more preferably, at least 20 mm, and upto 24 mm. It is highly preferred that the width of the unsealed pocket is 20 mm, which is 250 % of 8 mm.
• the height of the un-sealed pocket is less than 35 % of the height of the horizontal seal, preferably in the range of 10 to 30 %, and more preferably in the range of 10 to 20 %. Excessive height may weaken the horizontal seal. While the method can be used to form pouches with the un-sealed pockets formed at least three corners of the pouch, it is possible to form the pockets at all four corners.
• the height of the horizontal seal preferably the top horizontal seal, at one end is in the range of 167 to 240 % of the general height of the seal, wherein a notch/slit is provided on both or one side of the gussets-ears at the end, the notch/slit being positioned below the un-sealed pocket at the opposite end of the horizontal seal.
• the general height of the horizontal seal is 15 mm; the seal height at the end of the seal, where the notch/slit is to be provided, is preferably in the range of 25.05 to 36 mm, more preferably 30 mm.
• the notch is provided 5 to 10 mm, preferably 5 mm below the un-sealed pocket at the opposite end of the same horizontal seal.
• the gusset ears are not sealed to each other. Having introduced the un-sealed pockets, it is not essential to seal the gusset-ears to each other for low rate of failure in Bag-Drop test.
• the outermost layer of the laminated film is of heat-sealable grade, or a special type of lacquer is used to seal the layer, in case the outermost layer is not heat- sealable, the gusset-ears could be sealed to each other, thereby further reducing the rate of failure.
• Pouches may be manufactured from a variety of materials. It is particularly advantageous, however, that they be constructed, at least partly, from relatively thin, strong material such as Polyethyleneterepthalate (PET) , which is polyester; biaxially oriented nylon (BON) , linear low density polyethylene (LLDPE) , commonly abbreviated as PET/BON/LLDPE film.
• PET Polyethyleneterepthalate
• BON biaxially oriented nylon
• LLDPE linear low density polyethylene
• the following combinations, some with multiple layers or ply of the same material, may be used for making the pouches. It is preferred that 2-ply laminates are used, but, if desired, 3- ply laminates can also be used, although these laminates are less preferred because of their cost.
• Polyester/ adhesive or Extrusion Poly
• Polyester/ adhesive or Extrusion
• Material thickness may also vary.
• the sheet of film is a 2-ply laminate of 10/12 micron Polyethyleneterepthalate and 70/80 micron Polyethylene.
• a 2-ply laminate of 10/12 micron Polyethyleneterepthalate and 70/80 micron Easy-tear Polyethylene is used to make the pouches.
• the method according to this invention may be used to make "Quad-packs".
• the general method for making quad-packs is well-known to a person skilled in the art.
• the present invention provides a pouch obtainable by the method according to the first aspect.
• the present invention provides use of the pouch formed by the method according to the first aspect for packaging granular detergent composition .
• any particular upper concentration can be associated with any particular lower concentration or amount .
• Figure 1 is the isometric view of a system according to the invention.
• Figure 2 is front view of a horizontal sealing jaw of the system of Figure-1.
• Figure-3 is front view of a pouch formed in the system of Figure-1.
• Figure-4 is side-view of the pouch of Figure-3 with the gussets ears opened up.
• Figure-5 is the isometric view of another embodiment of a pouch formed by a system according to the invention.
• Figure-1 is the isometric view of a system for continuously forming, filling and sealing side-gusseted flexible pouches with product according to an aspect of the invention.
• the system is constructed in the form of an enclosed frame on which all parts for the forming, filling, and sealing of the pouches are mounted.
• a continuous sheet of film 1 is un-wound from a roll (not shown) and is drawn/conveyed over conveying Aluminium rollers 2 and 3. It then reaches a forming shoulder 4 and later on, a pouch-former 5 (also called a forming tube) .
• a pouch-former 5 also called a forming tube
• the sheet of film 1 is folded over itself so that the opposite longitudinal edges 6 and 7 are juxtaposed to form a common vertical film edge.
• a vertical sealer 8 then seals this common overlapped vertical film edge to form a film-tube.
• Pulling means (not shown) then continuously pull the film-tube 9 along machine direction, (shown by a solid arrow) as set on a stroke length lever (not shown) .
• a pair of gusset pins 10 and 11 (means for forming gussets) , disposed on either lateral sides of the film-tube than form gussets on both lateral sides of the film-tube.
• the film-tube is then sealed in the horizontal direction by a pair of horizontal sealing jaws 12 and 13 at a predetermined location below the vertical sealer 8.
• the horizontal sealing jaws have depressed areas, both represented by common numeral 14 which form un-sealed pockets at the intersection of the horizontal seal with inner ends of the gussets of the pouch.
• the same features are present in the other horizontal sealing jaw 12 (features not seen in this view) .
• the horizontal sealing jaws simultaneously define the top horizontal seal 15 of the filled pouch 16, and the bottom horizontal seal 18 of the pouch to be filled 19.
• Perforations 20 are formed between the top horizontal seal 15 and the bottom horizontal seal 18 for later severing the filled and sealed pouches to form individual pouches therefrom.
• this severing action takes place separately, whereas in the Poly heat- sealing system, the sealing and severing actions take place at the same time, because knives are mounted on the sealing jaws itself.
• a product is continuously fed through means in the form of a tube 21, below the vertical sealer 8 and above the pair of horizontal sealing jaws 12 and 13. The open end of the film-tube is then sealed with the horizontal sealing jaws, at a predetermined location, which corresponds to a distance of one bag length. The cycle is repeated to form plurality of pouches .
• the jaw has a bottom-sealing section in the form of seal bar 22 and a top-sealing section in the form of another seal bar 23 with a knife-edge 24 there-between .
• the jaw is provided with curved/semi-circular depressed areas, all represented by common numeral 14, with their corners rounded-off, so as to minimise sharp corners.
• the gusset alignment area is shown as L in the figure.
• the height of the seal bar "H-I" is greater than the general height of the seal bar "H”. This feature gives extra sealing height to the pouch in the top- horizontal seal, so that an easy-tear notch can be formed in this sealed region with the cavity 25.
• the pouch 16 has a top horizontal seal 15 and a bottom horizontal seal 18.
• the seal height of a portion of the top horizontal seal 15 at one end 27 is greater than the general seal-height of the top- horizontal seal. Both corners of 27 are rounded-off.
• Three curved semi-circular pockets, all represented by the common numeral 26 can be seen at the three inner corners of the pouch, at the intersection of the horizontal seal with the inner ends of the gussets represented by the centre line of the gussets 28.
• Figure-4 shows the pouch of Figure-3 in a side view, where the gusset-ears have been opened up, to show the total width of the gusset "W".
• Common numeral 28 indicates the centre-lines of the gussets, and the pockets 26 extend across this line. Both corners of each pocket are rounded-off .
• Figure-5 shows another embodiment of a pouch formed by a system according to the invention.
• the pouch has a top and bottom horizontal seals 15 and 18 respectively, with gusset- ears at one end shown by the common numeral 29.
• the seal height of a portion of the top horizontal seal 15 at one end 27 is greater than the general seal-height of the top- horizontal seal. Both corners of 27 are rounded-off.
• An easy-tear notch 30 is provided in this region, and the notch is positioned below the un-sealed pocket 26 at the opposite end of the same horizontal seal.
• 2250 pouches were made by the method in accordance with the invention and as described with reference to Figure-5.
• the pouches were made from a 2-ply laminate (10/12 micron Polyethyleneterepthalate and 70/80 micron easy-tear Polyethylene) .
• 1500 pouches were filled with 1 kg high bulk-density (BD) detergent powder, and 750 pouches were filled with 500 g of a low BD detergent powder.
• Specifications of the pouches were as follows:
• Width of the semi-circular 20 mm (33% of the width of pockets the gusset)
• pouches were made from different materials and had variation in the width of the semicircular un-sealed pockets.
• the total width of the gusset in all cases was 60 mm and shift in the centre-line of the gusset was 8 mm, i.e. one gusset-ear was 38 mm, while the other was 22 mm.
• the pouches were filled with 1 kg high BD detergent powder. Some pouches were filled with 1 kg low BD powder.
• the pouches were subjected to drop-test as in Example-1 above. Details of the pouches and the results are shown in Table-3 below.
• Laminate structure A was 10 PET / 10 PET / 70 Poly (3-ply) Laminate structure B was 12 PET / 70 Poly (2-ply) Laminate structure C was 12 PET / 80 Poly (2-ply) * pouches were filled with 1 kg low BD detergent powder ** pouches were filled with 1 kg high BD detergent powder
• the illustrated examples provide a method for making relatively stronger side-gusseted pouches on a vertical form, fill, seal machine.
• the illustrated examples provide a method for making side-gusseted pouches on a form, fill, seal machine where the rate of failure of pouches in the Bag Drop-Test is relatively lower.

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• 2009
  • 2009-10-30 CN CN2009801496586A patent/CN102245475B/zh not_active Expired - Fee Related
  • 2009-10-30 EP EP09751863A patent/EP2356030B1/en active Active
  • 2009-10-30 BR BRPI0922072-0A patent/BRPI0922072B1/pt not_active IP Right Cessation
  • 2009-10-30 WO PCT/EP2009/064360 patent/WO2010066509A1/en active Application Filing
  • 2009-10-30 ES ES09751863T patent/ES2392682T3/es active Active
  • 2009-12-09 AR ARP090104754A patent/AR074666A1/es active IP Right Grant

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