U.S. patent application number 10/100360 was filed with the patent office on 2003-01-16 for vertical multipack.
Invention is credited to Knoerzer, Anthony Robert, Kohl, Garrett William, Tucker, Steven Kenneth.
Application Number | 20030009989 10/100360 |
Document ID | / |
Family ID | 22279345 |
Filed Date | 2003-01-16 |
United States Patent
Application |
20030009989 |
Kind Code |
A1 |
Knoerzer, Anthony Robert ;
et al. |
January 16, 2003 |
Vertical multipack
Abstract
Multiple side-by-side packages are produced on a vertical form,
fill, and seal machine by using a former/delivery tube assembly
designed for this purpose. The front and back surfaces of the
package are sealed together to form separate pouches. The
technology is extendable to more than two pouches simultaneously
and can handle pouches of the same or different sizes and food
products that are either the same or unlike.
Inventors: |
Knoerzer, Anthony Robert;
(Allen, TX) ; Kohl, Garrett William; (Allen,
TX) ; Tucker, Steven Kenneth; (Hurst, TX) |
Correspondence
Address: |
CARSTENS YEE & CAHOON, LLP
P O BOX 802334
DALLAS
TX
75380
|
Family ID: |
22279345 |
Appl. No.: |
10/100360 |
Filed: |
March 18, 2002 |
Current U.S.
Class: |
53/451 ;
53/551 |
Current CPC
Class: |
B65B 2220/22 20130101;
B65B 9/20 20130101; B65B 2230/02 20130101; B65D 75/42 20130101;
B65D 75/527 20130101; B65B 9/2028 20130101; B65B 9/22 20130101 |
Class at
Publication: |
53/451 ;
53/551 |
International
Class: |
B65B 009/06 |
Foreign Application Data
Date |
Code |
Application Number |
May 18, 2001 |
GB |
2101909 |
Claims
What is claimed is:
1. A product package having a first and a second edge opposite each
other, said package comprising: a first pouch; a second pouch,
attached to said first pouch and separated from said first pouch by
a first seal; a second seal that runs across said first edge of
said package, perpendicular to and intersecting said first seal;
and a third seal that runs across said second edge of said package,
perpendicular to and intersecting said first seal; wherein said
product package is formed from a single sheet of film.
2. The product package of claim 1, wherein said first and said
second pouches are of equal size.
3. The product package of claim 1, wherein said first and said
second pouches are of unequal size.
4. The product package of claim 1, wherein said first seal is laser
scored for easy separation of said first and second pouches.
5. The product package of claim 1, wherein said first and second
pouches contain the same product.
6. The product package of claim 1, wherein said first and second
pouches contain complementary food products.
7. The product package of claim 1, wherein said first and second
pouches contain dissimilar food products.
8. The of product package of claim 1, wherein said film has one or
more layers, said layers being formed of materials from the group
consisting of polypropylene, polyester, paper, polyolefin
extrusions, and adhesive laminates.
9. A vertical form, fill, and seal machine having the capability of
producing a plurality of side-by-side packages.
10. The vertical form, fill, and seal machine of claim 9, wherein
said vertical form, fill, and seal machine forms a single sheet of
packaging film into a package having a front surface and a back
surface and makes a vertical seal that seals a portion of said
front surface to a portion of said back surface.
11. The vertical form, fill, and seal machine of claim 9, wherein
said produces side-by-side packages that contain identical
products.
12. The vertical form, fill, and seal machine of claim 9, wherein
said machine produces side-by-side packages that contain different
products.
13. The vertical form, fill, and seal machine of claim 9, wherein
said machine is capable of producing side-by-side packages that are
the same size.
14. The vertical form, fill, and seal machine of claim 9, wherein
said machine is capable of producing side-by-side packages that are
unequal in size.
15. A method of packaging products, comprising: feeding a roll of
packaging film into a vertical form, fill, and seal machine such
that said packaging film is directed to form a front surface and a
back surface for a plurality of pouches; forming a vertical seal on
said packaging film, wherein said vertical seal seals a portion of
said front surface to a portion of said back surface; forming a
first horizontal seal on said packaging film; and after advancing
said film a given distance, forming a second horizontal seal on
said packaging film; wherein said vertical seal extends from said
first horizontal seal to said second horizontal seal.
16. The packaging method of claim 15, further comprising, prior to
forming said second horizontal seal, placing a plurality of
products into first and second pouches that are separated by said
vertical seal.
17. The method of claim 15, wherein said plurality of food products
are identical foods.
18. The method of claim 15, wherein said plurality of food products
are dissimilar.
19. The method of claim 15, wherein said side-by-side packages are
of equal size.
20. The method of claim 15, wherein said side-by-side packages are
of unequal size.
21. The method of claim 15, wherein more than two side-by-side
packages are produced.
22. The method of claim 15, further comprising forming an aid to
separation between said side-by-side packages.
23. The method of claim 15, wherein said packaging step uses a
single sheet of packaging film.
24. A method of packaging products, comprising the steps of:
installing, on a vertical form, fill, and seal machine, a former
and multiple delivery tubes designed to produce multiple
side-by-side packages; packaging a plurality of products into
side-by-side packages.
25. The method of claim 24, further comprising forming a vertical
seal that seals a front portion of said package to a back portion
of said package to form said side-by-side packages.
26. The method of claim 24, further comprising forming first and
second horizontal seals, separated from each other by a vertical
distance, which are each intersected by a vertical seal that seals
a front portion of said package to a back portion of said package
to form said side-by-side packages.
27. The method of claim 24, wherein said packaging step uses a
single sheet of packaging film.
28. The method of claim 24, wherein said plurality of food products
are identical foods.
29. The method of claim 24, wherein said plurality of food products
are dissimilar.
30. The method of claim 24, wherein said side-by-side packages are
of equal size.
31. The method of claim 24, wherein said side-by-side packages are
of unequal size.
32. The method of claim 24, wherein more than two side-by-side
packages are produced.
33. The method of claim 24, further comprising forming an aid to
separation between said side-by-side packages.
34. The method of claim 24, wherein said packaging step uses a
single sheet of packaging film.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to packaging of a product on a
vertical form, fill, and seal machine, and more particularly to
simultaneously forming, filling and sealing two or more packages
side-by-side.
[0003] 2. Description of Related Art
[0004] Form, Fill, and Seal
[0005] Vertical form, fill, and seal packaging machines are
commonly used in the snack food industry for forming, filling, and
sealing bags of chips and other like products. One such packaging
machine is seen diagrammatically in FIG. 1. This drawing is
simplified, and does not show the cabinet and support structures
that typically surround such a machine, but it demonstrates the
working of the machine well. Packaging film 110 is taken from a
roll 112 of film and passed through tensioners 114 that keep it
taut. The film then passes over a former 116, which directs the
firm into a vertical tube around a product delivery cylinder 118.
As the tube is pulled downward by drive belts 120, the vertical
tube of film is sealed along its length by a vertical sealer 122,
forming a back seal 124. The machine then applies a pair of
heat-sealing jaws 126 against the tube to form a transverse seal
128. This transverse seal 128 acts as the top seal on the bag 130
below the sealing jaws 126 and the bottom seal on the bag 132 being
filled and formed above the jaws 126. After the transverse seal 128
has been formed, a cut is made across the sealed area to separate
the finished bag 130 below the seal 128 from the partially
completed bag 132 above the seal. The film tube is then pushed
downward to draw out another package length. Before the sealing
jaws form each transverse seal, the product to be packaged is
through the product delivery cylinder 118 and is held within the
tube above the transverse seal 128.
[0006] The material that is fed into the form, fill, and seal
machine is typically a packaging film, such as polypropylene,
polyester, paper, polyolefin extrusions, adhesive laminates, and
other such materials, or from layered combinations of the above.
For many food products, where flavor retention is important, a
metalized layer will form the innermost layer.
[0007] The form, fill, and seal machines are quite expensive, in
the range of $250,000 each, but pay for themselves easily when
compared to the cost of pre-formed bags and the machinery to fill
them. However, in order to maximize the productivity of the form,
fill, and seal machines, it is common for the product delivery tube
118 and former 116 to be made as a unit that is easily
interchangeable in less than 15 minutes. The length of the
transverse seal can also be changed, by exchanging the sealing
jaws, or in some cases, merely by exchanging the facing (the
portion of the sealing jaws which actually makes contact with the
packaging film). By changing these elements, as well as the width
of film roll feeding into the machine and the programming of the
machine, one form, fill, and seal machine can handle a number of
different products in different size packages, limited primarily by
the width of film the machine will handle, the maximum length of
bag the machine is designed to handle, and the available
former/delivery tube assemblies.
[0008] Multipacks
[0009] A popular marketing concept is that of packaging two or more
individually sealed items together. These can be, for example,
multiple single-servings of one product, or servings of two or more
complementary items, such as cheese and crackers. While the
marketing idea of multi-packs may be simple, the translation of
that idea to current packaging technology can be more difficult.
Often, rather than packaging a product into several different
packages at the same time, each package is separately produced, as
usual, then the various packages are boxed together or over-wrapped
to form a multi-pack. It would be preferable to be able to produce
multiple packages fastened together for sales, but which could be
separated by the consumer for convenience.
[0010] One current solution is the use of a "saddle-bag" pouch, an
example of which is seen in FIG. 2. Here, a product is packaged in
a twin-pack 210/211,using a pouch configuration. To achieve this
packaging end, the transverse seals 212A and 212D at each end of
the twin-pack are separated from the transverse seals adjacent to
them, but no cut is made between the two transverse seals 212B and
212C that separate bag 210 from bag 211. For convenience to the
consumer, perforations 214 are formed in the gap between the two
adjacent transverse seals 212B and 212C so that the consumer can
separate the two pouches easily.
[0011] This method of packaging is limited. Since there is only one
delivery tube, the same product must be packaged in each half of
the twin pack. That is, it is not possible to make attached bags
containing different products. Neither is it possible to speed up
the packaging process. Processes such as creating the transverse
seal will take a given amount of time, regardless of whether the
bag is 5 inches across or 15 inches. Since the saddle-bag packs
must be created and filled individually, it takes twice as long to
make a saddle-bag pack as it does to create one regular package of
the same size. If bags could be produced side-by-side, the
packaging time for a given number of packages would be cut, but
that has not been possible with the previous machinery. Further,
the programming of the machine (e.g., the length of bag to pull,
where to cut or perforate) will handle only segments of packaging
of 24 inches or less before the process repeats. This is the
maximum length of one impression and limits the size of packages
that can be produced in saddlebag packs.
[0012] New methods of producing a multi-pack are desirable to
maintain and expand the marketability of snack foods. It would be
desirable to be able to package several packages side by side in
order to fill them simultaneously and cut the packaging time. It
would also be desirable to package different products in this
side-by-side process, and to seal each item into an appropriately
size pouch, even when that meant creating different sizes of
pouches at the same time. Finally, it would be desirable to do all
of this using the current form, fill, and seal technology, so that
no large capital investments are necessary to use the
technology.
SUMMARY OF THE INVENTION
[0013] In the present invention, side-by-side multi-packs are
produced on a vertical form, fill, and seal machine. A specially
designed former/delivery tube assembly shapes the film into
side-by-side packages, while separate delivery tubes allow
identical or different snack items to be packaged simultaneously.
This inventive packaging can allow new methods of presenting foods
to the consumer. Various embodiments of the invention will have one
or more of the following advantages:
[0014] the products are packaged side-by-side, increasing
throughput and saving time;
[0015] different products can be packaged simultaneously, as well
as producing multi-packs of the same product;
[0016] the sizes of the different packages can be individually
determined to best fit the product; and
[0017] the multi-packs are produced on standard form, fill, and
seal machines, requiring only new former/delivery tube assemblies
and, when more than two bags are formed side-by-side, additional
sealers to form the vertical seals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The novel features believed characteristic of the invention
are set forth in the appended claims. The invention itself,
however, as well as a preferred mode of use, further objectives and
advantages thereof, will be best understood by reference to the
following detailed description of illustrative embodiments when
read in conjunction with the accompanying drawings, wherein:
[0019] FIG. 1 is a perspective view of a prior art form, fill, and
seal machine.
[0020] FIG. 2 is a cross-section of a prior art saddle-bag
package.
[0021] FIGS. 3A and B are front and top views respectively of an
exemplary twin-pack produced using a vertical form, fill, and seal
machine.
[0022] FIG. 4A is a front view of an exemplary former/delivery tube
assembly that can be used to package the side-by-side twin-packs of
FIGS. 3A and B.
[0023] FIG. 4B is a side view of the former/delivery tube assembly
of FIG. 4a.
[0024] FIG. 5 is a cross-section of the former/delivery tube
assembly taken at point 5-5' of FIG. 4B.
[0025] FIG. 6 is a cross-section of the former/delivery tube
assembly taken at point 6-6' of FIG. 4B.
[0026] FIG. 7 shows a cross-section of an exemplary former/delivery
tube assembly designed to produce a three-pack containing different
products.
[0027] FIG. 8 shows an exemplary package produced using the
former/delivery tube assembly of FIG. 7.
DETAILED DESCRIPTION
[0028] An exemplary embodiment of the invention will now be
discussed with reference to FIGS. 3A and 3B. FIG. 3A is a
diagrammatical front view of a twin-pack 310 produced by the
assignee of this application on a vertical form, fill, and seal
machine. Like the previous bags, a horizontal transverse seal 302,
304 runs all the way across the top and the bottom of the
twin-pack. However, the back seal, which seals the two halves of
the back together, is replaced by a longitudinal seal 306, which
seals each of the two halves of the back to the front of the
package, forming two separate pouches 310A, 310B from the packaging
film. Longitudinal seal 306 is wide enough that the two pouches
310A, 310B can be separated without destroying the integrity of
either pouch, and preferably has a feature to aid the consumer in
separating the two bags. This feature can be a line of perforations
308 to tear along, or it can be another, newer means of separation.
FIG. 3B is a diagrammatical cross-section of twin-pack 310 at line
B-B'. The horizontal transverse seal 302 is seen along the tops of
the bags 310A, 310B, which are separated by the longitudinal seal
306.
[0029] FIGS. 4A and 4B show a former/delivery tube assembly 400
that was designed to make the twin-packs of FIGS. 3A and 3B. Twin
delivery tubes 402 run the length of the assembly to deliver the
product into the packages prior to making the final seal. The
former 404 provides a curved surface across which the packaging
film can be smoothly led into the correct shape around all surfaces
of the two delivery tubes 402. In the rear of the assembly, an
extension 404E of the former runs behind the delivery tubes in
order to provide a support structure for the formation of the
longitudinal seal. In the middle of the former extension 404E, a
strip of teflon 406 provides a no-stick surface against which the
sealer can press the film to create the longitudinal seal. Support
posts 410 provide support for the structure and a handle by which
the assembly can be held when installing or removing the assembly,
while stabilizer bars 412 provide additional stability.
[0030] FIG. 5 is a cross-section of the former/delivery tube
assembly discussed above, taken at line 5-5' in FIG. 4B, although
it is seen as if one were standing in front of the machine. It is
important to note that the delivery tubes 402 are not completely
cylindrical, as were the prior art tubes, but are somewhat teardrop
shaped, with their narrowest points near the sealing area 502. In
this particular embodiment, the delivery tubes 402 have a circular
cross-section through 255.degree. of the circle, with 105.degree.
degrees forming the narrowing portion of the teardrop shape. At
this level of the assembly, the two delivery tubes 402, joined at
the midpoint of the assembly, are completely surrounded by the
former tube 404T, which forces the film material to maintain the
flattened area where the seal will be made.
[0031] FIG. 6 is a cross-section of the former/delivery tube
assembly, taken at line 6-6'. At this level, the delivery tubes 402
are no longer joined to each other, while only the extension 404E
of the former tube remains along the back of the tubes 402. As
previously mentioned, this extension 404E of the former tube
provides support against which the longitudinal seal can be formed.
A strip of velcro tape 606 is applied down the middle of the former
tube extension, to which will be attached a strip of padding having
a teflon coating. The teflon surface keeps the film from sticking
to the assembly, while the velcro makes the teflon padding easily
replaceable.
[0032] When the packaging film is fed into the twin-pack former,
the two lateral edges of the material are wrapped around the
delivery tubes and approach each other at the midline of the
machine, in the seal area 502. These edges can be somewhat
overlapped in the final package, or they can meet in a butt joint.
In some instances, it can be desirable to bring the two edges of
the film close together, but not abutting each other, so that the
very middle of the twin-pack is a single layer of film.
[0033] To change from packaging single bags to twin-packs, a
machine operator need only change out the current former/delivery
tube assembly for an embodiment of the disclosed assembly.
Depending on the respective sizes and types of bags being made, it
may also be necessary to change out the packaging film, and the
sealers or facings. These, however, are changes that the operator
performs on a daily basis, and do not disrupt the flow of packaging
unduly.
[0034] Once the machine has been changed to accommodate twin packs,
the packing process is run as usual, except that product is
delivered into both delivery tubes of the assembly. In the
presently preferred embodiment, separation of the two pouches, as
well as opening of the pouches, is provided by a small vertical cut
that extends partially through the horizontal seal area.
Preferably, this vertical cut is made by the knife assembly at the
same time that the package is separated from the packages either
above or below it. Also preferably, the cut is made in the region
of a set of laser scorings that help the packaging material to tear
in a straight line.
[0035] Alternate Embodiments
[0036] While the embodiment above has been described in terms of
two equal-sized packages of identical products, these are certainly
not limitations. For instance, the assembly described above can be
modified to produce pouches of different sizes, with different
products in each pouch. One example would be to package a sample
size of a chip having a new seasoning side-by-side with a regular
size package of a popular flavor.
[0037] Additionally, the two products to be packaged need not be
similar types of foods. For example, a slim tube of a dip can be
packaged side-by-side with a wider package of chips, or a dip with
pre-cut vegetables. Sauces and other seasonings can be packaged
side-by-side with the foods they are served.
[0038] Additionally, this packaging technology can be adapted for
more than two packages across. The number of side-by side packages
is limited primarily by the size of the form, fill, and seal
machine and the width of film that it can handle, so that a machine
that can handle wider packaging films could produce greater numbers
of side-by-side packages. FIG. 7 shows a cross-section of a
former/delivery tube assembly to create a triple-pack having
unequal sized pouches. Three delivery tubes are seen, 702A, 702B,
and 702C. Tubes 702A and 702C have the teardrop shape seen in the
former for the twin pack, while delivery tube 702B maintains a
cylindrical outline only in the outer 150.degree.. This figure is
shown at the level where the former tubing 704 still surrounds the
delivery tubes.
[0039] FIG. 8 shows an exemplary package produced using the
assembly of FIG. 7. Upper transverse seal 802 and lower transverse
seal 804 are standard; longitudinal seals 806 divide the package
into pouches 810A, 810B, and 810C. Note that there are three
different sized pouches and that they can contain unlike products.
It is anticipated that packaging such as this could be used to
package an entire meal side-by side. In one exemplary embodiment,
pre-cooked rice or noodles are packaged in one pouch, a meat sauce
is packaged in a second pouch, and vegetables are packaged in a
third package. In this exemplary embodiment, the entire package can
be placed in a microwave or in boiling water for heating, after
which the foods are removed from the packaging for consumption.
[0040] From the disclosure above, it will be seen that this
inventive method of packaging has many advantages over the existing
method. In addition to gaining the marketing advantages of
multi-packs, the products are packaged side-by-side, increasing
throughput and saving time. Additionally, different products can be
packaged simultaneously in package sizes determined individually,
yet the capital investment to do so is small (on the order of
$2,500-5,000 per former/fill tube assembly), as opposed to the cost
of the form, fill, and seal machine, which is 100 times more
expensive.
[0041] While the invention has been particularly shown and
described with reference to a preferred embodiment, it will be
understood by those skilled in the art that various changes in form
and detail may be made therein without departing from the spirit
and scope of the invention.
* * * * *