WO2016120273A1

WO2016120273A1 - Packaging and process for making it

Info

Publication number: WO2016120273A1
Application number: PCT/EP2016/051576
Authority: WO
Inventors: Christopher UNSWORTH; Ruoxin ZHANG
Original assignee: Nestec S.A.
Priority date: 2015-01-27
Filing date: 2016-01-26
Publication date: 2016-08-04

Abstract

There is described a method (and packs made from this method) for making self –standing, reclosable [form, fill and seal] packages that can be opened by hand and can be reclosed by hand without tools at least once after opening for the first time, the method comprising the steps of: i) converting the web into a continuous hollow tube by using a forming tube and sealing one edge of the web to the opposite edge; ii) optionally guiding the web around four sealing fins in the forming tube to form four sealed fins in the web, the sealed fins being radially disposed around the forming tube and consisting of two pairs of fins being located at opposite sides of the tube, where if step (ii) is optional the fins are be pre-formed on the web material prior to the forming tube; iii)using pivoting sealing jaws to seal the tube across the transverse direction of the tube in a direction substantially non orthogonal to the machine direction to form one closed end of an open flexible pouch which also forms one sealed end of the next pouch that will be formed from the web; to create a pouch sealed on three sides; iv) forming a pocket by tucking a top and bottom gusset within the tube within the sealing jaws, preferably step (iv) being performed simultaneously with step (iii), v) optionally where necessary orientating the first pouch on the web such that the open end is held above the closed end of the pouch (preferably the open end is substantially vertically above the closed end); vi) feeding product into the pouch so it falls though the open end; vii) moving the filled pouch and tube attached thereto in the machine direction by an indexed distance vii) pivoting the sealing jaws to be non parallel to their position in step (iii) to seal the tube across the transverse direction of the tube in a direction substantially non orthogonal to the machine direction but non parallel to the direction in step (iii) form the open end of the next pouch and seal the closed end of the pouch viii)separating the filled pouch from the tube to form a filled pack so the adjacent sealed ends of the filled pack are orientated substantially non parallel with respect to each other so the pack has a substantially trapezoidal cross section and is self-standing.

Description

PACKAGING AND PROCESS FOR MAKING IT

The present invention relates to the field of packaging, especially to self-standing, flexible film, form and seal packs and methods of making the same.

Film form and seal packs are prepared on a production line by a continuous method as described or similar to the following. A film web is folded around a suitable former and sealed to itself along a machine direction (MD) edge to form a continuous hollow tube that is fed into a bag making and filling part of the line. The hollow tube periodically is sealed across the transverse direction (TD) and then cut after the seal to create an opening, the seal and opening defining pouches which can receive product. Product is fed through the open end of each pouch which is then sealed and separated from the web to form a closed flexible pack filled with product, also referred to as a pillow pack. GB2271753 describes a film form and seal packaging where inclined transverse seals are formed at a non perpendicular angle across the tube by pressure heat sealing. This produces non rectangular packs having a triangular or trapezoid cross-section. These packs are flat packs and are not self- standing. The pack openings cannot be oriented vertically for ease of filling the product and thus these packs cannot be made using a vertical form fill seal (VFFS) bagging machine.

VFFS machines are advantageous as they can be run at high speeds and as the product is deposited vertically, gravity can be used to fill the pack.

It would also be preferred that a flexible pack is be self-standing as for example this is attractive and practical for the consumer and provides more opportunities for point of sale display.

The term self-standing as used herein denotes that the pack can stand upright either alone or partially supported (for example in a cup holder). Self-standing, sealed flexible plastic packs are known. One such pack is described in US3935993, the content of which are hereby incorporated by reference. Self-standing flexible packs are also available for example under the registered trademark Doypack. However self standing flexible packs have some disadvantages as for example if they are to be filled vertically on a VFFS machine the pack is currently required to have a rectangular shape.

It would be desirable to produce self-standing flexible packs having an attractive non rectangular cross section that can be produced on a VFFS bagging machine with minimal or very inexpensive modifications to the machine and little or no incremental cost in the bag.

Self-standing packs having a non rectangular cross section are aesthetically pleasing and have a differentiated appearance from other self-standing bags with a substantially rectangular shape. Standing bags with non rectangular (e.g. tapered) cross section and are perceived by the consumer as having greater value for money due to the greater size impression per footprint on the shelf. Preferred bags of the invention comprise straight edge sides (i.e. the edges connecting the bottom to the top when the pack is displayed upright), more preferably are substantially trapedozial or triangular in cross section, most preferably are designed so in use the shortest side is at the bottom (load bearing side) of the pack. A trapezoidal shaped stand-up pack has improved shape distinctiveness, standability, is easier for the consumer to hold, is easier to open and can be more readily reclosed compared to a conventional rectangular self standing bags.

It would also be useful to have a feature on the pack that allows the pack to be easily opened without tools, such feature being easy and inexpensive to add on a VFFS line.

WO2006-061654(Amcor) describes an easy opening pack which is rectangular in shape and has a line of weakness created across the full width of a top wall for easier opening by hand. Optionally the line of weakness is located in a gusset at the top of the pack to define an opening such that the removed section remains within the pack to reduce littering. The pack can have gripping fins located on opposite sides of the pack to aid tearing across the line of weakness. Such a pack is not reclosable with a seal to maintain product freshness and can be used once only.

It would also be helpful if the pack can be reclosed to maintain product freshness. This gives the consumer control of the portion size as they can reseal the pack without consuming its whole contents in one setting as product quality will remain acceptable if consumed later.

To form re-closable pillow packs various solutions have been proposed. Extra materials, such as continuous adhesive strips or separate sticky labels have been added to the pack. Consumers must remove and re-apply to strip or label to reclose and reopen the pack which is inconvenient and difficult. In addition applying discontinuous individual labels to each bag slows the speed at which the bagging line can be operated (and hence line capacity). The opening position and mechanism of this reclose solution precludes adding other features to facilitate easy of opening and thus the consumer needs tools (a pair of scissors or knife) to gain access to the bag contents.

US6659645 (Amcor) describes a pouch having overlapping walls which can be resealed by applying the inside film layer to the outside film layer in the region where the films overlap. The film must be made from special materials to enable the overlapping layers of film to seal and extra material is required to form the overlapping wall.

It is an object of the present invention to address some and/or all of the problems described herein preferably in a single pack. Current self-standing flexible packs may have easy opening or reclosable features but generally both features are not provided at the same time.

It would be desirable to provide a flexible self-standing pack which is easy to open by hand without any tools; can be reclosed after opening with full coverage of the opening; can be manufactured on a conventional vertical form fill seal machine (with no or minimal modification); has no (or minor) impact on the packing speed and/or which is simple and inexpensive to manufacture.

Therefore broadly in accordance with the invention there is provide a method of making form, fill and seal packages that are capable of self -standing, can be opened by hand and can be reclosed by hand without tools at least once after opening for the first time, the method comprising the steps of: i) converting the web into a continuous hollow tube by using a forming tube and sealing one edge of the web to the opposite edge; ii) optionally guiding the web around four sealing fins in the forming tube to form four sealed fins in the web, the sealed fins being radially disposed around the forming tube and consisting of two pairs of fins being located at opposite sides of the tube, where if step (ii) is optional the fins are be pre-formed on the web material prior to the forming tube;

iii) using pivoting sealing jaws to seal the tube across the transverse direction of the tube in a direction substantially non orthogonal to the machine direction to form one closed end of an open flexible pouch which also forms one sealed end of the next pouch that will be formed from the web; to create a pouch sealed on three sides;

iv) forming a pocket by tucking a top and bottom gusset within the tube within the sealing jaws, preferably step (iv) being performed simultaneously with step (iii),

v) optionally where necessary orientating the first pouch on the web such that the open end is held above the closed end of the pouch (preferably the open end is substantially vertically above the closed end);

vi) feeding product into the pouch so it falls though the open end;

vii) moving the filled pouch and tube attached thereto in the machine direction by an indexed distance

vii) pivoting the sealing jaws to be non parallel to their position in step (iii) to seal the tube across the transverse direction of the tube in a direction substantially non orthogonal to the machine direction but non parallel to the direction in step (iii) form the open end of the next pouch and seal the closed end of the pouch

viii) separating the filled pouch from the tube to form a filled pack so the adjacent sealed ends of the filled pack are orientated substantially non parallel with respect to each other so the pack has a substantially trapezoidal cross section and is self standing. A further aspect of the invention also provides a filled self-standing trapezoidal pack prepared by a method of the present invention. Preferably the wider edge of the two parallel sides of the trapezoid (nominally top and bottom) defines the top (i.e. openable) end of the pack.

In a further embodiment of the invention the pack of the invention has a line of weakening located across one side the pack substantially the full width of the pack, preferably near the edge of the pack (top edge) that it is desired to be opened. If the line of weakening is sufficiently weakened to allow opening by hand without tools this can be considered as providing easy opening.

Preferably the line of weakening may be applied continuously in the machine direction on the web or tube from which the pack is formed in the method of the present invention. The line of weakening if applied continuously may thus be alternately be located on the short and wider edges of the pack (nominally respectively bottom and top) or one side of the tube or an both (so the pack can be easily opened from either the top or bottom edge. The line of weakening may be a separate tear tape applied onto the surface of the bag. The tear tape may optionally be applied to the pack with reusable adhesive (e.g. low tack PSA) so that when the pack is opened (easy close) the tear tape can be removed from the pack and reattached thereon as a means to reclose the opened end of the pack to prevent the product from exiting the pack. Optionally the pack can be reclosed with a reclose feature that is sufficient resistant to moisture (and optionally air) to reseal the contents therein after initial opening and increase the length of time the product remains fresh. The pivotable sealing jaws used in the present invention may be straight or curved. Preferably the jaws are substantially straight and thus produce a trapezoidal pack. However packs according to the present invention with concave and convex sides may also be formed from curved jaws.

In one preferred alternative the line of weakening is substantially straight and parallel to the base. In another preferred alternative the line of weakening upwardly curved for example is a substantially concave curve where the apex of the curve lies towards the top edge of the pack.

More preferably the line of weakening is a perforated line.

The reclose feature may comprise a tuck in flap and/or fold over top either of which can be secured by an integral adhesive strip covered by a release layer, removed after opening.

Usefully in one embodiment of the method of the invention, the reclose feature may comprise a further line of weakening such that on initial opening an integral flap is created on the side wall which can be tucked under the top edge of the opened pack to reclose the opening of the opened pack.

Usefully in another embodiment of the method of the invention, the reclose feature comprises an separate adhesive part which can be removed and used to close the top of the bag.

Optionally in a yet other embodiment of the method of the invention, the reclose feature may comprises a further line of weakening such integral flap is created on the side wall which can be used to secure a folded over top edge to reclose the opening of the opened pack

Conveniently in still yet other embodiment of the method of the invention, the reclose feature may comprises an adhesive strip across the width of the pack with a removable release layer on the thereon such that after opening of the pack the release layer can be removed to expose the adhesive which can be used to secure a folded over top edge to reclose the opening of the opened pack. More conveniently the adhesive strip and release layer is applied continuously to the tube in the machine direction Broadly in accordance with another aspect of the invention, there is provided a pack obtained and/or obtainable by a method of the invention as described herein. Preferred packs of the present invention can be opened by hand without tools (easy opening), is reclosable, flexible, self-standing and have a substantially trapezoidal cross section. More preferred packs of the invention are easy opening, reclosable, flexible, self standing packs, with trapezoidal cross section as described in the description with reference any of the examples herein.

Other aspects of the invention broadly comprise use of any reclose feature as described herein (e.g. in any embodiment herein) to reclose a pack of the invention as described herein (e.g. in any embodiment herein) after initial opening where the pack contains some product and the reclose feature reseals the product therein sufficiently to improve product freshness compared to an open pack.

Reclosed means the pack is closed to prevent the product exiting the opened pack. Resealed means that the pack is closed sufficiently to act as a barrier to moisture to keep the contents fresher for longer.

Other aspects and preferred features of the present invention are described in the description and/or claims herein.

Embodiments

In one embodiment of the invention packs of the present invention may be prepared by the following method.

An endless tube of packaging film is formed which has fins or pleats thereon. The pack is closed either on one of the corners or by way of a centre seam. In one alternative the film tube is applied to a forming shoulder (former) and four fins are formed corresponding to each corner of the pack by folding and heat sealing the fins on the former. Alternatively heaters can be used to create an endless tube of the packaging film with pleats already formed thereon. The film tube is indexed to a pre-determined length at which point a gusset is applied. Pivotable sealing jaws are also used to close the pack and form a seal which will form the side of the pack when upright.

Preferaby the pivot angle is from 1 degree to 45 degrees from the horizontal, more preferably 2 to 20 degrees, most preferably from 5 to 10 degrees, for example about 6 degrees.

A curved pocket is created by tucking a top and bottom gusset within the tube, which allows the flexible pack sufficient rigidity to stand upright once filled with product. The jaw may also include integral cutting means (e.g. a knife) to separate each pack from the tube.

Typically the sealing jaws are oriented to be perpendicular across the tube in the transverse direction (TD). Thus in a machine where the tube is orientated vertically the sealing jaw would be orientated substantially horizontally. However in the present invention the sealing jaw can rotate or be held at a non perpendicular angle to the TD (i.e. is non-horizontal) which permits production of triangular and/or trapezoidal packs where the side walls are not parallel but tapered. The index length of the tube can also be adjusted (optionally in real time) to further change the shape and size of packs that are produced.

In further embodiment of the present invention provides a package of the invention as prepared herein comprising a top wall and a bottom wall, which are confined by two side walls. The joint seam of the walls are heat sealed. A line of weakness is formed on one of the side walls. The package is opened by griping the top and bottom part of the material of the weakened line by both hands, and pulling upwards and downwards at the same time (for example as shown in Figure 7). The packing material breaks along the line of weakness to form the opening. In another embodiment of the invention the easy opening and reclose feature are as described below. The line of weakness could be a straight or curved line, as shown in the Figures herein.

Optionally where the package of the invention comprises a curved weakened line, the middle part of the line is higher than the gusset and the two ends are at the same level of the gusset. By tucking the lower part of the side wall under the gusset, the package is closed. And the package can be open and reclosed for a few times until consumer has consumed all the product.

Alternatively where the package of the invention comprises a straight weakened line, the line is parallel to the top seam, located between the top and bottom seal, and preferably closer to the top seal, (optionally about 10 to 20mm away from the seam) which leaves plenty of material for consumer to grip. After the package is opened, the top gusset can be folded over to cover the opening.

This reclose feature requires no additional material (unlike pouches reclosed with an adhesive label or strip to reclose). The line of weakness enables consumer to open the package without any tools, the package requires no modification on the machine as suitable the line of weakness (such as perforation or laser weakening) can be added to the film web on the line, or already introduced in the film roll by the film converter at little additional cost. Thus the packing speed will not be compromised. Another still other embodiment of the present invention provides a reclose feature as described below which may be used separately from or in addition to the first reclose embodiment.

A strip of adhesive covered by a strip of release film is applied along the top seal extending the full width of the pack to each side seam. After the pack is opened, consumer can remove the release film and reveal the adhesive (as shown in Figure 9). By folding the pack downwards, the package can be closed and is held by the adhesive (as shown in Figure 10) to maintain a pack seal. Preferably the adhesive strip is sufficiently tacky allow the package to be reclosed for a few times until consumer has consumed all the product. Optionally the reclosing adhesive may be applied on the machine in a continuous manner in the machine direction and if the packs are also orientated such that the opening lies along the machine direction) the complete width of the pack is provided with adhesive, which provides improved protection when reclosed. The adhesive and release strip may be applied on the machine by an adhesive strip applicator in a continuous manner, which will not affect the machine speed.

These embodiments of the invention provides self standing packs which are both easy to open by pulling the pack by hand and do not require any tools. These packs can be re-closable at the same time and can be manufactured on a vertical form fill seal machine with limited modification other than for example pivotable sealing jaws and/or the special forming tube that forms the four fins. The material used for the packs of the invention may preferably comprise monolayer film or multilayer laminated film, which could be heat sealed to itself (innerlayer-to-innerlayer and outerlayer-to-outerlayer). Depending on requirements, polyethylene (PE) and/or polypropylene (PP) could be used. For laminated film, the inner layer film could be PE or non-oriented PP film, and the outer layer film could be oriented PP film. Metalized film can be used to achieve required barrier properties. Any other conventional packaging materials may also be used.

The line of weakening used in the present invention could be a perforated line, where the film is penetrated through all or some of its thickness. The line of weakening could also be realized by locally thinning the thickness of the film, which will retain the film barrier property. The line of weakness could be formed by laser or mechanical means (e.g. cutting).

The shape of the pack is substantially trapezoid or other similar shape, but is preferably trapezoidal. Further aspects, preferences and embodiments of the invention are described in the claims herein.

The invention will now be illustrated by the following non limiting Figures 1 to 7 in show examples of the present invention, in which:

Figures 1 to 3 show a trapezoid self-standing flexible pack of the invention as described in Example 1 herein having a curved weakened line as the easy opening feature and an integral tuck in flap as the reclose feature. Figure 1 shows the filled unopened pack, Figure 2 shows the pack opened for the first time to expose the tuck in flap and Figure 3 shows the reclosed pack with the flap tucked under the top gusset.

Figures 4 to 6 show a trapezoid self-standing flexible pack bag of the invention as described in Example 2 herein having a straight weakened line as the easy opening feature and fold over top as the reclose feature. Figure 4 shows the filled unopened pack, Figure 5 shows the pack opened for the first time to expose the fold over feature and Figure 6 shows the reclosed pack with the top folded over.

Figures 7 to 10 show a self-standing flexible pack bag of the invention as described in Example 3 having a weakened straight line as the easy opening feature and integral internal adhesive strip to secure a folded over top as the reclose feature. Figure 7 shows the filled unopened pack with directions on how it can be readily opened by hand, Figure 8 shows the pack opened for the first time to access the contents; Figure 9 shows how to remove the protective film strip to expose the adhesive on the top of the pack; and Figure 10 shows the reclosed pack with the top folded over secured by the exposed adhesive strip.

The figures are described in more detail below with reference to the Examples 1 to 3.

Example 1

A tuck-in pack was prepared by the method described herein in the form shown in Figure 1.

Figure 1 shows a curved weakened line on one of the side walls (indicated by the dotted line) and located between the top and bottom wall. The consumer opens the bag by gripping the top and bottom sealing area of the side wall and pulling towards the arrow direction which opens the bag along the weakening line. Figure 2 shows the open bag after the top and bottom parts of the side wall have be pulled apart to create a large opening through which the product can be dispensed. Figure 3 show the opened bag in which the bottom part of the side wall has been tucked under the top gusset to re-close the package. Example 2

A fold over pack was prepared by the method described herein to produce a pack as shown in Figure 4.

Figures 4 and 5 correspond to similar features as shown respectively in Figures 1 and 2 for the 'tuck in' embodiment of the present invention (Figure 4 showing the bag before opening and Figure 5 showing the bag after opening for the first time). Figure 6 shows the previously opened bag where the top gusset has been folded over to close the opening with the folded material so the package has been reclosed. Example 3

An adhesively re-closable pack was prepared by the method described herein in the form shown in Figure 7.

Figure 7 shows the easy opening featurein which the side wall of the pouch has a straight perforated across the width of the pack parallel to the plane of the base of the pack to form a line of weakening. The perforation line is located between the top and bottom wall, and closer to the top wall. To open the pack the consumer grips two sections of the same side wall located either side of the perforated line (one at the top one and at the bottom side) and applies force in the direction of the two arrows as shown in Figure 7. The pack will open along the perforated line. Figure 8 shows once the bag is open there is a large opening in the side wall through which product can be dispensed. Figures 9 and 10 show the reclose mechanism. On the top edge of the pack, there is a line of adhesive covered by a release film. The consumer peels off the release film to reveal the adhesive (as shown in Figure 9) and then folds over the top part of the pack with the exposed adhesive thereon and presses it against the side wall to close the package (as shown in Figure 10).

Claims

1 A method of making form, fill and seal packages that are capable of self -standing, can be opened by hand and can be reclosed by hand without tools at least once after opening for the first time, the method comprising the steps of:

i) converting the web into a continuous hollow tube by using a forming tube and sealing one edge of the web to the opposite edge;

ii) optionally guiding the web around four sealing fins in the forming tube to form four sealed fins in the web, the sealed fins being radially disposed around the forming tube and consisting of two pairs of fins being located at opposite sides of the tube, where if step (ii) is optional the fins are be pre-formed on the web material prior to the forming tube;

vi) feeding product into the pouch so it falls though the open end;

viii) separating the filled pouch from the tube to form a filled pack so the adjacent sealed ends of the filled pack are orientated substantially non parallel with respect to each other so the pack has a substantially trapezoidal cross section and is self standing.

2. A method of the preceding claim, which comprises a step where at least one line of weakening is introduced into the trapezoidal pack, where the or each line of weakening is located across substantially the full width of the pack and is sufficiently weakened to allow opening by hand without tools.

3. A method as claimed in claim 2, in which the line of weakening is substantially straight and parallel to the parallel sides of the trapezoidal pack.

4. A method as claimed in claim 2, in which the line of weakening is a substantially concave curve where the apex of the curve lies towards the top edge of the pack.

5. A method as claimed in any one of claims 2 to 4, in which the line of weakening is a perforated line.

6. A method as claimed in any one of claims 2 to 5, in which the reclose feature comprises a further line of weakening such that on initial opening an integral flap is created on the side wall which can be tucked under the top edge of the opened pack to reclose the opening of the opened pack.

7. A method as claimed in any one of claims 2 to 6, in which the reclose feature comprises a further line of weakening such integral flap is created on the side wall which can be used to secure a folded over top edge to reclose the opening of the opened pack

8. A method as claimed in any one of claims 2 to 7, in which the reclose feature comprises an adhesive strip across the width of the pack with a removable release layer on the thereon such that after opening of the pack the release layer can be removed to expose the adhesive which can be used to secure a folded over top edge to reclose the opening of the opened pack.

9. A method as claimed in claim 8 in which the adhesive strip and release layer is applied continuously to the tube in the machine direction

10. A pack obtained and/or obtainable by a method according to any preceding claim.

11. A pack as claimed in claim 12, which is can be opened by hand without tools (easy opening), is reclosable, flexible, self-standing and has a substantially trapezoidal cross section

12. An easy opening, reclosable, flexible, self standing pack, with trapezoidal cross section as described in the description with reference any of the examples therein.

13. Use of a reclose feature as described in any of method claims 6 to 9 to reclose after initial opening a pack as claimed in any of claim 10 to 11 where the pack contains some product and the reclose feature reseals the product therein sufficiently to improve product freshness compared to an open pack.