WO2016187176A1

WO2016187176A1 - Package with flexible spout

Info

Publication number: WO2016187176A1
Application number: PCT/US2016/032821
Authority: WO
Inventors: Stephen F. Compton; Joe M. Bowen; Robert A. Odabashian; Jason D. SCROGGS; Timothy Gary CAUDLE; Charles KANNANKERLL
Original assignee: Cryovac, Inc.
Priority date: 2015-05-21
Filing date: 2016-05-17
Publication date: 2016-11-24
Also published as: AR104724A1

Abstract

A package with a flexible spout includes a pouch including a first and second panel, a first and second end, a first and second side edge, a pouch interior, a first and second transverse seal, a skirt extending from the first transverse seal to the first end of the pouch, a longitudinal seal extending from the first transverse seal to the second transverse seal, and a flexible spout disposed within the skirt, and attached to the first transverse seal, the flexible spout comprising an interior channel in communication with the pouch interior; and a product disposed in the pouch. A method of making a package with a flexible spout in a vertical form/fill/seal process, and a method of making a plurality of flexible spouts, are also disclosed.

Description

PACKAGE WITH FLEXIBLE SPOUT

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of and priority from U.S. Provisional Application No. 62/164,793 filed May 21 , 2015. FIELD OF INVENTION

This invention relates to a package with a flexible spout, a method of making a package with a flexible spout, and a method of making a plurality of flexible spouts.

BACKGROUND

Vertical form/fill/seal (VFFS) packaging systems have proven to be very useful in packaging a wide variety of food and non-food pumpable and/or flowable products. Many vertical form/fill/seal systems are commercially available from manufacturers or suppliers such as Hayssen, lllipak, Kartridge Pak, DuPont and Fresco.

One example of such systems is the ONPACK™ flowable food packaging system marketed by Cryovac/Sealed Air Corporation. The VFFS process is known to those of skill in the art, and described for example in U.S. Patent Nos. 4,506,494 (Shimoyama et al.), 4,589,247 (Tsuruta et al), 4,656,818 (Shimoyama et al.),

4,768,41 1 (Su), 4,808,010 (Vogan), and 5,467,581 (Everette), all incorporated herein by reference in their entirety. Typically in such a process, lay-flat thermoplastic film is advanced over a forming device to form a tube, a longitudinal (vertical) fin or lap seal is made, and a bottom end seal is made by transversely sealing across the tube with heated seal bars. A liquid, flowable, and/or pumpable product, such as a liquid, semiliquid, or paste, with or without particulates therein, is introduced through a central, vertical fill tube to the formed tubular film. Squeeze rollers spaced apart and above the bottom end seal squeeze the filled tube and pinch the walls of the flattened tube together. When a length of tubing of the desired height of the bag has been fed through the squeeze rollers a heat seal is made transversely across the flattened tubing by heat seal bars which clamp and seal the film of the tube therebetween. After the seal bars have been withdrawn the film moves downwardly to be contacted by cooled clamping and severing bars which clamp the film therebetween and are provided with a cutting knife to sever the sealed film at about the midpoint of the seal so that approximately half of the seal will be on the upper part of a tube and the other half on the lower. When the sealing and severing operation is complete, the squeeze rollers are separated to allow a new charge of product to enter the flattened tube after which the aforementioned described process is repeated thus continuously producing vertical form/fill/seal pouches which have a bottom end and top end heat seal closure.

The process can be a two-stage process where the creation of a transverse heat seal occurs at one stage in the process, and then, downstream of the first stage, a separate pair of cooling/clamping means contact the just-formed transverse heat seal to cool and thus strengthen the seal. In some VFFS processes, an upper transverse seal of a first pouch, and the lower transverse seal of a following pouch, are made, and the pouches cut and thereby separated between two portions of the transverse seals, without the need for a separate step to clamp, cool, and cut the seals. A commercial example of an apparatus embodying this more simplified process is the ONPACK™ 2002 VFFS packaging machine marketed by

Cryovac/Sealed Air Corporation.

In some applications, e.g. in a food outlet such as a restaurant, squeeze bottles are filled with a food product from packages made on a VFFS system.

Typically, a worker will cut off a corner of the package at a transverse seal, and attempt to pour some or all of the contents of the package into the bottle through the bottle opening. Often the opening is missed, and some product is spilled onto the upper surface of the bottle, the surrounding table, or counter top.

Another problem is that if the package is not completely emptied, and it is desired to retain the remainder of the product for later use, preventing leakage is often an issue. A clip or closure of some sort is required to close the package.

These temporary closures can include "chip clips", paper clips, or stretch wrap;

packages so wrapped frequently leak as they are stored on the cooler or ambient storage shelf.

SUMMARY

In a first aspect, a package with a flexible spout comprises: a pouch

comprising a first and second panel, a first and second end, a first and second side edge, a pouch interior, a first transverse seal, a second transverse seal, a skirt extending from the first transverse seal to the first end of the pouch, a longitudinal seal extending from the first transverse seal to the second transverse seal, and a flexible spout disposed within the skirt, and attached to the first transverse seal, the flexible spout comprising an interior channel in communication with the pouch interior; and a product disposed in the pouch.

In a second aspect, a method of making a package with a flexible spout in a vertical form/fill/seal process comprises: providing a lay-flat film on a first roll;

providing a plurality of flexible spouts on a second roll of film; advancing a flexible spout from the second roll of film; attaching the flexible spout to the lay-flat film; separating the flexible spout from the second roll of film; advancing the lay-flat film with the attached flexible spout over a forming device to convert the lay-flat film to a folded film; making a longitudinal seal in the folded film; transversely sealing the folded film to form a first pouch having a first transverse seal; putting a product in the first pouch; advancing the folded film, with the first pouch, downward a

predetermined distance; transversely sealing the folded film to form a first transverse seal in the folded film, while simultaneously forming a second transverse seal across an upper end of the first pouch; and transversely cutting the folded film to separate the first pouch from the folded film to make a package, the package comprising a pouch comprising a first and second panel, a first and second end, a first and second side edge, a pouch interior, a first transverse seal, a second transverse seal, a skirt extending from the first transverse seal to the first end of the pouch, a longitudinal seal extending from the first transverse seal to the second transverse seal, and a flexible spout disposed within the skirt, and attached to the first transverse seal, the flexible spout comprising an interior channel in

communication with the pouch interior.

In a third aspect, a method of making a plurality of flexible spouts comprises providing a lay-flat printed film having a plurality of printed regions, the printed regions substantially identical to one another and spaced apart at fixed intervals on the film; advancing the lay-flat printed film to and across a first forming shoe to centerfold the film to make a folded, printed film having a first folded longitudinal edge; transversely sealing the folded, printed film at marginal portions of each of the plurality of printed regions to define a plurality of spouts each comprising an interior channel; advancing the folded, printed film to and across a second forming shoe such that the film is longitudinally folded over itself, along an axis parallel to and spaced apart from the first folded longitudinal edge, to make a folded, printed film having a second folded longitudinal edge; and applying a crimp seal to each of the plurality of spouts, the crimp seals disposed parallel to and between the first and second folded longitudinal edges. BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by reference to the following drawing figures, encompassing different views of various embodiments of the invention, wherein:

FIG. 1 is a perspective view of a package with a flexible spout;

FIG. 2 is a plan view of a portion of a package with a flexible spout in a folded position;

FIG. 3 is a plan view of a portion of a package with a flexible spout in an unfolded position;

FIG. 4 is a plan view of a portion of a package with a flexible spout in a position to dispense product;

FIG. 5 is a schematic view of an apparatus and process for making a flexible spout;

FIG. 6 is a view of a centerfolded web with a printed region and printed indicator;

FIG. 7 is a view of a centerfolded web of FIG. 6, with lateral seals installed on each side of the printed region;

FIG. 8 is a view of a centerfolded web of FIG. 7, with a folded section;

FIG. 9 is a view of a centerfolded web of FIG. 8, with a crimp seal;

FIG. 10 is an elevational view of a prior art VFFS process and apparatus for making a package; and

FIG. 1 1 is a schematic elevational view of an apparatus and method of positioning and attaching a plurality of flexible spouts to a tubular film in a vertical form/fill/seal system.

DETAILED DESCRIPTION

Drawings herein are not necessarily to scale, and certain features of the invention may be graphically exaggerated for clarity. As used in the specification and in the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly indicates otherwise. For example, reference to "a film" includes a plurality of such films.

"Film" is used herein to mean a thermoplastic film, laminate, or web, either multilayer or monolayer, that may be used in connection with the present invention. Film can be of any suitable thickness, e.g. between 0.1 and 30 mils.

"Lap seal" is used herein to mean a seal made by sealing an inside surface of a film to an outside surface of the same film.

"Longitudinal seal" herein refers to a fin seal or lap seal.

"Olefinic" and the like herein refer to a polymer or copolymer derived at least in part from an olefinic monomer.

"Polymer" and the like herein mean a homopolymer, but also a copolymer thereof, including terpolymer, tetrapolymer, block copolymer, etc.

"Pouch" herein means a pouch or bag.

"Seal" herein means a bond between two thermoplastic surfaces, e.g. as produced by heat sealing, radio frequency (RF) sealing, ultrasonic sealing, or the like. A "crimp" seal is one in which a spout is folded over to create a crease, using a seal bar or other device applying heat and pressure, such that the spout remains in the creased or folded condition during package production and distribution, but can be thereafter be easily unfolded, at the crease, when the package is opened and product is dispensed from the pouch.

"Sealant" is a polymeric material or blend of materials, such as olefinic polymer or copolymer such as an ethylenic polymer or copolymer that can form a surface of the film, and form a bond between two thermoplastic surfaces.

"Thermoplastic" herein includes plastic materials that when heated to a softening or melting point may be reshaped without significant thermal degradation (burning). Thermoplastic includes both materials that are not crosslinked, and that are crosslinked by chemical or radiation means.

All compositional percentages used herein are presented on a "by weight" basis, unless designated otherwise.

1 . Package With A Flexible Spout

Package 8 comprises a product 38, such as a food or non-food flowable product, disposed in pouch 10. In one embodiment, and referring to FIG. 1 , package 8 includes a pouch 10 having a first panel 11 , a second panel 13 disposed on the opposite side of pouch 10 from first panel 11 , a first transverse seal 12, a second transverse seal 14, an optional third transverse seal 15, and a longitudinal seal 16. Longitudinal seal 16 is shown as a lap seal, but can alternatively comprise a fin seal.

Pouch 10 also includes a first end 26, a second end 27, a first side edge 18, and a second side edge 20. As shown, first and second side edges 18, 20 will each typically comprise a fold, reflecting the tubular film from which the package can be made in a VFFS process and apparatus. Alternatively, first and second side edges 18, 20 can comprise lateral seals.

Pouch 10 additionally includes a skirt 21 comprising a first skirt panel 29 and a second skirt panel (not shown), congruent with the first skirt panel 29, that sandwich a flexible spout 64. Side edges of skirt 21 will in one embodiment, like first and second side edges 18, 20, each typically comprise a fold, reflecting the tubular film from which the package can be made in a VFFS process and apparatus. Skirt

21 extends from the first transverse seal 12 to the first end 26 of package 8. In one embodiment, third transverse seal 15 is present, and the first and third transverse seals 12, 15 define skirt 21. In one embodiment, skirt 21 includes a perforated strip

22 with a line of perforations 23. Spout 64 is attached to first transverse seal 12, and includes an interior channel 30 (see FIG. 3) in communication with the pouch interior.

Channel 30 is defined by an open end 25 within the interior of pouch 10, spout end 28 that before opening is in a sealed condition, and marginal lateral seals 24. Spout 64 also optionally includes a tear notch 34, and a crimp seal 62 (see FIGs. 2 and 5).

Films for use in the present invention, for construction of the pouch and spout, can comprise a thermoplastic material of any suitable composition, including those having as at least one component olefinic material such as ethylene polymer or copolymer, e.g. polyethylene or ethylene/alpha olefin copolymer; and/or polyamide (nylon); and including films typically used in VFFS packaging apparatus and processes. The films can be monolayer or multilayer in construction; can have any suitable thickness; and can be made by any suitable process, including coextrusion, extrusion coating, extrusion lamination, and conventional lamination using

polyurethane or other adhesives. Extrusion can be done in annular or flat dies. The extrudate can be hot blown or cast, and optionally solid-state oriented as desired. Chemical or electronic crosslinking of one or more layers of the film can be done. The film can be advanced through the apparatus and processes disclosed herein by suitable motive means (not shown, and well known in the art, such as a motor).

Examples of films useful in the invention, for construction of the pouch, include those with high oxygen or low oxygen barrier properties.

A representative multilayer film structure of some high oxygen barrier embodiments of the invention is shown in Table 1 :

TABLE 1

Multilayer Film Structure having High Oxygen Barrier Properties

Core layer D of the above film structure can comprise any suitable EVOH material, and can be blended in any proportion with other polymeric materials or organic or inorganic additives as desired.

Intermediate layers C and E each comprise a polyamide, such as a

semicrystalline polyamide such as nylon 6. In one embodiment, layers C and E can each comprise a blend of an amorphous polyamide and a semicrystalline polyamide.

In such an embodiment, the amorphous polyamide can comprise any suitable percent of the overall polyamide blend.

The semicrystalline polyamide can be any suitable polyamide, including nylon 6.

Tie layers B and F can comprise any suitable polymeric adhesive that functions to bond two layers together. Materials that can be used in embodiments of the present invention include anhydride grafted ethylene/alpha olefin copolymer.

Layer A will typically function as a sealant layer of the film. This layer can comprise one or more semicrystalline olefinic polymers. Polymers that may be used for the layer A include ethylene polymer or copolymer, ethylene/alpha olefin copolymer, ethylene/vinyl acetate copolymer, ionomer resin, ethylene/ acrylic or methacrylic acid copolymer, ethylene/ acrylate or methacrylate copolymer, etc., or blends of any of these materials.

Layer G can comprise a material as defined herein for layer A. Alternatively, layer G can comprise an amorphous polymer e.g. amorphous cyclic olefin copolymer, e.g. ethylene/norbornene copolymer (ENB). In one embodiment, layer G can comprise one outermost layer of the film such that when formed into a pouch, layer G comprises the layer furthest from the packaged product; and an olefinic polymer or copolymer such as ethylene/alpha olefin copolymer (EAO) can comprise the inner layer A of the film, such that when formed into a pouch, the EAO comprises the layer closest to the packaged product. In this embodiment, the film can be lap sealed such that layer G is sealed to the EAO inner layer A.

A representative multilayer film structure of some low oxygen barrier embodiments of the invention is shown in Table 2:

TABLE 2

Multilayer Film Structure having Low Oxygen Barrier Properties

The materials for film structures in accordance with table 2 can be as disclosed herein for table 1 .

Pouches made from the film of the present invention can be fin sealed or lap sealed depending on the desired configuration of the finished pouch, the equipment used, and the composition of the two outer layers.

Additional materials that can be incorporated into one or both of the outer layers of the film, and in other layers of the film as appropriate, include antiblock agents, slip agents, antifog agents, fillers, pigments, dyestuffs, antioxidants, stabilizers, processing aids, plasticizers, fire retardants, UV absorbers, etc.

Additional film layers can be included either within the film structure, or adhered to an outer layer thereof.

In general, the film can have any total thickness desired, and each layer can have any thickness desired, so long as the film provides the desired properties for the particular packaging operation in which the film is used. Typical total thicknesses are from 0.5 mils to 15 mils, such as 1 mil to 12 mils, such as 2 mils to 10 mils, 3 mils to 8 mils, and 4 mils to 6 mils.

2. Method Of Making A Package With A Flexible Spout

FIG. 10 schematically illustrates a VFFS apparatus 122 that can be used in the process of making a package in accordance with the present invention. VFFS packaging systems are generally well known to those of skill in the art, and described for example in U.S. Patent Nos. 4,589,247 (Tsuruta et al), 4,656,818 (Shi- moyama et al.), 4,768,41 1 (Su), 4,808,010 (Vogan), 5,467,581 (Everette), 6,244,747 (Caudle), and US Patent Application Publication No. US 2006/01 1 1224 (Caudle), all incorporated herein by reference in their entirety.

Apparatus 122 utilizes a lay-flat film 141. Product 38 is manually or mechanically supplied to the upper end portion of forming tube 144 via any conventional means, such as a funnel or feed tube.

The product can be any food or non-food product, liquid, semi-liquid, or paste, e.g. flowable or pumpable high acid or low acid foods, such as tomato products, milk or dairy products, medical products, or the like.

Packages are formed in a lower portion of apparatus 122. Film 141 from which the packages are formed is advanced from a feed roller (not shown), over forming tube 144 (sometimes known as a "sailor's collar" or "forming collar") and is provided with a longitudinal lap seal 16 by longitudinal heat sealing device 146, resulting in the formation of a vertically-oriented folded film in the form of a tube 148.

In one embodiment of the invention (see FIG. 1 ), transverse heat seal bars 145 operate to close and seal horizontally across the lower end of vertically-sealed tube 148, to form a pouch 10 having a first transverse seal 12. Pouch 10 is thereafter filled with product 38.

Film drive belts 152, powered and directed by rollers, as illustrated, or by a suitable alternative motive device, advance tube 148 and pouch 10 downward a predetermined distance. Squeeze rollers (not shown) typically close on the moving film in order to meter the amount of product in the pouch and to void/clean the area where a transverse seal is to be applied. In accordance with the invention, after this step, seal bars 145 again close and seal horizontally across the lower end of vertically-sealed tube 148 to form a first transverse seal 12, while simultaneously sealing horizontally across upper end of sealed pouch 10 to form a second transverse seal 14.

In an alternative embodiment, a third transverse seal 15 (see FIG. 1 ) can be included in the finished package 8. This can be done by configuring the transverse seal bars so that while the first transverse seal is being made, an additional, third transverse seal is made. This seal is spaced apart, typically vertically, from the first transverse seal. The first and third transverse seals define between them skirt 21. In one embodiment, to facilitate a user's removal of third transverse seal 15 from the end of the package, a line of perforations 23 can be imparted to the tube 148, at any suitable location between first and third seals 12, 15 by any suitable perforating device known in the art.

In any of these embodiments, the next pouch 150, thereabove, is then filled with a metered quantity of product, and advanced downwardly, and the packaging cycle is repeated.

It is conventional to incorporate with seal bars 145 a cut-off knife (not shown) which operates to sever a lower sealed pouch 10 from the bottom of upstream pouch 150

Lay-flat film 141 of FIG. 10 will in operation travel typically vertically downward from the forming tube 144.

Spout 64 is present in each finished package 8. Each spout 64 can be attached to lay-flat film 141 using in one embodiment an apparatus as depicted in FIG. 1 1 . In one embodiment, to attach each flexible spout 64 to each respective pouch 10, in production, packaging film 141 is fed through the VFFS apparatus 122 from a roll, but in addition spouts 64 are also fed into the apparatus 122 but from a separate roll 162. With each machine cycle, a spout 64 is indexed from the spout roll 162, initially attached (via e.g. partial seals along the sides of each spout 64) to lay flat film 141 and then separated (for example by cutting) from the spout roll 162. The film index cycle is then used to index film 141 (with the attached spouts 64) through apparatus 141. An eye spot or other suitable mechanism can be used on film 141 to accurately index spouts 64 though apparatus 141. This helps maintain alignment of the attached spouts 64 as they enter the area of apparatus 141 where transverse seals are made. Spouts 64 are attached at pre-determined intervals to the lay-flat film 141 , the gap between sequential spouts pre-determined based on the desired length of each pouch 10 made in the downstream VFFS apparatus, and the ultimate desired length of each final package 8.

Once a given spout 64 is indexed into the area of apparatus 141 where transverse seals are made (multiple indexed to arrive at this position), transverse seal bars 145 completely seal the spout 64 in place. As shown in the embodiment of FIG. 1 1 , this process includes a roll 162 having a ribbon of spouts (not shown) that advances past a cantilevered dancer bar 164, splicing pad 166, film feed assist nip rollers 168, code dater adjustable roller 170 (in embodiments where code dating the package is desired), eye sensor adjustable roller 172 (in embodiments where eye spots are utilized), and a film tensioning roller 174. Each spout 64 is initially attached to lay flat film 141 with a spout attachment device 176.

Transverse seal bars 145 seal each given spout 64 to the pouch while producing first transverse seal 12.

3. Method of Making a Plurality of Flexible Spouts

Referring to FIGs. 5 through 9, a plurality of flexible spouts can be made using a spout making apparatus 40. A lay-flat film 42 has on at least one surface thereof a repeating pattern of printed regions 44. Each printed region 44 provides a portion of film 42 that will not seal to itself during normal heat sealing processes. Thus, when each spout 64 is made and ultimately installed in a respective pouch 10, by heat sealing the spout to the interior of the pouch at a transverse seal, the interior channel 30 (see FIGs. 3 and 4) of spout 64 remains unsealed to preserve the utility of the spout. "Printed" herein means the application of an ink or any other suitable substance (food-grade substance for applications involving food as product 38) and/or any surface treatment, that will as a result inhibit the film 42 sealing to itself so as to preserve the interior channel 30 in the finished pouch 10 with spout 64 installed therein. A printed indicator 46 can optionally be selectively printed on film 42 in association with each printed region 44. Each printed indicator 46 carries a visual colored print, dye, or pigment that, in the finished spout 64, highlights the spout 64 in package 8 for ease of use in locating the spout, and ensuring that it is extended properly for dispensing product. The indicator may be less important and

unnecessary with trained personnel, e.g. in the environment of a trained work force in a restaurant environment. Alternatively, in one embodiment, the printed indicator can be a clear coating, although this approach may not offer the visual advantage discussed above. Printing or coating of the printed regions 44 and optional printed indicators 46 can be done in and during the overall process as shown in FIG. 5.

Alternatively, film 42 can be pre-printed at another location or in a separate process, by any suitable printing process. Although printed regions 44 are shown illustratively as a "T" shape, any suitable shape can be used provided that the spouts 64 function as described herein. The printed lay-flat film 42 is advanced to and across a first folding shoe 48 so as to centerfold the film to make a folded, printed film 50 having a first longitudinal edge fold 51. Sealing platen 52 is used to produce lateral seals 54a, b at marginal portions of each of the plurality of printed regions to define an interior channel 30 for each respective printed region. The spout proximal end 53 for each spout 64 is open. It is this segment of each spout that provides an opening 25 (see FIGs. 2 and 3) into the interior of a respective pouch 10. Although the drawings, especially FIGs. 8 and 9, illustrate in one embodiment a gap or space between the lateral seals 54a, b and the printed region 44 of each spout, those skilled in the art will appreciate that in alternative embodiments, the space between lateral seals 54a, b and printed region 44 of each spout can be minimal or entirely absent. The folded, printed film 50 is advanced to and across a second folding shoe 56 such that the film is longitudinally folded over itself, along an axis parallel to and spaced apart from the first longitudinal edge fold 51 , to make a folded, printed film 58 having a second longitudinal edge fold 59. Crimp seals 62 are then applied to each spout, using a crimp sealer 60, the crimp seals disposed parallel to and between the first and second folded longitudinal edges. Although the drawings, and in particular FIGs. 5 and 9, illustrate in one embodiment a space between the second longitudinal edge fold 59 and crimp seals 62 for each spout, those skilled in the art will appreciate that in alternative embodiments, the space between the second longitudinal edge fold 59 and crimp seals 62 of each spout can be minimal or entirely absent.

4. Method of Operation

To use the package of the present invention, if third transverse seal 15 and perforated strip 22 are present in the package, strip 22 is manually removed from package 8. If desired, perforations 23 can be visually highlighted by a distinctive color or printed indicia to make it easier to locate the perforations. Optionally, a tear notch or other tear initiation feature can be included in skirt 21 to facilitate removal of strip 22. This action removes third seal 15. Spout 64 is then grasped, and unfolded along crimp seal 62, bringing the distal end 28 of spout 64 out beyond the end 35 of that portion of skirt 21 that remains after removal of strip 22 (see FIG. 3). The tip of spout 64 is torn off at tear notch 34 (see FIG. 4), removing the end seal at the distal end 28 of spout 64. Spout 64 is directed toward the opening of the container into which, or product onto which, product 38 is to be dispensed. Manual pressure is applied to package 8 simultaneously while the spout 64 is being pulled, and product flows from the interior of the package, through opening 25 and interior channel 30, and out of the spout 64. After dispensing is completed, spout 64 can be pressed to remove residual product, and then refolded along crimp seal 62 and tucked between the two walls of skirt 21.

The above descriptions are those of embodiments of the invention. All parts and percentages are by weight, unless otherwise indicated or well understood in the art. Any reference to an item in the disclosure or to an element in the claim in the singular using the articles "a," "an," "the," or "said" is not to be construed as limiting the item or element to the singular unless expressly so stated.

With reference to the drawings, the flow of materials is in the direction of the arrows.

A package according to the invention can optionally carry printed indicia, which can be decorative or informational in nature. Decorative printed indicia can include a logo, a trademark, product information, etc. with text and/or graphics.

Although flexible spout 64 is disclosed in the drawings as longitudinally centered in package 8, it can in alternative embodiments be located in a

longitudinally uncentered location in the package, for example near or at one side edge of the package.

In some embodiments, the line of perforations 23 if present, or tear notch 34, can be highlighted with color or other indicia to make it easier for the user to open the package.

In one embodiment, the portion of spout 64 at the open end 25 within the interior of pouch 10 is sealed or otherwise attached to the interior surface of pouch 10, i.e. to the interior surface of one or both side panels 11 , 13. This configuration helps to avoid the possibility of the open end 25 being obstructed by outside edges of the spout folding over at the interior end of the spout.

Spout 64 can have any suitable shape. For example, spout 64 can be rectangular or curved.

First end 26 of pouch 10 and package 8 is typically defined by the outer longitudinal extremity of skirt 21 ; or if third transverse seal 15 is present, by the outer longitudinal extremity of third transverse seal 15. Second end 27 of pouch 10 and package 8 is typically defined by the outer longitudinal extremity of second transverse seal 14. In some embodiments, some unsealed pouch material can be present between the outer longitudinal extremity of a transverse seal, and the actual respective longitudinal end of the pouch or package. Such embodiments are also contemplated within the scope of the present invention.

Statement of Embodiments of the Invention

The present application is directed in various embodiments to the subject matter described in the following paragraphs. These are optional embodiments of any of the first (package), second (method of making a package), and third (method of making a plurality of flexible spouts) aspects of the invention as described hereinabove in the Summary of the Invention. For each aspect, these features be incorporated alone or in any suitable combination of these features:

a) the longitudinal seal comprises a fin seal.

b) the longitudinal seal comprises a lap seal.

c) the package has substantially no headspace.

d) the transverse seals are ribbed seals.

e) the first side edge comprises a fold.

f) the second side edge comprises a fold.

g) the first side edge comprises a seal.

h) the second side edge comprises a seal.

i) the skirt comprises a first wall and a second wall, each wall laterally coextensive with respective first and second panels.

j) the flexible spout comprises a first portion disposed between the first transverse seal and the first end of the pouch, and a second portion extending from the first transverse seal into the interior of the pouch.

k) the flexible spout is folded over within the skirt, and adapted when in use to unfold and dispense product from the interior of the pouch.

I) the interior channel is selectively printed such that when the first transverse seal is made, the interior channel remains unsealed to itself in the area of the first transverse seal.

m) the flexible spout is configured to extend, when in use, beyond the first end of the pouch. n) the flexible spout comprises lateral edges spaced from respective first and second side edges of the skirt.

o) the flexible spout is substantially rectangular, with its longitudinal axis parallel to the longitudinal axis of the pouch.

p) the package comprises a line of perforations in the skirt, disposed near and substantially parallel to the first end of the pouch.

q) the flexible spout comprises a tear notch disposed near the distal end of the flexible spout.

r) the flexible spout comprises an end seal at the distal end thereof, an opening at the proximal end thereof, and lateral seals that define the interior channel. s) the package comprises a third transverse seal, spaced apart from the first transverse seal, the first and third transverse seals defining the skirt.

t) the package comprises a third transverse seal, spaced apart from the first transverse seal, and disposed at the end of the package, the first and third transverse seals defining the skirt.

u) the flexible spout comprises a printed indicator that provides, in a package in which the spout is disposed, a visual indication of the location of the spout.

v) the portion of the flexible spout at the open end within the interior of the pouch is sealed or otherwise attached to the interior surface of the pouch.

w) the portion of the flexible spout at the open end within the interior of the pouch is sealed or otherwise attached to the interior surface of one or both side panels.

Claims

What is claimed is:

1 . A package with a flexible spout comprising:

a) a pouch comprising

i) a first and second panel,

ii) a first and second end,

iii) a first and second side edge,

iv) a pouch interior,

v) a first transverse seal,

vi) a second transverse seal,

vii) a skirt extending from the first transverse seal to the first end of the pouch,

viii) a longitudinal seal extending from the first transverse seal to the second transverse seal, and

ix) a flexible spout disposed within the skirt, and attached to the first transverse seal, the flexible spout comprising an interior channel in communication with the pouch interior; and b) a product disposed in the pouch.

2. The package of claim 1 , wherein the package further comprises a third transverse seal disposed at the first end of the pouch.

3. The package of one of claims 1 or 2, further comprising a line of perforations in the skirt.

4. The package of claim 3, wherein the line of perforations is disposed near and substantially parallel to the first end of the pouch.

5. The package of claim 1 , wherein the first and second side edges comprise a first and second fold respectively.

6. The package of claim 1 , wherein the skirt comprises a first wall and a second wall, each wall laterally coextensive with respective first and second panels.

7. The package of claim 1 , wherein the interior channel is selectively printed such that when the first transverse seal is made, the interior channel remains unsealed to itself in the area of the first transverse seal.

8. The package of claim 1 , wherein the flexible spout comprises a first portion disposed between the first transverse seal and the first end of the pouch, and a second portion extending from the first transverse seal into the interior of the pouch.

9. The package of claim 8, wherein the flexible spout is folded over within the skirt, and adapted when in use to unfold and dispense product from the interior of the pouch.

10. The package of claim 8, wherein the flexible spout is configured to extend, when in use, beyond the first end of the pouch.

1 1 . The package of claim 8, wherein the flexible spout comprises lateral edges spaced from respective first and second side edges of the skirt.

12. The package of claim 1 1 , wherein the flexible spout is substantially

rectangular, with its longitudinal axis parallel to the longitudinal axis of the pouch.

13. The package of one of claims 8 to 12, wherein the flexible spout comprises a tear notch disposed near the distal end of the flexible spout.

14. The package of claim 13, wherein the flexible spout comprises an end seal at the distal end thereof, an opening at the proximal end thereof, and lateral seals that define the interior channel.

15. The package of claim 13, wherein the flexible spout is longitudinally centered in the pouch.

16. The package of claim 13, wherein the flexible spout comprises a printed region that is configured to not seal to itself.

17. The package of claim 16, wherein the flexible spout comprises a printed indicator that provides, in a package in which the spout is disposed, a visual indication of the location of the spout.

18. The package of claim 8, wherein the flexible spout has one of a rectangle shape and a curve shape.

19. A method of making a package with a flexible spout in a vertical form/fill/seal process comprising:

a) providing a lay-flat film on a first roll;

b) providing a plurality of flexible spouts on a second roll of film;

c) advancing a flexible spout from the second roll of film;

d) attaching the flexible spout to the lay-flat film;

e) separating the flexible spout from the second roll of film;

f) advancing the lay-flat film with the attached flexible spout over a

forming device to convert the lay-flat film to a folded film; g) making a longitudinal seal in the folded film;

h) transversely sealing the folded film to form a first pouch having a first transverse seal;

i) putting a product in the first pouch;

j) advancing the folded film, with the first pouch, downward a

predetermined distance;

k) transversely sealing the folded film to form a first transverse seal in the folded film, while simultaneously forming a second transverse seal across an upper end of the first pouch; and

I) transversely cutting the folded film to separate the first pouch from the folded film to make a package, the package comprising a pouch comprising

(a) a first and second panel,

(b) a first and second end,

(c) a first and second side edge,

(d) a pouch interior,

(e) a first transverse seal,

(f) a second transverse seal,

(g) a skirt extending from the first transverse seal to the first end of the pouch, (h) a longitudinal seal extending from the first transverse seal to the second transverse seal, and

(i) a flexible spout disposed within the skirt, and attached to the first transverse seal, the flexible spout comprising an interior channel in communication with the pouch interior.

20. The method of claim 19, further comprising, during steps h) and k),

transversely sealing the folded film to form a third transverse seal, spaced from the first transverse seal, to define the skirt.

21 . The method of claim 19, further comprising making a line of perforations in the skirt.

22. The method of claim 19, wherein the flexible spout comprises a first portion extending from the first transverse seal toward the first end of the pouch, and a second portion extending from the first transverse seal into the interior of the pouch.

23. The method of claim 22, wherein the flexible spout is folded over within the skirt, and adapted when in use to unfold and conduct product from the interior of the pouch.

24. The method of one of claims 19 to 23, wherein the flexible spout comprises a tear notch disposed near the distal end of the flexible spout.

25. The method of claim 24, wherein the flexible spout comprises an end seal at the distal end thereof, an opening at the proximal end thereof, and lateral seals that define the interior channel.

26. A method of making a plurality of flexible spouts comprising:

a) providing a lay-flat printed film having a plurality of printed regions, the printed regions substantially identical to one another and spaced apart at fixed intervals on the film;

b) advancing the lay-flat printed film to and across a first forming shoe to centerfold the film to make a folded, printed film having a first folded longitudinal edge; c) transversely sealing the folded, printed film at marginal portions of each of the plurality of printed regions to define a plurality of spouts each comprising an interior channel;

d) advancing the folded, printed film to and across a second forming shoe such that the film is longitudinally folded over itself, along an axis parallel to and spaced apart from the first folded longitudinal edge, to make a folded, printed film having a second folded longitudinal edge; and

e) applying a crimp seal to each of the plurality of spouts, the crimp seals disposed parallel to and between the first and second folded

longitudinal edges.

27. The method of claim 26, further comprising providing a printed indicator on each of the plurality of spouts, the printed indicator configured to provide, in a package in which the spout is disposed, a visual indication of the location of the spout.