WO2023007148A1

WO2023007148A1 - Carton blank forming machine and associated methods

Info

Publication number: WO2023007148A1
Application number: PCT/GB2022/051957
Authority: WO
Inventors: Martin Myerscough
Original assignee: Splyt-Pak Limited
Priority date: 2021-07-27
Filing date: 2022-07-26
Publication date: 2023-02-02
Also published as: GB202110800D0; CN117836213A; CN117836212A; WO2023007150A1; WO2023007149A1; GB2609401A

Abstract

A machine for forming a roll of carton blanks and a method of forming a carton blank is provided. The carton blanks have a card outer adhered to a liner, the card outer having a line of perforations defining a tear line, allowing a user to separate the card outer from the liner after use. The machine comprises a perforating station, coating station, first adhesive station, second adhesive station and liner joining station. The method comprises perforating a card blank, applying a protective coating to the card blank, applying adhesive to the card blank and adhering a liner to the card blank.

Description

Carton Blank Forming Machine and Associated Methods

Field

The present invention relates to a machine for forming a roll of carton blanks, and associated methods for manufacturing carton blanks.

Background

Cartons for liquid, for example juice, are typically made from a laminate material formed of a card layer and a polymeric inner layer laminated onto the card to provide a sealed inner surface and prevent contact of the liquid contents with the card.

In such cartons it is not possible to easily separate the card layer of the laminate material from the polymeric inner layer. The laminate material also cannot be easily recycled because the polymeric layer prevents the card recycling process (usually mixing the card with water) from working on the card component. Because conventional cartons cannot typically be recycled, it is common practice for Materials Recovery Facilities (MRFs) to reject any such cartons when sorting and processing waste material. The sorting is typically done by a visual inspection of the material, and MRFs will typically therefore reject any item that appears similar to a conventional laminate carton.

Summary of Invention

The present inventors have developed a new design of carton comprising a card outer layer and a liner adhered to the card outer layer around a periphery of the liner. The card outer layer comprises a line of perforations that defines a tear line, that enables the carton to be opened in a “book-like” manner. This new design allows a user to easily separate the liner from the card outer layer, so that they can be disposed of and recycled separately.

The new design of carton necessitates an innovative method of manufacture, and associated machine to produce the carton blanks used to form the carton.

According to a first aspect of the present invention, there is provided a machine for forming a roll of carton blanks, the machine comprising: a perforating station configured to receive a card web comprising a plurality of card blanks, and form a plurality of perforations in each card blank of the card web; a coating station configured to apply a protective coating to a first surface of each card blank of the card web; a first adhesive applicator configured to apply adhesive to the first surface of each card blank of the card web; a second adhesive applicator configured to apply adhesive to a second surface of each card blank of the card web, the second surface opposing the first surface; a liner joining station configured to receive a liner material, and adhere the liner material to overlay the second surface of each card blank of the card web, wherein the liner joining station is located downstream from the coating station, the first adhesive applicator, and the second adhesive applicator.

In one example, the coating station is located downstream from the perforating station, and the coating station is configured to apply the protective coating at least over the plurality of perforations to prevent passage of liquid through the plurality of perforations.

By providing the coating station downstream from the perforating station, and applying the protective coating to prevent passage of fluid through the perforations, the coating can prevent ingress of fluid between the liner and the card outer via the perforations, thereby removing the need for any additional adhesive or sealing material to be added to the card outer to seal the perforations.

The coating station may be configured to apply the protective coating to substantially cover the first surface of each card blank of the card web except the first edge of the first surface of each card blank of the card web.

In one example, the coating station is located upstream from the perforating station.

By providing the coating station upstream from the perforating station, the performance of the coating station can be improved. In particular, the inventors have appreciated that the process of forming perforations in the card web performed by the perforating station can deform the surface of the card web. The deformation of the surface of the card web can make it difficult forthe coating station to achieve an even distribution of protective coating. Therefore, providing the coating station upstream from the perforating station ensures that the card web received by the coating station has not been deformed by the perforating process, and therefore the coating station can coat the card web more evenly.

In one example the first adhesive applicator is configured to apply adhesive along a first edge of the first surface of each card blank of the card web and the second adhesive applicator is configured to apply adhesive along a second edge of the second surface of each card blank of the card web, wherein the first edge and second edge are opposing side edges of the card blank.

The first side edge and second side edge may be arranged such that the card blank can be folded, bent, or rolled to bring the first and second side edges into contact, and adhered to form a side seam of a carton.

The carton blank is subsequently formed into a carton and filled, typically in a form-filling machine. The carton blank is formed into a carton by folding and adhering the carton blank to form top, bottom, and side seams of the carton, where the side seam extends between the top and bottom seams. As part of this forming and filling process, the carton blank is formed into a tube, such that the first edge of the first surface, and second edge of the second surface are brought into contact and adhered together to form the side seam of the carton. By applying adhesive along the first edge and a second edge, the integrity of the resulting side seam when the carton blank is formed into a carton is improved compared to only applying the adhesive to one side, particularly where the adhesive is a heat-activated adhesive. The high speed at which vertical form-filling machines run mean that the adhesive must adhere the side seam in a small length of time. Providing adhesive on both surfaces of the seam allows a strong seam to be formed in a short time, particularly when using heat-activated adhesive, which is preferred. Where a heat-activated adhesive is used, the adhesive applied to the first and second side edges is absorbed by the card material. When the two edges are subsequently brought into contact and heated, the adhesive applied to the first side edge forms a strong bond with the adhesive applied to the second side edge. In one example, the first adhesive applicator and second adhesive applicator are configured to apply a heat-activated adhesive.

A heat-activated adhesive is advantageous, since once it is applied it dries in a non-tacky state allowing the card outer to be more easily processed, and then the adhesive can be activated at a later time when forming the carton blank into a carton by heating the adhesive. The non-tacky nature of heat-activated adhesive is further advantageous, as it allows the carton blanks to be formed into a roll without the roll of carton blanks stickling to itself. As set out above, heat-activated adhesives are also preferred as they allow the first and second side edges to be quickly adhered to form the side seam of a carton.

In one example, the liner material is a web of liner material.

Providing the liner material as a web of liner material is advantageous, as it allows for faster and simpler assembly of the carton blanks.

In one example, the machine further comprises a turning device configured to flip the orientation of the card web, wherein the turning device is located between the first adhesive applicator and the second adhesive applicator.

Providing the machine with a turning device between the first and second adhesive applicators is particularly advantageous, as it allows the first and second adhesive applicators to be oriented the same way. This is advantageous as typically, preferred types of adhesive applicator such as gravure printing systems store the adhesive in a bath into which the web itself, or a gravure roller or other application means can be partially submerged in order to apply the adhesive to the card web. Accordingly, including a turning device allows the first and second adhesive applicators to be oriented in the same direction, thus allowing both the first and second adhesive applicators to be configured as preferred types of adhesive station such as gravure printing systems comprising an adhesive bath. It will be appreciated that providing two applicators with different orientation avoids the need for turning the card web and so can reduce the size of the machine. In one example, the machine further comprises a web guide configured to maintain the lateral position of the card web in the carton blank forming machine, wherein the web guide is located upstream from the liner joining station, preferably upstream from the perforation station.

Including a web guide is advantageous, as the scrap rate (the number of improperly manufactured carton blanks) is reduced by accurately maintaining the lateral alignment of the card web. There is even greater benefit when the web guide is located upstream from the perforation station.

In one example the machine further comprises a splicing table configured to join the leading end of a new sheet of card web material to the trailing end of the card web to form a continuous sheet of card web material, wherein the splicing table is located upstream from the perforation station and coating station.

Including a splicing table is advantageous, as it can allow the machine to operate continuously, without having to shut down in order to switch to a new roll of card web, or new roll of liner web.

In one example the liner joining station comprises a third adhesive applicator configured to apply adhesive to the liner material to adhere the liner material to the card web.

In one example the liner joining station comprises a third adhesive applicator configured to apply adhesive to the card web prior to adhere the liner material to the card web.

Applying the adhesive to the liner material rather than the card web can be advantageous, because the card web material is more absorbent than the liner material, causing the applied adhesive to soak into the card web material before curing. This can reduce the durability of the bond between the liner material and the card web.

In one example, the protective coating is an ultraviolet (UV) curable varnish.

Using a UV curable varnish is advantageous, since the varnish can be very quickly cured using UV lamps, allowing shorter manufacturing times.

In one example the coating station comprises an ultraviolet lamp configured to cure the varnish.

Including a UV lamp to cure the varnish is advantageous, since this reduces the curing time of the varnish, and therefore allows the card web to proceed next processing step more quickly. In one example the machine further comprises a first drying apparatus located immediately downstream from the first adhesive applicator, and a second drying apparatus located immediately downstream from the second adhesive applicator, wherein the first drying apparatus and second drying apparatus are configured to dry the adhesive applied to the first and second surfaces of each card blank of the card web respectively.

Including a drying apparatus is advantageous, as it allows the adhesive to be quickly dried, thus enabling the card web to proceed to the next processing step more quickly.

Allowing the card web to proceed to subsequent processing stations more quickly is particularly advantageous. It is important to keep the card web and liner web running through the stations of the machine at a constant speed. Accordingly, reducing the time spent between stations decreases the distance needed between the stations, thus allowing the machine to have a smaller footprint, or removes the need to include looped rollers to increase the path length of the card web between stations.

In one example, the first adhesive applicator and second adhesive applicator are comprised in a single adhesive station. The single adhesive station may further comprise a drying apparatus. The drying apparatus is preferably located downstream of the first adhesive applicator and the second adhesive applicator. The drying apparatus may be configured to dry the first and second surfaces of the card web simultaneously.

By providing a single adhesive station, the overall size of the machine can be reduced, thereby providing a machine with a reduced footprint. By providing the single drying station with a drying apparatus configured to dry the first and second surfaces of the card web simultaneously, the total drying time is reduced, and thereby the manufacturing time is also reduced.

In one example, the first adhesive applicator, second adhesive applicator, and drying apparatus are arranged such that the card web is conveyed in a substantially straight line through the first adhesive applicator, second adhesive applicator, and drying apparatus.

By arranging the first adhesive applicator, second adhesive applicator, and drying apparatus such that the card web is conveyed in a substantially straight line therethrough, and hence in a substantially straight line through the single adhesive station, there is no need to manipulate the card web between the adhesive applicators and the drying apparatus, before the adhesive has dried. It has been appreciated by the inventor that manipulating the card web while the adhesive is still wet can increase the unwanted transfer of wet adhesive to the machine, for example via contact with manipulating rollers and/or nip rollers. Therefore, removing the need to manipulate the card web between the adhesive applicators and the drying apparatus reduces the risk of unwanted transfer of adhesive to the machine.

In one example the card web comprises an array of card blanks arranged with a plurality of card blanks arranged longitudinally along the web and a plurality of card blanks arranged laterally across the web, such that each station of the machine processes multiple laterally-arranged card blanks simultaneously.

Providing the card web with multiple card blanks arranged across the width is advantageous as it greatly increases the throughput of the machine.

In one example the liner joining station is configured to receive a web of liner material having a width corresponding to the width of the card web, and the liner joining station further comprises a cutting means configured to remove strips of the liner web at locations corresponding to a side edge of each of the multiple laterally-arranged card blanks immediately before adhering the web of liner material to the card web.

Providing the liner as a single web, and cutting the liner web to remove strips as necessary is advantageous as it simplifies the process of aligning the liner web with the card web, since only one alignment is required. This advantage is further supported by providing the cutting means to remove the strips immediately before the liner web is adhered to the card web, so that any misalignment following the removal of the sections is minimized.

In one example the processing order of the stations is:

1) coating station

2) perforating station

3) first adhesive station 4) second adhesive station

5) liner joining station.

In one example, the machine further comprises a creasing station configured to crease the card web to form one or more fold lines in each card blank of the card web.

Including a creasing station is advantageous, since forming fold lines in the card web improves the accuracy with which the resulting carton blank is folded when being formed into a carton, and ensures that the folds are formed in the correct location to form the panels and seams of the carton with the correct dimensions.

In one example, the creasing station is located downstream from the coating station.

Providing the creasing station downstream from the coating station is advantageous, as this can improve the performance of the coating station. In particular, applying the protective coating before forming the fold lines prevents excessive protective coating from accumulating in the creased card material in the fold lines. Furthermore, applying the protective coating to the card web before the fold lines are formed and when the card web is a flat surface ensures an even and uniform protective coating is formed.

In one example, the creasing station is located upstream from the liner joining station.

In one example, the machine further comprises a punching station configured to cut or punch the card web to form one or more openings in each card blank of the card web.

In one example, the punching station is located downstream of the coating station, and upstream from the liner joining station.

In one example, each card blank of the card web has a top edge, a bottom edge, and opposing first and second side edges; the perforation station is configured to form a line of perforations in each card blank of the card web, extending from at or adjacent the top edge of the card blank to at or adjacent the bottom edge of the card blank, wherein the top edge of the card blank is arranged to form a top seam of a carton and the bottom edge of the card blank is arranged to form a bottom seam of the carton; the coating station is configured to apply the protective coating to substantially cover the first surface of each card blank of the card web except the first edge of the first surface of each card blank of the card web; and the liner joining station is configured to adhere the liner to each card blank such that one edge of the liner is spaced from the second side edge of the card blank, and the remaining edges of the liner are aligned with the top, bottom, and first side edges of the card blank, wherein the first and second side edges are arranged to be joined to form a side seam of the carton extending between the top seam and bottom seam.

According to a further aspect of the present invention, there is provided a method of manufacturing a carton blank, the method comprising the steps of: receiving a card blank; perforating the card blank to form a plurality of perforations therein; applying a protective coating to a first surface of the card blank; applying adhesive to a first surface of the card blank; applying adhesive to a second surface of the card blank, the second surface opposing the first surface; and adhering a liner to overlay the second surface of the card blank, wherein the adhering the liner is performed after applying the protective coating, applying adhesive to the first surface, and applying adhesive to the second surface.

Applying the protective coating may comprise applying a protective coating to substantially cover the first surface of the card blank except the first edge of the card blank

In one example, the applying a protective coating comprises applying the protective coating at least over the plurality of perforations to prevent passage of fluid through the plurality of perforations, and the applying a protective coating is performed after the perforating of the card blank.

By applying the protective coating such that the coating enters the plurality of perforations, the coating can prevent ingress of fluid between the liner and the card blank via the perforations, thereby removing the need for any additional adhesive or sealing material to be added to the card blank to seal the perforations.

In one example, the applying a protective coating is performed before the perforating of the card blank.

By applying the protective coating before perforating the card blank, the card blank can be coated more evenly. In particular, the inventor has appreciated that the process of forming perforations in the card blank can deform the surface of the card blank. The deformation of the surface of the card web can make it difficult to achieve an even distribution of protective coating. Therefore, applying the protective coating before perforating the card blank ensures that the surface of the card blank has not been deformed by the perforating process, and therefore the coating can be applied more evenly.

In one example the card blank is received as a card web comprising a plurality of card blanks.

In one example the liner is provided as a web of liner material, the web of liner being adhered to the web of card blanks.

In one example the applying adhesive to the first surface of the card blank comprises applying adhesive along a first edge of the card blank and the applying adhesive to the second surface of the card blank comprises adhesive along a second edge of the card blank, wherein the first edge and second edge are opposing side edges of the card blank.

The first and second edges may be arranged such that the card blank can be folded, bent, or rolled to bring the first and second side edges into contact, and adhered to form a side seam of a carton. By applying adhesive along the first edge and a second edge, the integrity of the resulting side seam when the carton blank is formed into a carton is improved compared to only applying the adhesive to one side. The high speed at which vertical form-filling machines run mean that the adhesive must adhere the side seam in a small length of time, and thus providing adhesive on both surfaces of the seam allows a strong seam to be formed in a short time.

In one example the method further comprises flipping the orientation of the card blank after applying the adhesive to the first surface, and before applying the adhesive to the second surface.

Flipping the orientation of the card blank after applying the adhesive to the first surface and before applying the adhesive to the second surface is advantageous as it allows the first and second adhesive applicators to apply the adhesive in the same orientation - thus the two adhesive applicators can be configured in substantially the same way, thereby resulting in a simpler configuration of the machine. It will be appreciated that providing two applicators with different orientation avoids the need for turning the card web and so can reduce the size of the machine.

In one example the adhering the liner to the card blank comprises applying an adhesive to the liner to adhere the liner to the card blank.

In one example the adhering the liner to the card blank comprises applying an adhesive to the card blank to adhere the liner to the card blank.

Applying the adhesive to the liner can be advantageous, because the card blank material is absorbent, such that the applied adhesive can soak into the card blank material before curing. This can reduce the durability of the bond between the liner and the card blank.

In one example the protective coating is an ultraviolet (UV) curable varnish.

In one example the method further comprises curing the varnish, via an ultraviolet lamp.

Using a UV lamp to cure the varnish is advantageous, since this reduces the curing time of the varnish. In one example the applying adhesive to the first surface and applying adhesive to the second surface further comprises drying the adhesive using a drying apparatus.

In one example, the method further comprises drying the adhesive applied to the first surface before applying the adhesive to the second surface, and drying the adhesive applied to the second surface before adhering the liner, wherein drying the adhesive is performed using a drying apparatus.

Using a drying apparatus is advantageous, as it allows the adhesive to be dried more quickly, thus enabling subsequent processing of the card web, without the card web sticking to itself or other elements of the machine. The drying apparatus also greatly speeds up the drying time, thereby enabling shorter manufacturing times.

In one example, the method further comprises drying the adhesive applied to the first and second surfaces simultaneously, wherein the drying the adhesive is performed using a drying apparatus.

Drying the adhesive applied to the first and second surfaces simultaneously is advantageous because it can reduce the total time taken to dry the adhesive, and therefore reduce the manufacturing time of the carton blank.

In one example, the method is specifically performed in the order:

1) receiving the card blank;

2) applying the protective coating;

3) perforating the card blank;

4) applying adhesive to the first surface;

5) applying adhesive to the second surface;

6) adhering the liner to the card blank.

In one example, the method further comprises creasing the card blank to form one or more fold lines.

In one example, the method further comprises punching or cutting one or more openings in the card blank. In one example, the card blank has a top edge, a bottom edge, and opposing first and second side edges; perforating the card blank comprises forming a line of perforations in the card blank, the line of perforations extending from at or adjacent the top edge of the card blank to at or adjacent the bottom edge of the card blank, wherein the top edge of the card blank is arranged to form a top seam of a carton and the bottom edge of the card blank is arranged to form a bottom seam of a carton; applying the protective coating comprises applying a protective coating to substantially cover the first surface of the card blank except the first edge of the card blank; and adhering the liner comprises applying adhesive around the entire periphery of the liner, and arranging the liner to overlay the second surface of the card blank such that one edge of the liner is spaced from the second side edge of the card blank, and the remaining edges of the liner are aligned with the top, bottom, and first side edges of the card blank, wherein the first and second side edges of the card blank are arranged to form a side seam of the carton extending between the top seam and the bottom seam.

Brief Description of the Drawings

The invention will now be described, byway of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows an example of a carton.

FIG. 2 shows a different view of the carton in FIG. 1.

FIG. 3 shows a carton blank.

FIG. 4 shows a schematic of a machine for manufacturing carton blanks according to embodiments of the present invention.

FIG. 5 shows illustrates a process of joining a web of liner material to a card web according to embodiments of the present invention.

FIG. 6 shows a web of carton blanks. FIG. 7 shows a machine for manufacturing carton blanks according to an embodiment of the present invention.

FIG. 8A shows a first section of a machine for manufacturing carton blanks according to an embodiment of the present invention.

FIG. 8B shows a second section of the machine for manufacturing carton blanks of FIG. 8B.

FIG. 9 shows a flow diagram of a method of manufacturing a carton blank according to an embodiment of the present invention.

Detailed Description

The present invention relates to methods of manufacturing carton blanks, and a machine for producing carton blanks. The carton blanks are folded and sealed to form a carton. FIG. 1 shows an illustrative example of a carton formed by folding and sealing a carton blank manufactured using the machine and methods of the present invention. The carton 1 is a brick-type carton, having a cuboidal shape. The carton 1 is formed of a card outer 2 and a liner 17 (not visible in FIG. 1). The liner 17 is within the card outer 2 and holds the contents of the carton, i.e. the liquid.

The card outer 2, as illustrated, has an opening 3. In some examples, the opening 3 is an insert, for example a plastics insert that includes a re-closable flap or screw lid. In other examples, the opening may have a pierceable membrane that can be pierced to provide access into the carton. In other examples, the opening may have a peelable membrane adhered over the opening 3 that can be peeled away to expose the opening 3.

The illustrative carton 1 is cuboidal, having a top end 4 and a bottom end 5, opposing major sides 6, 7, and opposing minor sides 8, 9, the major sides 6, 7, being larger in area than the minor sides 8, 9. It will be appreciated that other sizes and shapes of carton 1 may also be formed using carton blanks manufactured using the machine and method according to the present invention.

The opening 3 is formed in the top end 4 of the carton 1. The carton 1 is formed from a carton blank (10, see FIG. 3) that is folded and sealed to form the carton 1 , which has three seams: a top seam 11 disposed on the top end 4 of the carton 1 , a bottom seam 110 (not shown), and a side seam 12 extending between the top seam 11 and the bottom seam 110 through one of the major sides 6, 7, or minor sides 8, 9, in this example through major side 7. The formation of the top seam 11 creates a pair of top flaps 13 on the top end 4 of the carton 1 , one of which is visible in FIG. 1. The top flaps 13 are folded over onto the opposing major sides 6, 7 or minor sides 8, 9, as illustrated. Similarly, the formation of the bottom seam 110 creates a pair of bottom flaps 130 on the bottom end 5 of the carton. The bottom flaps 130 are folded over onto the bottom end 5 of the carton 1. The top flaps 13 and the bottom flaps 130 are glued into their folded positions.

FIG. 3 shows an illustrative example of a carton blank 10 that may be manufactured via machines according to the present invention and using methods according to the present invention. The carton blank 10 comprises a card outer blank 2 and a liner 17. To form the carton blank 1 , the liner 17 is attached to the card outer blank 2 using an adhesive.

The card outer blank 2 is rectangular and has a top edge 22, a bottom edge 23, and two opposing side edges 24, 25.

As shown, the card outer blank 2 includes a major side panel 26 corresponding to the major side 6 of the carton 1 of FIGS. 1 and 2. The card outer blank 2 also includes first and second side panels 27, 28 corresponding to the opposing minor sides 8, 9 of the carton 1 of FIG. 1. The card outer blank 2 also has two major sub panels 29, 30 that are later joined together at the side seam (12, see FIG. 1) to form the major side panel 7 of the carton 1 of FIG. 1.

The card outer blank 2 also includes a major top end panel 31 , and top end sub-panels 32, 33,

34, 35 that after the carton 1 has been formed provide the top end 4 of the carton of FIG. 1. The card outer blank 2 also includes a major bottom end panel 36, and bottom end sub-panels 37,

38, 39, 40 that after the carton 1 has been formed provide the bottom end 5 of the carton of FIG.

1. The top end sub-panels 34, 35 and the bottom end sub-panels 39, 40 are folded diagonally on forming the carton of FIG. 1 to provide the top flaps (13, see FIG. 1) 5 and bottom flaps 130.

The card outer blank 2 also includes an opening 3. The opening 3 in this example is a through- hole in the card outer blank 2. The opening 3 is formed in the top end sub-panel 33 so that the opening 3 is formed in the position shown in FIGS. 1 and 2. As illustrated, the card outer blank 2 comprises a plurality of crease lines 41 along the edges of each of the panels and along other fold lines (i.e. diagonally across the top end panels 34, 35 and the bottom end panels 39, 40 that form the top flaps and bottom flaps 130 of the carton 1). These crease lines 41 are preferably embossed lines formed by pressing the card material to form a crease to ease folding of the card outer blank 2 along those lines during assembly of the carton 1. However, the crease lines 41 might alternatively be other lines of weakness or variations in material to permit folding of the card outer blank 2.

Crease lines 42 (not shown) are also provided adjacent to the top edge 22 and bottom edge 23 of the card outer blank 2, where the top seam (11, see FIG. 1) and bottom seam 110 are formed on assembly of the carton 1 .

The card outer blank 2 includes the line of perforations 15. The line of perforations defines the tear line 14 illustrated in FIGS. 1 and 2. In this example, the line of perforations 15 extends from the top edge 22 of the card outer blank 2, in the region of the major top end panel 31 near to the intersection of the major top end 31 and top-end sub panel 35, across the intersection of the major side panel 26 and major top end panel 31 , and into the major side panel 26. From there, the line of perforations 15 defines a v-shape in the major side panel 26, with a center-point located at the mid-line of the card outer blank 2. The line of perforations 15 then extends to the intersection of the major side panel 26 and major bottom end panel 36. The line of perforations 15 then extends into the major bottom end panel 36, and then extends to the bottom edge 23 of the card outer blank 2 in the region of the major bottom end panel 36, near to the intersection between the major bottom end panel 36 and the bottom end sub panel 40.

Preferably, the liner 17 is a film material having a polymeric component. More preferably, the liner 17 is a laminate film material having a polymeric layer and a metallic layer, for example foil. However, in other examples the liner can be made of other materials, for example the metallic layer could be replaced by an ethylene vinyl alcohol (EVOH) film, which gives similar barrier properties. If EVOH were used as the barrier layer then a heat sealing system could be used to seal the liner, as described further hereinafter. As shown in FIG. 3, in this example the liner 17 is rectangular and has a top edge 44, a bottom edge 45 that are coincident, i.e. in line with, the top and bottom edges 22, 23 of the card outer blank 2, respectively. The liner 17 also has a first side edge 46 that is coincident with a side edge 25 of the card outer blank 2. The liner 17 also has a second side edge 47. In preferred examples, the second side edge 47 is spaced from the corresponding side edge 24 of the card outer blank 2, as illustrated. The side edge 24 of the card outer blank is adhered to the opposing surface (without the liner 17) of opposite side edge 25 to form the side seam (12, FIG. 1) of a carton. The liner 17 covers the majority of the surface area of the card outer blank 2.

Preferably, the liner 17 is attached to the card outer 2 using adhesive that is disposed about the entire periphery of the liner 17. By adhering the liner 17 to the card outer 2 around the entire periphery, the space between the liner 17 and the card outer 2 is sealed against the ingress of liquid, such as sterilisation fluid in which the carton blank 1 may be immersed during a forming and filling process. By adhering the liner 17 to the card outer 2 around the periphery of the liner 17, the liner 17 is secured within the resulting carton 1 within the top seam 11 and bottom seam 110. It will be appreciated therefore that the top and bottom seams each have a sandwiched construction comprising card outers that sandwich two layers of liner material.

As illustrated in FIGS. 1 , 2, and 3, the card outer includes a tear line 14. The tear line 14 is defined by a line of perforations 15 in the card outer 2 that can be broken by a user. The line of perforations extends from at or adjacent the top seam 11 to at or adjacent the bottom seam 110 across one or more of the sides. In one example, the line of perforations extends from at or adjacent the top seam 11 , across major side 6, and to at or adjacent the bottom seam 110. The tear line 14 thereby defines a line extending substantially along the length of the carton along which the card outer may be broken and the carton opened by a user. In alternative embodiments, the tear line may extend from at or adjacent the top seam 11 across either of the minor sides 8, 9, to at or adjacent the bottom seam 110. The line of perforations 15 may extend from at or adjacent the top seam, across multiple sides of the card outer before extending to at or adjacent the bottom seam 110. As discussed in some embodiments, the line of perforations 15 may extend from a point adjacent to the top seam 11 , to a point adjacent to the bottom seam 110. In such embodiments, the line of perforations does not extend into either the top seam 11 or bottom seam 110. When opening the carton 1 , a user can tear the carton blank along the line of perforations 15, and then open the top seam 11 and bottom seam 110 to remove the liner. In some alternative embodiments, the line of perforations 15 may extend from a point spatially separated from the top seam 11 , to a point spatially-separated from the bottom seam 110. In such embodiments, when opening the carton 1 the user may tear the carton blank 10 along the line of perforations 15, and is then able to tear the remainder of the carton blank to the top seam 11 and/or bottom seam 110 which may subsequently be peeled apart to open the carton and allow the user to remove the liner 17. The line of perforations 15 may include at least one portion that is not perpendicular to the top edge 22 or bottom edge 23. For example, the line of perforations 15 may include at least a portion that is oriented at an acute, or obtuse angle relative to the top edge 22 and bottom edge 23. The line of perforations 15 may be arranged such that the line of perforations 15 extends between the top edge 22 and the bottom edge 23 through one or more panels of the card blank that are not adjacent to either opposing side edges 24, 25.

It will be appreciated that the card outer can include a tear line 14 defined by a, or multiple, line(s) of perforations 15 having any other configuration, and is not limited to those specific illustrative examples described above.

FIG. 4 shows a machine 400 for forming a roll of carton blanks according to an embodiment of the present invention. The machine 400 comprises a number of stations, with each station performing one or more processing steps that are involved in the manufacture of carton blanks according to the present invention.

The machine 400 is configured to receive a card web 402. The card web 402 is a continuous sheet of card material and may be provided on a roll. The card web 402 has a first surface 402a and a second surface 402b. One of the first surface 402a and second surface 402b may be a printed surface, printed with a packaging design. Accordingly, the printed surface forms the outer surface of the carton formed by folding and sealing the carton blank 401 produced by machine 400. In some embodiments, the card web 402 is dimensioned such that the card web 402 comprises multiple card outer blanks. An illustrative example is shown in FIG. 6, where card web 602 is dimensioned such that card web 602 comprises three card outer blanks arranged across the width of card web 602, where the width of the card web 602 is defined as the dimension perpendicular to the conveyance direction of the card web 602 through a machine. In this way, the machine 400 is able to produce multiple carton blanks 401 simultaneously. In some embodiments, the card web 402 may have a width equal to three times the width of a card outer blank, or 5 times the width of a carton blank 401 , or any suitable integer multiple of the width of the resulting carton blank 401. Accordingly, for a resulting carton blank 401 having, for example, a width of 24cm, the card web 402 may have a width of 48cm, 72cm, 96cm, 120cm etc. In some embodiments, the machine 400 comprises a card feed reel that unwinds a roll of card web into the machine 400.

The machine 400 comprises a perforation station 403. The perforation station 403 is configured to receive the card web 402 and form a plurality of perforations in the card web 402. The perforation station forms perforations in the card web 402 using a perforating roller. The perforating roller may comprise perforating needles arranged to form a predetermined pattern of perforations in the card web 402. The predetermined pattern of perforations may form the line of perforations in the card outer blank that define the tear line in the resulting carton, extending from at or adjacent the top edge of the card outer blank to at or adjacent the bottom edge of the card outer blank as described above in relation to FIGS. 1 to 3. The perforating needles form the perforations from one surface in the card web 402 to the other. Where one surface of the card web 402 is a printed surface, the perforation station 403 forms the perforations from the printed surface to the other surface, where the printed surface forms the external surface of a resulting carton. Forming the perforations from the printed surface to the other surface ensures that any fibres of card material that may be torn by the perforating needles do not protrude from the printed side. For example, where the first surface 402a is a printed surface of the card web 402, the perforation station 403 is configured such that the perforating needles perforate the card web 402 from the first surface 402. The perforation station 403 is configured to form perforations in the card web 402 having a predetermined perforation length, perforation width, and perforation spacing. The inventors have appreciated that if the length or width of the perforations is too great, liquid can ingress through the perforations. If liquid is able to ingress through the perforations, additional adhesive may be required to seal the perforations to prevent this from occurring, which would in turn make it more difficult for a user to separate the liner from the card outer when disposing of the resulting carton. Accordingly, preferred embodiments of the perforation station 403 are configured to form perforations in the card web 402 having a perforation width of 0.6mm, a perforation length of between 1mm and 1.5mm, and a perforation spacing between 1mm to 1.5mm, wherein the perforation spacing is defined as the distance between the centres of consecutive perforations. It will be appreciated that this is merely an exemplary configuration, and that the perforation station 403 may be configured to form other arrangements of perforations in the card web. Advantageously, the perforation needles may be fitted to the perforation roller via a magnetic sleeve, allowing specific arrangements of perforation needles to be quickly removed and replaced. The circumference of the perforation roller is equal to an integer multiple of the length of the card outer blank, such that one full rotation of the perforation roller forms the predetermined pattern of perforations on one or more card outer blanks. In embodiments where the card web 400 comprises multiple card outer blanks arranged across the width of the card web 402, the perforation station 403 is configured to form the predetermined pattern of perforations in each of the multiple card outer blanks simultaneously. It will be appreciated that other methods of forming perforations in the card web 402 are equally applicable and well-known to one skilled in the art.

The machine 400 further comprises a coating station 404. The coating station 404 is configured to receive the card web 402 and apply a protective coating to a surface of the card web 402. The coating station 404 may be located upstream or downstream from the perforation station 403. In embodiments where the coating station 404 is located downstream from the perforation station 403, the coating station 404 applies the protective coating at least over the perforations in the card web 402 formed by the perforation station 403, and in some embodiments may apply the protective coating to substantially cover the surface of the card web 402, apart from areas to which adhesive may be later applied. The protective coating is applied to the surface of the card web 402 on which the perforations are formed. For example, where the first surface 402a of the card web 402 is a printed surface, and the perforation station 403 forms the perforations by piercing the card web 402 from the first surface 402a, the coating station 404 applies the protective coating to the first surface 402a of the card web 402. By applying the protective coating to the surface of the card web 402 having the perforations formed thereon, the protective coating can enter the perforations. The inventors have appreciated that this helps prevent the ingress of fluid through the perforations, and thus avoids requiring additional adhesive to be applied to the card web along the line of perforations when adhering the liner material.

In embodiments where the coating station 404 is located upstream from the perforation station, the coating station 404 applies the protective coating to the surface of the card web 402 that is to be perforated by the perforation station 403. For example, where the first surface 402a is a printed surface, the coating station 404 applies the protective coating to the first surface 402a, through which perforations are later formed by the perforation station 403. The coating station 404 may apply the protective coating to substantially cover the surface of the card web 402, apart from areas to which adhesive may be later applied. By applying the protective coating to the surface of the card web 402 before the perforations are formed thereon, the coating may be applied more evenly. The inventors have appreciated that the process by which the perforations are formed can cause the surface of the card web 402 to be deformed. The deformations in the surface of the card web 402 can make it more difficult to apply the protective coating evenly. Therefore, the inventors have appreciated that applying the protective coating before forming the perforations can be advantageous.

The protective coating may be any suitable protective coating for preventing the ingress of fluid into/through the card web. The protective coating is configured to protect the resulting carton from a sterilising bath into which the carton blank is immersed during a subsequent forming and filling process. For example, some forming and filling processes involve immersing carton blanks in a hydrogen peroxide bath prior to filling the cartons. The protective coating is configured to protect the carton blank from the hydrogen peroxide bath, preventing the card outer from absorbing the hydrogen peroxide liquid, and preventing the ingress of liquid between the card outer and the liner. In some embodiments, the protective coating is an Ultraviolet (UV) varnish. A UV varnish refers to a varnish that is applied wet, and may then be rapidly cured/dried using UV light. In embodiments wherein the protective coating is a UV varnish, the machine 400 further comprises a UV lamp immediately downstream from the coating station 404 (not shown in FIG. 4) for drying the UV varnish. In other embodiments, the protective coating may be any other suitable coating that is applied wet, and the machine 400 may further comprise a means for drying and/or curing the protective coating.

The machine 400 may further comprise a creasing station. The creasing station may be configured to receive the card web 402 and form one or more crease lines in the card web 402. The crease lines are preferably embossed lines formed by pressing the card web 402 material to form a crease to ease subsequent folding of the carton blank 401 along the one or more crease lines during assembly of the carton. However, crease lines might alternatively be other lines of weakness or variations in material to permit folding of the carton blank 401. FIG. 3 shows examples of crease lines 41 that may be formed by the creasing station. The crease lines 41 define the individual panels 26, 27, 28, 29, 30, 31 , 32, 33, 34, 35, 36, 37, 38, 39, 40 of the card outer blank shown in FIG. 3.

In some embodiments, the creasing station may be arranged downstream of the liner joining station 407. It can be advantageous to form crease lines after adhering the liner material 408 to the card web 402 so that the liner material 408 is also creased by the creasing station, as this can prevent a gap forming between the liner material 408 and the card web 402. In other embodiments, the creasing station is located upstream of the liner joining station 407 such that the card web 402 is creased prior to adhering the liner material 408 to the card web 402.

In some embodiments, the creasing station is located downstream from the coating station 404. The creasing station may be located immediately downstream from the coating station 404 such that there are no processing stations between the creasing station and the coating station 404. Arranging the creasing station downstream from the coating station 404 may prevent the applied protective coating from accumulating in the crease lines. This is advantageous because if the protective coating accumulates in the crease lines, the protective coating 404 in the crease lines may take longer to cure, and may not fully cure before the card web 402 proceeds to the next processing station. In addition, providing the creasing station downstream from the coating station 404 can improve the performance of the coating station 404. In particular, the inventors have appreciated that applying the protective coating to the card web 402 before the crease lines are formed in the card web 402 can provide a more even and uniform coating, because it is more effective to apply the protective coating to the card web 402 when it is a flat, uniform surface.

In other embodiments, the creasing station is located upstream from the coating station 404. The creasing station may be located immediately upstream of the coating station 404 such that there are no processing stations located between the creasing station and the coating station 404. Arranging the creasing station upstream from the coating station 404 may ensure good coverage of the card material forming the crease lines by the protective coating. In some cases, the protective coating may be broken by the creasing process. Therefore, by applying the protective coating directly to the crease lines, it can help ensure that the card material within the crease lines themselves is fully coated by the protective coating.

The machine 400 may further comprise a punching station. The punching station may be configured to receive the card web 402 and punch and/or cut one or more openings in the card web 402. For example, the punching station may be configured to punch or cut the card web 402 to form an opening that corresponds to the opening 3 shown in the exemplary embodiments of FIGS. 1 to 3. The punching station may form one or more openings via a die-cutting system. In other embodiments, the one or more openings may have already been formed in the card web 402 before it is received by machine 400.

In some embodiments, the punching station may be arranged downstream of the liner joining station 407. It can be advantageous to form openings after adhering the liner material 408 to the card web 402 so that the openings are also formed in the liner material. However, in some embodiments, it may be preferable not to form openings in the liner material 408 and in such embodiments the punching station may be located upstream of the liner joining station 407.

In some embodiments, the punching station may be located downstream from the coating station 404. The punching station may be located immediately downstream from the coating station 404 such that there are no processing stations between the punching station and the coating station 404. In other embodiments, the punching station may be located upstream from the coating station

404. The machine 400 further comprises a first adhesive applicator 405. The first adhesive applicator 405 is configured to receive the card web 402 and apply an adhesive to a first surface 402a of the card web 402. The first adhesive applicator 405 may be configured to apply an adhesive to the card web 402 in a strip corresponding to a first side edge of a card outer blank. In embodiments where the card web 402 comprises multiple card outer blanks arranged across the width of the card web 402, the first adhesive applicator 405 is configured to apply an adhesive to the card web 402 in multiple strips, each strip corresponding to a first side edge of a card outer blank.

The adhesive may be a heat-activated adhesive. A heat-activated adhesive is an adhesive that is configured to form an adhesive bond when heated to a certain temperature. Heat-activated adhesives are typically non-tacky when dried and before they are activated, when exposed to a certain temperature fora certain period of time, a chemical reaction forms a strong adhesive bond. The heat-activated adhesive is non-tacky when applied to the card web 402. Heat-activated adhesives are known in the art. It will be appreciated that in alternative embodiments, other types of adhesive may be used.

The first adhesive applicator 405 may comprise a gravure printing system. The gravure printing system comprises a gravure roller and an impression roller. The outer surface of each of the gravure roller comprises cells that contain the adhesive. The size, shape, and position of the cells corresponds to the desired pattern of adhesive that is to be applied to the surface of the card web 402. The circumference of the gravure roller may be equal to an integer multiple of the length of one card outer blank, such that one full rotation of the gravure roller results in adhesive being applied to one or more card outer blanks. The gravure printing system further comprises a doctor blade configured to remove excess adhesive from the cells of the one or more gravure rollers. The gravure roller and impression roller are configured such that the card web 402 passes between the gravure roller and impression roller, such that the card web 402 is pressed against the gravure roller, and the adhesive in the cells of the gravure roller is transferred to the surface of the card web 402. The cells of the gravure roller may be formed on an annular sleeve, that is releasably attachable to a central roller, for example via a magnetic attachment means. In this way, different arrangements of cells, to form different patterns of adhesive, can be quickly interchanged. Providing the first adhesive station 405 as a gravure printing system is advantageous since the gravure rollers last through large-volume runs without suffering from degradation.

In other embodiments, the first adhesive applicator 405 may comprise an alternative printing system, such as a flexographic printing system wherein the adhesive is applied to flexible printing plates mounted on a rotating cylinder, which is then directly pressed onto the card web 402. Gravure, flexographic, and other suitable printing systems such as spraying heads and movable dispensing nozzles are known to the skilled person.

The machine 400 further comprises a second adhesive applicator 406. The second adhesive applicator 406 is configured to receive the card web 402 and apply an adhesive to a second surface 402b of the card web 402. The second adhesive applicator may be configured to apply an adhesive to the card web 402 in a strip corresponding to a second side edge of a card outer blank. In embodiments where the card web 402 comprises multiple card outer blanks arranged across the width of the card web 402, the second adhesive applicator 406 is configured to apply an adhesive to the second surface 402b of the card web 402 in multiple strips, each strip corresponding to a second side edge of a card outer blank.

The second adhesive applicator 406 may comprise a gravure printing system, as described above with reference to the first adhesive applicator 405. In alternative embodiments, the second adhesive applicator 406 may comprise another suitable printing system such as a flexographic system, or a system comprising spray heads or movable dispensing nozzles.

The adhesive applied by the first adhesive applicator 405 and second adhesive applicator 406 along the first side edge of the card outer blank and second side edge respectively is provided to form the side seam (12, see FIG. 1) of a carton formed using the carton blank produced by machine 400. The first side edge and second side edges are opposing side edges of a card outer blank, and corresponding carton blank. During the forming and filling process the two side edges are brought into contact to form the web of carton blanks into a continuous tube, such that the adhesive applied to the first surface 402a along the first side edge and the adhesive applied to the second surface 402b along the second side edge are brought into contact. If the adhesive is a heat- activated adhesive, heat may then be applied to activate the adhesive on the first and second surfaces in order to form the side seam of a carton. The inventors have appreciated that applying a heat-activated adhesive to the opposing side edges of both surfaces of a card outer blank when forming the side seam ensures that the seam is properly formed and adhered during the forming and filling process. Preferably, the forming and filling process operates at high speed and high throughput, and applying heat-activated adhesive to only one surface of the card outer blank may result in a side seam with reduced adhesion, since the side seam may only be heated for a short period of time before the carton blank is filled.

In some embodiments, the first adhesive applicator 405 may be comprised in a first adhesive station, and the second adhesive applicator 406 may be comprised in a second adhesive station. The first and second adhesive stations may be separate stations, and the card web 402 is conveyed from the first adhesive station to the second adhesive station, or vice versa. The first adhesive station and second adhesive station may be arranged immediately upstream/downstream from each other, or there may be one or more processing stations arranged between the first adhesive station and the second adhesive station.

In other embodiments, the first adhesive applicator 405 and the second adhesive applicator 406 may be comprised in a single adhesive station. In such embodiments, the card web 402 will be conveyed directly from the first adhesive applicator 405 to the second adhesive applicator 406. The first adhesive applicator 405 and the second adhesive applicator may be arranged on opposite sides of the card web 402, or alternatively the single adhesive station may comprise a means to flip the orientation of the card web 402 between the first and second adhesive applicators such as a turn bar or loop of rollers. As will be described below in more detail, the single adhesive station may comprise a means for drying the adhesive applied to the card web 402. The drying apparatus may comprise a single drying apparatus arranged downstream from the first and second adhesive applicators, or alternatively separate drying apparatus may be provided downstream from each of the first and second adhesive applicators respectively.

The machine 400 may further comprise means for drying the adhesive applied by the first and second adhesive applicators 405, 406. A first drying apparatus may be located immediately downstream from the first adhesive applicator 405, and a second drying apparatus may be located immediately downstream from the second adhesive applicator 406. Each drying apparatus may be provided as an infrared drying apparatus comprising one or more heating elements. The one or more heating elements are arranged to heat the first or second surface 402a of the card web, to dry the adhesive applied thereto.

In embodiments wherein the first adhesive applicator 405 and the second adhesive applicator 406 are arranged in a single adhesive station, a single drying apparatus may be located immediately downstream from the first and second adhesive applicators 405, 406. The single drying apparatus is configured to dry the adhesive applied to the first surface 402a and second surface 402b of the card web 402 simultaneously. The single drying apparatus may be provided as an infrared drying apparatus comprising one or more heating elements arranged to heat both surfaces 402a, 402b of the card web 402 to dry the adhesive applied thereto. For example, the single drying apparatus may comprise a first array of infrared heating elements arranged to heat the first surface 402a of the card web 402, and a second array of infrared heating elements arranged to heat the second surface 402b of the card web 402. Alternatively, the single drying apparatus may comprise a single array of infrared heating elements, such as a curved array of infrared heating elements, arranged to heat both surfaces 402a, 402b of the card web 402.

In some embodiments wherein the first adhesive applicator 405 and the second adhesive applicator 406 are comprised in a single adhesive station comprising a single drying apparatus, the first adhesive applicator 405, second adhesive applicator 406, and single drying apparatus may be positioned such that the card web 402 is conveyed through the first adhesive applicator 405, second adhesive applicator 406, and single drying apparatus in a substantially straight line. The inventor has appreciated that this removes the need to manipulate the card web 402 between the adhesive applicators 405, 406 and the drying apparatus, for example via rollers and/or nip rollers. This is advantageous because manipulating the card web 402 when the applied adhesive is still wet risks the unwanted transfer of the wet adhesive from the card web 402 to other parts of the machine 400.

In some embodiments, the machine 400 further comprises a turning device 409, located between the first adhesive applicator 405 and the second adhesive applicator 406 and configured to flip the orientation of the card web 402. For example, the turning device 409 may rotate the card web 402 through 180 degrees such that the orientation of the first surface 402a and second surface 402b are reversed. The turning device 409 may comprise a turn bar system having a plurality of rollers arranged to rotate the orientation of the card web 402 through a predetermined angle, such as 180 degrees. In alternative embodiments, the turning device 409 may comprise a looped arrangement of rollers, arranged such that the card web 402 travels through the second adhesive applicator in the reverse direction to the first adhesive applicator, and with the orientation of the card web 402 reversed. It will be appreciated that in some embodiments the order of the first and second adhesive applicators may be reversed, and the turning device 409 is arranged to reverse the orientation of the card web 402 after exiting the second adhesive applicator 406 and before entering the first adhesive applicator 405. The inventors have appreciated that providing a turning device between the first and second adhesive applicators is advantageous, since this allows the configuration of the two adhesive applicators to be substantially the same, while still allowing the adhesive to be applied to both opposing surfaces 402a, 402b of the card web 402.

As discussed above, in other embodiments, the first and second adhesive apparatus 405, 406 may be combined as a single adhesive station. The adhesive station may be configured to apply adhesive to the first surface of the card web 402, then apply adhesive to a second surface of the card web 402, then pass the card web through a combined drying apparatus configured to dry both the first and second surfaces of the card web 402 simultaneously. Providing the first and second adhesive stations 405, 406 as a single combined adhesive station can be more efficient, and decrease the drying time, and hence the total manufacturing time of the carton blank.

The machine 400 further comprises a liner joining station 407. The liner joining station 407 is configured to receive the card web 402, and a liner material 408, and adhere the liner material 408 to the card web 402. Preferably, the liner joining station 407 is located downstream from each of the coating station 404, first adhesive station 405, and second adhesive station 406.

The liner material 408 is positioned and adhered to the card web 402 to form the liner 17 of the resulting carton blank 401. For example, in the exemplary carton blank shown in FIG. 3, the card outer 2 has four edges, and the liner 17 has four edges. At least one edge of the liner 17 may be aligned with an edge of the card outer blank. Preferably, three edges of the liner 17 are aligned with three corresponding edges of the card outer 2. The liner 17 may comprise an edge that is spaced from a corresponding edge of the card outer 2, which may be a side edge of the card outer 2 that is used to form a side seam (12, see FIG. 1) of the resulting carton.

The liner material 408 may be provided as a web of liner material (i.e. a continuous sheet of liner material). The web of liner material may be provided on a roll of liner material, that is unrolled and fed to the liner joining station 407 then adhered to the card web 402.

The liner material 408 may have a width corresponding to the width of the liner of the resulting carton blank produced by machine 400. Alternatively, the liner material 408 may have a width greater than the width of the liner and in such embodiments the liner joining station 407 may further comprise cutting means arranged to cut the liner material 408 to the correct width prior to joining the liner material 408 to the card web 402. The cutting means may comprise one or more cutting blades arranged immediately upstream from the joining point at which the liner material 408 is adhered to the card web 402. In particular, the cutting means is arranged such that the distance between the cutting means and the joining point at which the liner material 408 is minimised. The one or more cutting blades may be stationary cutting blades, over which the liner material 408 is conveyed in order to cut the liner material 408. The one or more cutting blades may be rotating blades, which rotate such that the relative speed of the liner material 408 and cutting surface of the one or more cutting blades is increased.

In embodiments wherein the card web 402 comprises multiple card outer blanks arranged across the width of the card web 402, and the liner material 408 is provided as a web of liner material, the liner joining station 407 may further comprise a cutting means for removing multiple strips 408a of the web of liner material before the liner material 408 is adhered to the card web 402. This process is illustrated in FIG. 5, where the exemplary card web 502 comprises three card outer blanks 502a- c arranged across the width of the card web 502. The removed strips 508a-b of liner material 508 correspond to the a side edge of each of the multiple card outer blanks 508. It will be appreciated that the cutting means may be configured to remove any excess liner material 408 from other locations in the web of liner material as required. In the example shown, where the liner 508 of the resulting carton blank is spaced from the side edge of the card outer blank 502a-c by 8mm, the cutting means is configured to remove 8mm strips 508a-b from the web of liner material before it is adhered to the card web 502.

The cutting means may comprise a plurality of cutting blades, positioned immediately upstream from the joining point at which the liner material 408 and card web 402 are joined. The cutting means is arranged close to the joining point, such that the distance that the liner material has to travel from the cutting means to the joining point is minimised. The inventors have appreciated that positioning the cutting means immediately upstream from the joining point, such that the distance from the joining point is minimised ensures that the liner material 408 maintains proper alignment with the card web 402, and the correct tension of the liner material can be maintained. By removing the strips of liner material, the web of liner material is split by the cutting means into multiple webs of liner material each having a width equal to the length or width of the liner of a carton blank. Increasing the distance between the cutting means and the joining point makes it more difficult to maintain alignment between each of the resulting multiple liner webs and the card web 402. Reducing the distance between the cutting means and the joining point reduces the chances of the resulting multiple liner webs from becoming misaligned or incorrectly tensioned. Including a cutting means is further advantageous as it enables the liner material 408 to be provided as a single web, rather than multiple webs depending on the number of card outer blanks arranged across the width of the card web 402. Providing the liner material 408 as a single web greatly simplifies the process of aligning the liner material 408 with the card web 402, since only one web needs to be aligned with the card web 402.

In some embodiments, the cutting means is located less than 20cm from the joining point, preferably less than 10cm from the joining point, even more preferably less than 5cm from the joining point, even more preferably less than 2cm from the joining point.

The liner joining station 407 may comprise an adhesive applicator for applying adhesive to the liner material 408 in order to adhere the liner material 408 to the card web 402. The adhesive applicator may be configured to apply adhesive to the liner material 408 in an area corresponding to the periphery of the liner of a resulting carton blank. To produce a carton blank such as the example shown in FIG. 3, the adhesive may be applied to the liner material 408 in an area corresponding to each of the four outer edges of the liner 17. It will be appreciated that the adhesive may be applied to the liner material 408 in other suitable areas and patterns in order to adhere the liner material 408 to the card web 402. In alternative embodiments, the adhesive applicator may be configured to apply adhesive to the card web 402 instead of, or in addition to, the liner material 408. The adhesive applicator may be any suitable means, such as a gravure printing system, flexographic printing system, spray head applicator, or movable nozzle applicator. The adhesive applied by the adhesive applicator may be a laminating adhesive, or other suitable type of adhesive.

The liner joining station 407 may further comprise one or more web smoothing means, located upstream of the joining point at which the liner material 408 and card web 402 are joined. The web smoothing means may comprise a web spreading roller, designed to ensure that the card web 402 and/or web of liner material is smooth prior to adhering the liner material 408 to the card web 402.

The liner joining station 407 may further comprise an abrading apparatus, located upstream of the adhesive applicator. The abrading apparatus may be configured to abrade the surface of the liner material, such that the surface of the liner material is roughened. Roughening the surface of the liner material, and thereby increasing its surface energy, may improve the strength of the bond between the liner material and the card web 402.

The machine 400 may further comprise one or more web conveying means, configured to drive the card web 402 and/or the web of liner material (in embodiments where the liner material 408 is provided as a web of liner material) through the stations of the machine 400. The conveying means may comprise one or more web drive rollers. The conveying means may be further configured to maintain the tension of the card web 402 and/or web of liner material at a predetermined value. In this regard, the conveying means may further comprise a tension sensor, arranged to measure the tension of the web as it is conveyed through the machine. Based on the measured tension, the conveying means may adjust the speed of one or more of the web drive rollers to maintain the tension of the web. Alternatively, one or more of the web drive rollers may be arranged as a floating roller, wherein the lateral position of the roller is unfixed such that the roller may change position in order to maintain the desired tension in the web.

The perforation station 403, coating station 404, first adhesive applicator 405, second adhesive applicator 406 and liner joining station 407 may be arranged in any order. However, as set out above, it is preferred that the perforating station 403 is arranged downstream from the coating station 404, and that the liner joining station 407 is arranged downstream of the coating station 404, first adhesive applicator 405, and second adhesive applicator 406.

The machine 400 may further comprise a splicing means 411. The splicing means 411 is arranged to join a new card web to the card web 402. The card web 402 is typically provided on a roll, which is unwound and then conveyed through the machine 400 via the web conveying means. The splicing means 411 may be configured to attach a new roll of card web to the card web 402, for example when card web 402 reaches the end of a roll. This allows the machine 400 to continue to operate without pausing to change rolls of card web 402.

The machine 400 may further comprise a web guide 412. The web guide 412 is configured to maintain the lateral alignment between the card web 402 and each of the stations of the machine 400. The web guide 412 may comprise one or more sensors, such as optical sensors, that are configured to detect the lateral position of the card web 402 as it is conveyed through the machine 400. Based on the detected position, the web guide may adjust the angle of one or more rollers such as rollers comprised in the web conveying means, in order to maintain the lateral position of the card web 402 within a predetermined range of lateral position. The lateral position is the position perpendicular to the direction of travel of the card web 402, in the plane of the card out web material.

In some embodiments, the machine 400 may be arranged as a single processing line, wherein each of the perforation station 403, coating station 404, first adhesive applicator 405, second adhesive applicator 406, and liner joining station 407 are arranged consecutively, such that card web 402 is conveyed directly from one station to the next. Alternatively, the machine 400 may be modular in nature, wherein the stations are split into two or more separate sections. For example, in some embodiments the liner joining station 407 may be separated from the remaining stations. FIG. 7 illustrates an exemplary embodiment of a machine 700 for forming a roll of carton blanks in accordance with the present invention. The machine 700 receives card web 702 as a roll of card web. The card web 702 is unwound from the roll and conveyed through the machine using a plurality of nip rollers arranged throughout the machine 700. Nip rollers are known in the art, and comprise two opposing rollers between which the card web passes. One or both of the opposing rollers are driven such that the card web is conveyed through the machine 700. The card web 702 has a width that is approximately equal to three times the width of a carton blank, as illustrated in FIG. 6.

In the illustrated embodiment of FIG. 7, the machine 700 operates from left to right. The top and bottom surfaces of the card web 702 are labelled “T” and “E3”.

The card web 702 is received by perforation station 703, via splicing table 711. As set out above, the splicing table 711 is arranged to join a new roll of card web material to the existing card web 702, for example when the existing roll is depleted. The perforation station 703 receives the card web 702 and forms perforations in the card web 702. The perforations in the card web 702 may, for example, correspond to the line of perforations 15 defining the tear line 14 shown in the exemplary carton embodiments of FIGS. 1 to 3. The perforation station 703 perforates the card web 702 from the top surface to the bottom surface.

The perforation station 702 outputs the perforated card web 702. The machine 700 is configured to convey the perforated card web 702 to the coating station 704. The coating station 704 receives the perforated card web 702 from the perforation station 703 and applies a UV varnish to the top surface of the card web 702. As described above, othersuitable protective coatings may be applied by the coating station. The UV varnish is applied to the top surface of the card web 702 at least over the perforations in the card web 702, so that the varnish can flow into the perforations before the varnish is cured. The coating station 704 further comprises one or more UV lamps (not shown) arranged to cure the UV varnish before the card web 702 leaves the coating station 704.

The coating station 704 outputs the coated, perforated card web 702. The machine 700 is configured to convey the card web to a creasing and punching station 710. The creasing and punching station 710 is configured to form crease lines in the card web. The crease lines are embossed lines formed by pressing the card web 702. For example, the creasing and punching station 710 may form crease lines in the card web 702 corresponding to the crease lines 41 of the exemplary carton blank shown in FIG. 3.

The creasing and punching station 710 outputs the card web 702. The machine 700 is configured to convey the card web 702 from the creasing and punching station to the first adhesive station 705. The first adhesive station 705 comprises first adhesive applicator, configured as a gravure printing system configured to receive the card web 702 and apply a heat-activated adhesive to the bottom surface of the card web 702. The first adhesive applicator comprises a gravure roller and an impression roller, arranged to apply the heat-activated adhesive to the bottom surface of the card web 702 in a pattern that corresponds to a first side edge of each of the card outer blanks arranged across the width of the card web 702. The first adhesive station 705 further comprises an infrared drier comprising a plurality of infrared lamps arranged to dry the adhesive before the card web 702 leaves the first adhesive station 705.

The first adhesive station 705 outputs the card web 702. The machine 700 is configured to convey the card web 702 to a second adhesive station 706 via a turn bar 709. The turn bar 709 reverses the orientation of the card web 702 as the card web 702 passes through the turn bar, such that the top and bottom surfaces are swapped.

The second adhesive station 706 is configured to receive the card web 702 and apply a heat- activated adhesive to the top surface of the card web 702. The second adhesive station 706 comprises a second adhesive applicator configured to apply the heat-activated adhesive in a pattern corresponding to a second side edge of each of the card outer blanks arranged across the width of the card web 702. The second side edge opposes the first side edge to which the heat- activated adhesive is applied by the first adhesive applicator. The first and second side edges are the side edges that are adhered together to form the side seam (12, FIG. 1) of a carton. The second adhesive station 706 further comprises an infrared drier having a plurality of infrared lamps arranged to dry the adhesive before the card web 702 leaves the second adhesive station 706.

The second adhesive station 706 outputs the card web 702. The machine 700 is configured to convey the card web 702 from the second adhesive station 706 to the liner joining station 707. The liner joining station 707 is configured to receive the card web 702, and a linerweb 708, and adhere the linerweb 708 to the card web 702 to produce a web of carton blanks such as the web of carton blanks 602 shown in FIG. 6.

The liner joining station 707 is configured to align and adhere the linerweb 708 to the card web so that the liner web 708 forms the liner of each respective carton blank of the web of carton blanks. The liner joining station 707 comprises a gravure printing system configured to apply a laminating adhesive to the linerweb 708 in a pattern that corresponds to the periphery of the liner of each carton blank of the web of carton blanks. As described above with respect to FIGS. 3 and 4, the liner of each resulting carton blank is aligned with three edges of the card outer blank, but is spaced apart from the first side edge to which the first adhesive station applies heat-activated adhesive. The liner joining station 707 comprises cutting blades configured to remove sections of the liner web 708 prior to the linerweb 708 being adhered to the card web 702, as illustrated in FIG. 5. The removed sections 508a-b of liner web 508 correspond to the first side edges of each card outer blank 502a-c of the card web 502. The inventors have appreciated that by providing the liner material as a single linerweb 708, and cutting the linerweb 708 to form the respective liners of each carton blank of the web of carton blanks, the process of maintaining alignment between the liner material and card web 702 is simplified.

The machine 700 may further comprise a rewinding station configured to receive the web of carton blanks from the liner joining station and wind the web of carton blanks onto a roll.

FIGS. 8A and 8B illustrate a specific embodiment of a machine 800 for forming a roll of carton blanks in accordance with the present invention. The machine 800 receives card web 802 as a roll of card web. The card web 802 is unwound from the roll and conveyed through the machine using a plurality of nip rollers arranged throughout the machine. The card web 802 has a width that is approximately equal to 3, 4, 5, or another integer, times the width of a carton blank.

In the illustrated embodiment of FIGS. 8A and 8B, the machine 800 operates from left to right. The dotted line indicates where the machine 800 is split across FIGS. 8A and 8B. The machine 800 as illustrated is continuous, although it will be appreciated that the machine 800 is modular, and may comprise two or more modules each having one or more processing stations that are arranged separately.

The machine 800 comprises a splicing table 811. The splicing table 811 is arranged to join a new roll of card web material to the existing card web 802. For example, when the current roll of card web material is depleted, the splicing table 811 may be configured to join the leading end of a new roll of card web material on to the trailing end of the card web 802 to provide a seamless transition to a new roll of card web material. The card web 802 is received by the coating station 804. The coating station 804 receives the card web 802 and applies a UV-curable varnish to a first surface 802a of the card web 802. Where the card web 802 has a printed surface, the printed surface is the first surface 802a. As described above, other suitable protective coatings may be applied by the coating station 804a. The UV-curable varnish is applied to the first surface 802a at least over an area covering where the plurality of perforations are subsequently formed in each card blank of the card web 802. The coating station 804 may apply the UV-curable varnish to the first surface 802a of the card web 802 to substantially cover each card blank of the card web 802. The coating station 804 may not apply the protective coating to an area of the card web to which adhesive is later applied, such as along a first side edge of the first surface 802a.

The coating station 804 outputs the coated card web 802. The machine is configured to convey the card web 802 to the perforation station 803. The perforation station 803 receives the card web 802 and forms perforations in the card web 802. The perforations in the card web 802 may, for example, correspond to the line of perforations 15 defining the tear line 14 shown in the exemplary carton and carton blank embodiments of FIGS. 1 to 3. The perforation station 803 perforates the card web 802 from the first surface 802a of the card web 802 to the second surface 802b of the card web 802.

The perforation station 803 outputs the perforated and coated card web 802. The machine 800 is configured to convey the card web 802 to the creasing station 810. The creasing station 810 receives the card web 802 and forms one or more crease/fold lines in the card web. In the embodiment of FIGS. 8A and 8B, the creasing station 810 forms the crease/fold lines as embossed lines formed by pressing the card material of the card web 802. The creasing station 810 may be configured to form crease/fold lines in the card web 802 that correspond to the crease lines 41 of the exemplary carton blank shown in FIG. 3.

The creasing station 810 outputs the card web 802. The machine 800 is configured to convey the card web 802 to the punching station 812. The punching station 812 receives the card web and punches one or more openings in the card web 802. The punching station 812 may be configured to form an opening in the card web 802 that corresponds to the opening 3 of the exemplary carton and carton blank illustrated in FIGS. 1 to 3.

The punching station 812 outputs the card web 802. The machine 800 is configured to convey the card web 802 from the punching station 812 to the adhesive station 805. The adhesive station 805 comprises a first adhesive applicator 805a and a second adhesive applicator 805b. The first adhesive applicator 805a is arranged to apply a heat-activated adhesive to the first surface 802a of the card web 802 in a pattern that corresponds to a first side edge of each of the card outer blanks arranged across the width of the card web 802. The second adhesive applicator 805b is arranged to apply a heat-activated adhesive to the second surface 802b of the card web in a pattern that corresponds to a second side edge of each of the card outer blanks arranged across the width of the card web 802. The second side edge opposes the first side edge to which the heat- activated adhesive is applied by the first adhesive applicator 805a. The first and second side edges correspond to the side edges that are adhered together to form the side seam of a carton, such as the exemplary carton shown in FIGS. 1 and 2. The adhesive station 805 further comprises an infrared drier 813 comprising a plurality of infrared lamps arranged on both sides of the card web and configured to dry the heat-activated adhesive on both sides of the card web 802 simultaneously before the card web 802 leaves the adhesive station 805. The first adhesive applicator 805a, second adhesive applicator 805b, and infrared drier 813 are preferably positioned such that the card web 802 travels through the first adhesive applicator 805a, second adhesive applicator 805b and infrared drier 813 in a straight line. This is preferred because it removes the need to guide the card web 802 using rollers or guides as it travels from the adhesive applicators to the infrared drier 813, while the heat-activated adhesive is still wet, thereby reducing the risk of adhesive being smudged, or transferred from the card web 802 to the machine 800. The adhesive station 805 outputs the card web 802. The machine 800 is configured to convey the card web 802 from the adhesive station 805 to the liner joining station 807. The liner joining station 807 is configured to receive the card web 807, and a liner web 808, and adhere the liner web 808 to the card web 802 to produce a web of carton blanks such as the web of carton blanks 602 shown in FIG. 6.

The liner joining station 807 is configured to align and adhere the linerweb 808 to the card web so that the liner web 808 forms the liner of each respective carton blank of the web of carton blanks. The liner joining station 807 comprises an adhesive applicator configured to apply a laminating adhesive to the linerweb 808 in a pattern that corresponds to the periphery of the liner of each carton blank of the web of carton blanks. As described above with respect to FIGS. 3 and 4, the liner of each resulting carton blank is preferably aligned with three edges of the card outer blank, but is spaced apart from the first side edge to which the first adhesive station 805a applies heat- activated adhesive. The liner joining station 807 comprises cutting blades configured to remove sections of the linerweb 808 prior to the liner web 808 being adhered to the card web 802, as illustrated in FIG. 5. The removed sections 508a-b of liner web 508 correspond to the first side edges of each card outer blank 502a-c of the card web 502. The inventors have appreciated that by providing the liner material as a single linerweb 808, and cutting the linerweb 808 to form the respective liners of each carton blank of the web of carton blanks, the risk of the liner material and the card web 802 becoming misaligned is reduced.

The machine 800 further comprises a rewinding station 809 configured to receive the web of carton blanks from the liner joining station 807 and wind the web of carton blanks onto a roll.

FIG. 9 illustrates a method of manufacturing a carton blank according to the present disclosure. The method may be performed by the machines of the present disclosure. The method comprises receiving 901 a card blank. The card blank is comprised in a web of card blanks, such as the card web 602 illustrated in FIG. 6. The method further comprises applying 902 a protective coating to the perforated card web. The protective coating is applied 903 to the card web in an area at least covering the perforations subsequently formed in the card web, and preferably the protective coating is applied 903 to cover the surface of the card web, apart from an area to which adhesive will be subsequently applied. The protective coating is applied 903 in accordance with coating station 404, coating station 704, and coating station 804 described above. The method further comprises perforating 903 the card blank to form a plurality of perforations therein. The perforations may be arranged in accordance with those described above in relation to perforation station 403, perforation station 703, and/or perforation station 803. The method further comprises applying 904 an adhesive to a first surface of the card blank. In particular, the method comprises applying 904 a heat-activated adhesive along a first side edge of the card blank, as described above in relation to first adhesive applicator 405, first adhesive station 705, and first adhesive applicator 805a. The method further comprises applying 905 an adhesive to a second surface of the card blank. In particular, the method comprises applying 905 a heat-activated adhesive to the second surface along a second side edge of the card blank, wherein the first side edge and second side edges are opposing side edges that are used to form the side seam (12, FIG. 1) of a carton. The adhesive may be applied 905 in accordance with the second adhesive applicator 406, second adhesive station 706, and/or second adhesive applicator 805b as described above. The method further comprises adhering 906 a liner to the card blank to form the carton blank. The liner may be adhered 906 in accordance with the liner joining station 407 and/or liner joining station 707 as described above.

Throughout the present application, reference to “upstream” and “downstream” refers to the a position with respect to the movement of the card web (and/or liner material) through the machine. For example, during operation of the machine, the card web will travel from an “upstream” station to a “downstream” station. Reference to a first station or apparatus being “immediately upstream” and “immediately downstream” from a second station or apparatus infers that there are no processing steps or stations between the first object or station and the second object or station. It will be appreciated that where a first processing station is described as being arranged “upstream” or “downstream” from a second processing station, the first processing station may be arranged immediately upstream or downstream from the second processing station.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention^) may be practiced and provide for a superior carton, carton blank, and associated methods of manufacture. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims

1. A machine for forming a roll of carton blanks, the machine comprising: a perforating station configured to receive a card web comprising a plurality of card blanks, and form a plurality of perforations in each card blank of the card web; a coating station configured to apply a protective coating to a first surface of each card blank of the card web; a first adhesive applicator configured to apply adhesive to the first surface of each card blank of the card web; a second adhesive applicator configured to apply adhesive to a second surface of each card blank of the card web, the second surface opposing the first surface; a liner joining station configured to receive a liner material, and adhere the liner material to overlay the second surface of each card blank of the card web, wherein the liner joining station is located downstream from the coating station, the first adhesive applicator, and the second adhesive applicator.

2. The machine of claim 1 , wherein the coating station is located downstream from the perforating station, and the coating station is configured to apply the protective coating at least over the plurality of perforations to prevent passage of liquid through the plurality of perforations.

3. The machine of claim 1 , wherein the coating station is located upstream from the perforating station.

4. The machine of any one of the preceding claims, wherein the first adhesive applicator is configured to apply adhesive along a first side edge of the first surface of each card blank of the card web and the second adhesive applicator is configured to apply adhesive along a second side edge of the second surface of each card blank of the card web, wherein the first and second side edges are opposing side edges of the card blank.

5. The machine of any one of the preceding claims, wherein the first adhesive applicator and second adhesive applicator are configured to apply a heat-activated adhesive.

6. The machine of any one of the preceding claims, wherein the liner material is a web of liner material.

7. The machine of any one of the preceding claims further comprising a turning device configured to flip the orientation of the card web, wherein the turning device is located between the first adhesive applicator and the second adhesive applicator.

8. The machine of any one of the preceding claims further comprising a web guide configured to maintain the lateral position of the card web in the carton blank forming machine, wherein the web guide is located upstream from the liner joining station, preferably upstream from the perforation station.

9. The machine of any one of the preceding claims, further comprising a splicing table configured join the leading end of a new sheet of card web material to the trailing end of the card web to form a continuous sheet of card web material, wherein the splicing table is located upstream from the perforation station.

10. The machine of any preceding claim, wherein the liner joining station comprises a third adhesive applicator configured to apply adhesive to either the liner material or to the card web to adhere the liner material to the card web.

11. The machine of any one of the preceding claims, wherein the protective coating is an ultraviolet, UV, curable varnish.

12. The machine of claim 11 , wherein the coating station comprises an ultraviolet lamp configured to cure the varnish.

13. The machine of any one of the preceding claims, further comprising a first drying apparatus located immediately downstream from the first adhesive applicator, and a second drying apparatus located immediately downstream from the second adhesive applicator, wherein the first drying apparatus and second drying apparatus are configured to dry the adhesive applied to the first and second surfaces of each card blank of the card web respectively.

14. The machine of any one of claims 1 to 12, wherein the first adhesive applicator and second adhesive applicator are comprised in a single adhesive station, the single adhesive station further comprising a drying apparatus; wherein the drying apparatus is located downstream from the first adhesive applicator and the second adhesive applicator; and wherein the drying apparatus is configured to dry the first and second surfaces of the card web simultaneously.

15. The machine of claim 14, wherein the first adhesive applicator, second adhesive applicator, and drying apparatus are arranged such that the card web is conveyed in a substantially straight line through the first adhesive applicator, second adhesive applicator, and drying apparatus.

16. The machine of any one of the preceding claims, wherein the card web comprises an array of card blanks arranged with a plurality of card blanks arranged longitudinally along the web and a plurality of card blanks arranged laterally across the web, such that each station of the machine processes multiple laterally-arranged card blanks simultaneously.

17. The machine of claim 16, wherein the liner joining station is configured to receive a web of liner material having a width corresponding to the width of the card web, and the liner joining station further comprises a cutting means configured to remove strips of the liner web at locations corresponding to a side edge of each of the multiple laterally-arranged card blanks immediately before adhering the web of liner material to the card web.

18. The machine of any one of the preceding claims, wherein the processing order of the stations is: coating station; perforating station; first adhesive station; second adhesive station; liner joining station.

19. The machine of any one of the preceding claims, further comprising a creasing station configured to crease the card web to form one or more fold lines in each card blank of the card web.

20. The machine of claim 19, wherein the creasing station is located downstream from the coating station.

21. The machine of claim 19 or claim 20, wherein the creasing station is located upstream from the liner joining station.

22. The machine of any one of the preceding claims, further comprising a punching station configured to cut or punch the card web to form one or more openings in each card blank of the card web.

23. The machine of claim 22, wherein the punching station is located downstream of the coating station, and upstream from the liner joining station.

24. The machine of any one of the preceding claims, wherein: each card blank of the card web has a top edge, a bottom edge, and opposing first and second side edges; the perforation station is configured to form a line of perforations in each card blank of the card web, extending from at or adjacent the top edge of the card blank to at or adjacent the bottom edge of the card blank, wherein the top edge of the card blank is arranged to form a top seam of a carton and the bottom edge of the card blank is arranged to form a bottom seam of the carton; the coating station is configured to apply the protective coating to substantially cover the first surface of each card blank of the card web except the first edge of the first surface of each card blank of the card web; and the liner joining station is configured to adhere the liner to each card blank such that one edge of the liner is spaced from the second side edge of the card blank, and the remaining edges of the liner are aligned with the top, bottom, and first side edges of the card blank, wherein the first and second side edges are arranged to be joined to form a side seam of the carton extending between the top seam and bottom seam.

25. A method of manufacturing a carton blank, the method comprising the steps of: receiving a card blank; perforating the card blank to form a plurality of perforations therein; applying a protective coating to a first surface of the card blank; applying adhesive to a first surface of the card blank; applying adhesive to a second surface of the card blank, the second surface opposing the first surface; and adhering a liner to overlay the second surface of the card blank, wherein the adhering the liner is performed after applying the protective coating, applying adhesive to the first surface, and applying adhesive to the second surface.

26. The method of claim 25, wherein the applying a protective coating comprises applying the protective coating at least over the plurality of perforations to prevent passage of liquid through the plurality of perforations, and the applying a protective coating is performed after the perforating of the card blank.

27. The method of claim 25, wherein the applying a protective coating is performed before the perforating of the card blank.

28. The method of any one of claims 25 to 27, wherein the card blank is received as a card web comprising a plurality of card blanks.

29. The method of claim 28, wherein the liner is provided as a web of liner material, the web of liner material being adhered to the web of card blanks.

30. The method of any one of the preceding claims, wherein the applying adhesive to the first surface of the card blank comprises applying adhesive along a first edge of the card blank and the applying adhesive to the second surface of the card blank comprises adhesive along a second edge of the card blank, wherein the first edge and second edge are opposing side edges of the card blank.

31. The method of any one of the preceding claims, further comprising flipping the orientation of the card blank after applying the adhesive to the first surface, and before applying the adhesive to the second surface.

32. The method of any one of the preceding claims, wherein the adhering the liner to the card blank comprises applying an adhesive to either the liner or to the card blank to adhere the liner to the card blank.

33. The method of any one of the preceding claims, wherein the protective coating is an ultraviolet (UV) curable varnish.

34. The method of claim 33, further comprising curing the varnish, via an ultraviolet lamp.

35. The method of any one of the preceding claims, further comprising drying the adhesive applied to the first surface before applying the adhesive to the second surface, and drying the adhesive applied to the second surface before adhering the liner, wherein drying the adhesive is performed using a drying apparatus.

36. The method of any one of claims 25 to 34, further comprising drying the adhesive applied to the first and second surfaces simultaneously, wherein drying the adhesive is performed using a drying apparatus.

37. The method of any one of the preceding claims, performed in the order: receiving the card blank; applying the protective coating; perforating the card blank; applying adhesive to the first surface; applying adhesive to the second surface; adhering the liner to the card blank.

38. The method of any one of the preceding claims, further comprising creasing the card web to form one or more fold lines.

39. The method of any one of the preceding claims, further comprising punching or cutting one or more openings in the card web.

40. The method of any one of the preceding claims, wherein: the card blank has a top edge, a bottom edge, and opposing first and second side edges; perforating the card blank comprises forming a line of perforations in the card blank, the line of perforations extending from at or adjacent the top edge of the card blank to at or adjacent the bottom edge of the card blank, wherein the top edge of the card blank is arranged to form a top seam of a carton and the bottom edge of the card blank is arranged to form a bottom seam of a carton; applying the protective coating comprises applying a protective coating to substantially cover the first surface of the card blank except the first edge of the card blank; and adhering the liner comprises applying adhesive around the entire periphery of the liner, and arranging the liner to overlay the second surface of the card blank such that one edge of the liner is spaced from the second side edge of the card blank, and the remaining edges of the liner are aligned with the top, bottom, and first side edges of the card blank, wherein the first and second side edges of the card blank are arranged to form a side seam of the carton extending between the top seam and the bottom seam.