U.S. patent application number 12/061788 was filed with the patent office on 2008-10-09 for stand-up flexible pouch and method of forming.
This patent application is currently assigned to POUCH PAC INNOVATIONS, LLC. Invention is credited to R. C. Murray.
Application Number | 20080247682 12/061788 |
Document ID | / |
Family ID | 39826976 |
Filed Date | 2008-10-09 |
United States Patent
Application |
20080247682 |
Kind Code |
A1 |
Murray; R. C. |
October 9, 2008 |
STAND-UP FLEXIBLE POUCH AND METHOD OF FORMING
Abstract
A stand-up flexible pouch for packaging a product and a method
of forming and filling the pouch is provided. The pouch includes a
panel forming a body of the pouch using a flexible material having
an inner surface and an outer surface. A rib is integrally formed
in the pouch body, and the rib is spaced a predetermined distance
from an edge of the pouch body. The pouch also includes opening
means integral with the panel for accessing a product contained
within the pouch. The method of forming the pouch thermoforms a rib
in each panel of material across multiple lanes of a high speed
machine.
Inventors: |
Murray; R. C.; (Lakewood
Ranch, FL) |
Correspondence
Address: |
GIFFORD, KRASS, SPRINKLE,ANDERSON & CITKOWSKI, P.C
PO BOX 7021
TROY
MI
48007-7021
US
|
Assignee: |
POUCH PAC INNOVATIONS, LLC
Sarasota
FL
|
Family ID: |
39826976 |
Appl. No.: |
12/061788 |
Filed: |
April 3, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60909797 |
Apr 3, 2007 |
|
|
|
Current U.S.
Class: |
383/104 ;
53/457 |
Current CPC
Class: |
B65D 75/5805 20130101;
B65B 31/041 20130101; B65B 43/465 20130101; B65B 31/042 20130101;
B31B 2155/00 20170801; B65B 53/02 20130101; B65B 61/28 20130101;
B65D 75/566 20130101; B65D 75/5866 20130101; B31B 70/00 20170801;
B31B 2155/0014 20170801; B65B 3/045 20130101; B65B 61/02 20130101;
B65B 61/188 20130101; B65D 75/008 20130101; B65B 31/024 20130101;
B65B 61/16 20130101; B65B 61/06 20130101; B65B 61/186 20130101;
B31B 2160/10 20170801; B65D 2575/565 20130101; B31B 2155/001
20170801; B65B 55/06 20130101; B65B 61/18 20130101; B65B 43/50
20130101; B65B 3/02 20130101; B65B 61/005 20130101 |
Class at
Publication: |
383/104 ;
53/457 |
International
Class: |
B65D 30/16 20060101
B65D030/16; B65B 43/00 20060101 B65B043/00 |
Claims
1. A stand-up flexible pouch for packaging a product, said pouch
comprising: a panel forming a body of the pouch using a flexible
material having an inner surface and an outer surface; a rib
integrally formed in the pouch body, wherein the rib is spaced a
predetermined distance from an edge of the panel and forms a shaped
edge of the pouch; and an opening means integrally formed in said
panel for accessing the product contained within the pouch.
2. The pouch as set forth in claim 1 wherein the pouch holds up to
20 L of the product.
3. The pouch as set forth in claim 1 wherein the rib has a height
that is less than a thickness of the flexible material.
4. The pouch as set forth in claim 1 wherein a second rib is spaced
a predetermined distance apart from a first rib.
5. The pouch as set forth in claim pouch 1 wherein the rib is
thermoformed in the panel, such that the outer surface of the
flexible material is convex in shape.
6. The pouch as set forth in claim pouch 1 wherein a shape of the
rib corresponds to a shape of a side edge of the pouch body.
7. The pouch as set forth in claim pouch 1 wherein the pouch body
includes a front wall and a back wall and a gusset positioned
between the front wall and the back wall.
8. The pouch as set forth in claim 1 wherein said opening means
includes a fitment and a cap removably attached to said
fitment.
9. A stand-up flexible pouch for packaging a product, said pouch
comprising: a panel forming a body of the pouch using a flexible
material having an inner surface and an outer surface; a plurality
of ribs integrally formed in the pouch body, wherein each rib is
thermoformed in a wall of the pouch body and forms a corresponding
shaped edge of the pouch body; and an opening means integrally
formed in said panel for accessing the product contained within the
pouch.
10. The pouch as set forth in claim 9 wherein the rib has a height
that is less than a thickness of the flexible material.
11. The pouch as set forth in claim 9 wherein the pouch holds up to
20 L of the product.
12. The pouch as set forth in claim pouch 9 wherein the rib is
spaced a predetermined distance form a side edge of the pouch
body.
13. The pouch as set forth in claim pouch 9 wherein the pouch body
includes a front wall and a back wall and a gusset positioned
between the front wall and the back wall.
14. The pouch as set forth in claim 9 wherein said opening means
includes a fitment and a cap removably attached to said
fitment.
15. A method of forming a stand-up flexible pouch on a machine,
said method comprising the steps of: unrolling a laminate material
across lanes of a high speed machine; thermoforming a rib in the
material; forming a body of the pouch from the material, wherein
the body of the pouch includes a wall having an edge, and the rib
is positioned to form a shaped edge of the pouch; and applying an
opening means to the pouch.
16. The method as set forth in claim 15, further including the
steps of: opening the pouch; filling the pouch with the product;
and closing the pouch.
17. The method as set forth in claim 15 further including the step
of thermoforming a plurality of ribs to form a corresponding shaped
edge of the pouch.
18. The pouch as set forth in claim 15 wherein said opening means
includes a fitment and a cap removably attached to said fitment.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent
Application Ser. No. 60/909,797 filed on Apr. 3, 2007, which is
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a flexible pouch
for packaging a product and, more specifically, to a stand-up
flexible pouch for packaging a product and a method of
manufacturing the same.
DESCRIPTION OF THE RELATED ART
[0003] Various factors influence the type of disposable, portable
container used to store a product, including volume of the product.
Examples of containers include a box, a can, a bottle, or a
flexible pouch. A larger volume of the product may be stored in a
barrel or keg or the like. While barrels and kegs work well for
larger quantities, they are expensive, and may be subject to abuse
by consumers, which impedes reusability. Flexible pouches are
available for storing limited quantities of a product, such as
fruit juice and the like. Flexible pouches are convenient to both
the consumer and manufacturer. However, their use in storing larger
quantities of a product is limited, since the flexible pouch tends
to collapse as the product is removed. Thus, there is a need in the
art for a flexible pouch capable of retaining its shape even as the
product is removed, and an improved method of making such a
flexible pouch.
SUMMARY OF THE INVENTION
[0004] Accordingly, the present invention is a stand-up flexible
pouch for a product, and a method for manufacturing the pouch. A
stand-up flexible pouch for packaging a product and a method of
forming and filling the pouch is provided. The pouch includes a
panel forming a body of the pouch using a flexible material having
an inner surface and an outer surface. A rib is integrally formed
in the pouch body, and the rib is spaced a predetermined distance
from an edge of the pouch body. The pouch also includes opening
means integral with the panel for accessing a product contained
within the pouch.
[0005] One advantage of the present invention is that a stand-up
flexible pouch for a product and an improved method of making the
flexible pouch is provided. Another advantage of the present
invention is that a stand-up flexible pouch and method of making
the flexible pouch is provided that utilizes a laminate material
that includes a laminate structure of PET, foil, nylon, LLDPE and
cast polypropylene layers. Still another advantage of the present
invention is that a stand-up flexible pouch and the method of
making the flexible pouch is provided that has a barrel shape. Yet
a further advantage of the present invention is that a stand-up
flexible pouch and method of making the flexible pouch is provided
that includes an integrally formed rib to add rigidity to the pouch
and assist the pouch in retaining its shape as the product is
removed. A further advantage of the present invention is that a
stand-up flexible pouch and method of making the flexible pouch is
provided that is cost effective to manufacture. Still a further
advantage of the present invention is that the flexible pouch can
stand upright unsupported. Yet still a further advantage of the
present invention is that a stand-up flexible pouch and method of
making the flexible pouch is provided that can store a liquid
product, including a carbonated product or a product having an
alcohol content.
[0006] Other features and advantages of the present invention will
be readily appreciated, as the same becomes better understood after
reading the subsequent description taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an elevational view of stand-up flexible pouch for
a product, according to the present invention.
[0008] FIG. 2 is a perspective view of a stand-up pouch for a
product, according to the present invention.
[0009] FIG. 3 is an elevational view of another shaped stand-up
flexible pouch, according to the present invention.
[0010] FIG. 4 is a sectional view taken along line 4-4 of a rib
formed in the panel of the pouch, according to the present
invention.
[0011] FIG. 5 is an elevational view of another stand-up flexible
pouch, according to the present invention.
[0012] FIG. 6 is a perspective view of still another example of a
stand-up flexible pouch, according to the present invention.
[0013] FIG. 7 is a perspective view of a further example of a
stand-up flexible pouch, according to the present invention.
[0014] FIG. 8 is a flowchart of a method of forming the stand-up
flexible pouch of FIGS. 1-7, according to the present
invention.
[0015] FIG. 9 is a diagrammatic view of a form-fill-seal machine
for use with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring to FIGS. 1-7 a stand-up flexible pouch 10 is
illustrated. The pouch 10 may be filled with a product (not shown)
and sealed. It is contemplated that the pouch may contain a single
portion or multiple portions of the product. For example, the pouch
may contain twenty liters of the product. Various shapes are
contemplated for the pouch. The pouch 10 may have a generally
cylindrical shape, a box-like shape, an hourglass shape, a barrel
shape or another shape. In this example, the product is a liquid.
The liquid may be a consumable product having an alcohol content,
such as wine, beer or liquor, or the like. The product may be a
carbonated product, such as a sparkling wine or juice or the like.
The liquid may be any other type of product, such as shampoo or
liquid soap or the like. An example of a pouch for a carbonated
liquid is disclosed in commonly assigned PCT Patent Application No.
PCT/US03/034396, which is incorporated herein by reference.
[0017] The stand-up flexible pouch 10 is preferably formed from a
roll of preprinted material of extruded or laminate layers. The
material is typically a three, or four, or five or more gauge
material or multiple laminations of material or the like. The outer
layer is usually preprinted. Alternatively, at least a portion of
the material may be not printed, i.e. translucent, in order to view
the contents contained therein, as shown in FIG. 7 at 48 as a
window. The clear portion could also be in a gusset or insert. The
outer layer may include preprinted information, as with a label or
shrink sleeve. The pouch may include more than one type of
material.
[0018] The choice of sheet layer material is non-limiting, and is
influenced by factors such as the product contained in the pouch,
the shape of the pouch, or the anticipated use of the pouch. One
example of a laminate material structure includes at least one
layer of virgin polyethylene terephthalate (PET), at least one
layer of aluminum foil and another layer such as EVOH, PET,
polyethylene or nylon or the like. Another type of laminate
material structure may also include a metalized foil paper layer
laminated to a cast polypropylene layer and another layer of PET,
polyethylene or EVOH. There may be a fourth layer of nylon.
Similarly, the laminate structure may include a cast polypropylene
(CPP) layer, a polyethylene (PET) layer, a foil (AL) layer, a nylon
(ONO) layer and another CPP layer. Another structure is the use of
nylon, foil, nylon and cast polypropylene (ONO/AL/ONO/CPP) or
CPP/NY/AL/CPP, or PET/AL/NYLON/CPP, or ONO/AL/COEX-ONO-LDPE.
[0019] For certain products, such as a carbonated liquid or
beverage, certain materials are somewhat permeable, thereby
allowing loss of the internal carbon dioxide gas from the pouch and
its replacement with oxygen. The presence of oxygen in the filled
pouch increases the chance of bacteria forming, or may affect the
taste. Therefore, material structures that include CPP are well
suited for packaging a beverage, such as wine or beer or other
carbonated fluids, to add strength to the walls of the pouch,
preserve the carbonation, and protect with the nylon the AL layer
from cracking. Carbonation is beneficial since it acts as a
microbiocide and preserves the flavor and aroma of the products.
The use of cast polypropylene laminate material also assists in
retaining the filled shape of the container, even as the product is
removed from the pouch 10. A further example of a laminate material
structure is CPP/AL/ONO/PE. This structure works well when the
product has a short shelf life, and the nylon eliminates stretching
or cracking of the AL layer. Still a further example of a material
structure is a co-extruded laminate such as PET/CO-PP/AL/NY/LLDPE.
It should be appreciated that the CO-PP layer can include multiple
layers, such as three in this example. An example of a material
structure for a white wine product is PET/EVOH/PE or AL/PET/NY/PE.
Similarly, a material structure for a red wine product includes
PET/EVOH/PE or AL/NY/PET/PE.
[0020] Other film structures may also be utilized that offer
protection from sunlight, as well as organoleptic protection from
the development of undesirable flavors. In addition, the selected
material may be organoleptic compliant in order to avoid the
transfer of odor contaminates to the product, or product
contamination during the shelf life period of the product.
[0021] It should be appreciated that for certain types of filled
pouches stored at ambient temperature, the laminate material may
start to creep after a period of time, such as within ten days. For
a carbonated product, the creepage results from carbonation
expansion. The use of a laminate material with an extrusion layer
contains "creepage" or "stretch" of the film.
[0022] The pouch 10 is formed from at least one panel of material.
The panel has an inner surface 11a that is adjacent the product,
and an outer surface 11b. The pouch formed out of the panel has a
front wall 12 and a back wall 14. Each wall 12, 14 is further
defined by an upper edge 16, an opposed lower edge 18, and side
edges 20 extending therebetween the upper and lower edges 16, 18.
The edges of the panel are joined to form a sealed seam 22. In an
example of a pouch formed using a single panel of material, the
panel edges may be joined along a center seam. The seam may be a
flat seam or a fin style seam or the like. In an example of a pouch
10 formed using two sheets of material, the panel edges may be
joined along two side seams 22. Again, the side seam may be a flat
seam, a fin style seam or the like.
[0023] The wall of the pouch includes an integral rib 50 formed in
the panel of material, and a wall may include a plurality of ribs.
The rib 50 is selectively shaped to form a shaped edge of the pouch
as shown at 26 and oriented to provide structural rigidity to the
pouch 10. The arrangement and shape of the rib adds structural
strength to the pouch wall, so that the pouch can stand upright
unassisted, regardless of the pouch volume. Further, the rib 50 may
have a shape and arrangement that generally defines an overall
shape of the pouch 10. The pouch 10 may include a plurality of ribs
in order to define the shape and structure of the pouch. The rib 50
is positioned a predetermined distance from the edge, such as 1''.
In an example, the rib 50 has a generally vertical orientation, and
is positioned adjacent a side edge 20 of the pouch. In another
example, one or more ribs 50 are positioned adjacent each side edge
20 of the pouch. In still another example, the ribs 50 are
positioned a varying distance apart. In yet another example, the
ribs 50 are spaced an equidistance apart. Each rib 50 has a
predetermined length and cross-sectional shape. The rib length may
be selectively determined, depending on factors such as the size of
the pouch 10, or desired structural rigidity for the pouch 10, or
the like. For example, the rib 50 may extend along about 80% of a
length of the finished pouch 10. Referring to FIG. 4, the rib 50
may have a uniform cross-sectional shape extending the length of
the rib. Similarly, the rib 50 may have a cross-sectional shape
that varies along the length of the rib 50. An overall height H of
the rib 50 may be less than a thickness T of the panel material.
The rib 50 is formed in the inner surface of the panel of material,
so that the outer surface of material is concave. The rib 50 is
formed by the application of heat to the panel of material. For
example, a heat seal bar may be utilized to form the rib 50 in the
panel of material.
[0024] The pouch 10 retains its predetermined shape even as product
is removed from the pouch, due to the structural rigidity provided
by the ribs. For example, the predetermined shape may be generally
cylindrical, similar to a traditional metal barrel, or a cubical
shape, similar to a carton, or the like. Other shapes are
contemplated, depending on factors such as the product contained
therein, volume and use of the pouch.
[0025] The pouch 10 may also include an insert, sidewall or gusset
24. The gusset 24 may be integrally formed in the panel, or a
separate piece of material. The insert, sidewall or gusset material
may be a different structure than that of the pouch body. The
gusset 24 may be disposed between the front and back walls 12, 14,
and positioned between the side edges of the walls, the lower
edges, the upper edges, or any desired combination. It should be
appreciated that the shape of the gusset 24 is non-limiting. For
example, the gusset 24 may be generally wider at one end and taper
upwardly towards the opposite end. The gusset 24 may also be of a
uniform width. The use of the gusset may be functional, i.e. it may
allow the pouch 10 to acquire another shape, such as cylindrical,
or to stand upright. The gusset also enhances the strength and
rigidity of the pouch 10 during filling and processing. A side
gusset is advantageous since it allows the walls of the pouch to
expand as the internal pressure within the pouch increases. A
gusset positioned between the lower edges 18 of the pouch 10 may
form a base, enabling the pouch 10 to stand upright unsupported.
The edges of the gusset may be sealed against the wall of the
pouch, as shown in FIG. 6 at 25.
[0026] Similarly, the pouch may include an insert. The insert is a
generally planar member that is inserted between the walls 12, 14
of the pouch 10. The shape of the insert is non-limiting, i.e.
square, round or oval or rectangular, and generally influences the
shape of the flexible pouch. The insert may be positioned
internally within the pouch or externally. Various materials may be
utilized for the insert, such as foil, cardboard, plastic, nylon,
laminate or the like. Further, the insert may be formed from a
printed material, or it may be clear. In one example, the insert is
inserted between the lower edges of the panel and sealed to the
walls of the panel. The seal may be an ultrasonic seal or a heat
weld or a combination of both or the like. The insert may include
an integral opening means, such as a fitment. Similarly a first
insert may be positioned between the lower edges of the panel, and
a second insert positioned between the upper edges of the panel.
The first insert may include an integral opening means, such as a
fitment.
[0027] The pouch 10 also incorporates an opening means 28 for
accessing the contents of the pouch. Various types of opening means
28 are known in the art for this purpose, and are non-limiting. The
position of the opening means 28 is determinable by many factors,
such as the type of product contained or type of opening means or
use of the pouch or the like. For example, the opening means 28 may
be positioned in an upper edge, a lower edge or side edge, or front
wall or back wall, or on an insert or gusset. It should be
appreciated that the opening means 28 may be incorporated into the
pouch 10 prior to filling the pouch 10, or after filling.
[0028] An example of an opening means is a tear-off portion 30. The
tear-off portion 30 usually has an integral tear notch 32 and tear
line, for removing a designated portion of the pouch to access the
product contained therein. The tear-off portion 30 could be
utilized in conjunction with another opening means, such as a
zipper. The zipper opening means is a resealable zipper that
provides a hermetic seal through interlocking teeth, such as a
zipper that is sold under the name TopTite.TM.. The zipper may be
used with another opening means. Another example of an opening
means 28 is a weakened, straw-pierceable portion in the pouch for
receiving a straw within at least one of the compartments. A
further example of an opening means 28 is a pull tab covering an
opening in the pouch.
[0029] Still another example of an opening means is a spout fitment
34 that includes a cap 36 for containing the product within the
pouch. The fitment 34 includes a base 38, and a spout 40 projecting
upwardly from the base 38. The base portion includes a centrally
located passageway extending through the center of the fitment, to
provide access to the contents of the pouch. An outer surface of
the base portion forms a seal-engaging surface that is sealed to
the panel in a manner to be described. The spout 40 is generally
cylindrical in shape, and includes a centrally located passageway
that is continuous with the central passageway of the base portion
38. The spout 40 may be sealed, such as by a sleeve or a cap.
Various styles of caps 36 may be utilized in conjunction with the
spout, such as a removable cap, or a slideable cap or the like. The
removable cap can be the traditional round shape. Alternatively,
the cap 36 can have another shape, such as oval. The cap 36 may
include a tamper-evident feature. In addition, the cap 36 may be
permanently retained on the spout to be environmentally friendly.
The cap 36 and fitment 34 can be made from a variety of materials.
For example, the cap 36 may be made from plastic, such as reground
resins. The fitment 34 may be made of polypropylene (PP), depending
on the product. The fitment base 38 is sealed into the upper edges
of the panel using a sealing means, such as an ultrasonic seal or a
heat weld, or the like. The spout 40 may include a removable seal
to prevent leakage of the product or evidence of tampering. The cap
36 may include an insert of an oxygen absorbent material.
[0030] The pouch 10 may include an angled top seal 42 as described
in commonly assigned U.S. Patent Application Ser. No. 60/779,796,
which is incorporated herein by reference. The position of the
angled top seal 42 is dependent on the location of the opening
means 28. In one example, the angled top seal 42 extends between
one side edge and the upper edge, and the opening means 28 is
located between the other side edge 20 and the upper edge 16. The
shape and position of the angled top seal 42 facilitates the
removal of product from the pouch 10 by directing the flow of the
product towards the opening means 28. The angle top seal may have a
radius to keep the interior of the pouch rounded. The angle top
seal preferably reduces the right angle corner headspace. This is
advantageous because it assists in pouring the product, reduces
headspace (and oxygen), and influences the shape of the pouch.
[0031] It should be appreciated that the barrel-shaped flexible
pouch 10 may advantageously include other features that are known
in the art. For example, the pouch 10 may include a guide pocket
formed in a wall 12, 14 of the pouch 10 prior to filling and
sealing, to facilitate the separation of the front and back walls
12, 14 prior to the filling of the pouch 10. An example of such a
pouch is disclosed in commonly assigned U.S. patent application
Ser. No. 10/310,221.
[0032] The pouch 10 may include other features, such as an
ergonomic shape. An example of an ergonomically shaped pouch for a
carbonated beverage is disclosed in commonly assigned U.S. patent
application Ser. No. 11/454,241 which is incorporated by reference.
The flexible pouch 10 may include a feature such as an outer layer
or sleeve covering the outer surface of the pouch. The sleeve may
be a label containing information about the product, such as a
barcode or the like. The sleeve may cover only a portion of the
pouch outer surface. Preferably, the sleeve is shrunk over the
outer surface of the pouch 10 after the pouch 10 is formed and
filled with the product. The sleeve is advantageous because it
covers the side seam. It also adds one or more layers of material
to strengthen the pouch and improve its durability. Various types
of material may be utilized for the sleeve, such as paper or
plastic including PET or PVC and the choice is non-limiting.
[0033] Another example of a feature is a hanging aperture 44 formed
in a seam for supporting the pouch by a support means. One or more
hanging apertures may be formed along an edge of the pouch 10 for
receiving a fastener, such as a clip or the like. The aperture may
be used to transport or display the pouch. The aperture 44 may have
various shapes, such as round or curved. Advantageously attaching
the pouch another object via the hanging aperture enhances the
convenience of the flexible pouch.
[0034] A further example of a feature is a tracking device 46
integrally located within the pouch 10 that includes electronic
tracking information relevant to the pouch 10, as described in
commonly assigned U.S. patent application Ser. No. 11/686,666,
which is incorporated by reference. The tracking device 46 may be
an electronic tag, such as a Radio Frequency Identification (RFID)
transmitter. The tracking device 46 can store a predetermined
amount of electronic information. An example of the information is
unique tracking information for a particular package 10. For
example, the tracking device 46 can provide information about the
status of the pouch 10, such as physical location of the pouch 10,
or age of the pouch 10 or the like. In addition, the tracking
device 46 can be utilized for inventory control, delivery, purchase
behavior, returns, pricing, and other tracking purposes. The
tracking device 46 is in communication with a receiver (not shown)
for reading the information. The receiver may be a computer system
having a memory and a processor, a handheld device for receiving an
RFID signal, or any other type of device capable of electronic
communication with the tracking device 46. The receiver may be a
transceiver capable of emitting a radio signal that initiates
transmission of information from the tracking device 38. Although
the packages are individually read, the RFID tag may be
advantageously read at a faster rate than using a barcode in
conjunction with a barcode scanner, since the packages are not
physically scanned on an individual basis. In addition, the signal
from the RFID tag may be advantageously read through an outer layer
of material, such as a packaging material, or under various
environmental conditions. Another advantage is that the tracking of
the physical location of the package may be electronically
monitored within a predetermined geographical range. The tracking
device 46 may be integrally embedded in the pouch 10. The tracking
device 46 may be inserted in an air pocket formed within one of the
gusset apertures. Alternatively, the tracking device 46 may be
inserted in a sealed portion of the pouch, and an air pocket is
formed around the tracking device 46 during application of the
seal. The tracking device may be integrally formed in the opening
means.
[0035] The pouch 10 may include other features as a result of a
secondary process after it is filled with the product. For example,
the filled pouch 10 may be frozen. Alternatively, the filled pouch
10 may be pasteurized in order to have an extending shelf stable
life under ambient temperature.
[0036] It is contemplated that the flexible pouch 10 may
incorporate any of the above-described features in any combination.
For example, the pouch 10 may include an insert in the bottom
portion of the pouch and a tapered top portion, or an insert in the
bottom portion of the pouch and a spout and cap in the top portion
of the pouch. In addition, the finished pouch may assume various
shapes, such as cylindrical, cubical, and conical, hourglass or
barrel shaped or the like, as influenced by the type of product and
intended usage of the pouch. The pouch may assume a traditional
shape for a product, such as a keg for beer.
[0037] In addition the barrel-shaped flexible pouch may include an
outer frame to allow for stacking of the pouches. The frame can be
of a suitable material, such as metal, plastic or corrugated paper
or the like.
[0038] Referring to FIG. 8, a method for forming and filling the
stand-up flexible pouch 10 using a high-speed machine is
illustrated. The method begins in block 100 at a first station with
the step of forming the body of the pouch. For example, a roll of
laminate material, as previously described, is unrolled along a
horizontally oriented plane. The initial width of the roll of
material is determined by the desired finished size of the pouch 10
and the number of pouches to be obtained from the width. For
example, three or four or six pouches, representing six to twelve
panels, can be obtained from a width of the roll of material on a
multiple lane machine. Each panel has an inner surface and an outer
surface. One layer of the material is preferably preprinted with
information or locating indicia (not shown), such as a registration
mark. The registration marks are located on the material to denote
an edge of a wall 12, 14. The registration marks are read by an
optical reading device (not shown), such as a scanner or
registration eye, to index the material in a predetermined position
at the cutting station. The preprinted information may include
labeling information that describes the product contained within
the pouch. In this example, the layer of preprinted information is
located on an outer layer of the material.
[0039] The methodology advances to block 105 and a rib 50 is formed
in the panel of material corresponding to each pouch formed from
the panel of material. In this example, the rib 50 is formed using
a thermoform technique, such as a heat bar. As previously
described, features of the rib 50, such as orientation, shape,
number, size, height, curvature, etc., are dependent on various
factors, such as the size of the pouch, the product contained in
the pouch or the shape of the pouch 10. Additional ribs 50 may be
spaced a predetermined distance apart from a first rib, or
otherwise positioned where necessary to provide strength or shape
to the pouch. It should be appreciated that for multiple panels and
lanes, the rib is simultaneously formed in each panel across each
lane.
[0040] The methodology advances to block 110 and a feature, such as
a gusset 24 or insert, is optionally positioned between the aligned
first and second unrolling sections of material. In addition, an
opening means 28 may be applied at this time. For example, an
opening means, such as a spout fitment 34 may be applied.
[0041] The methodology advances to block 115 and the edges of the
panel are sealed together to form the body of the pouch, such as
the side edges, or the upper edge or the lower edge. An edge, such
as the upper edge, may be left open for filling, or all of the
edges may be sealed. In this example, the open edge is designated
the upper edge, as a reference. For example, fitment 34 may be
sealed between an edge, if the pouch 10 is filled through the
fitment 34. The edges to be sealed generally depends on the type of
fitment, product or filling technique.
[0042] The seal used to form the seam 22 can be a permanent seal, a
temporary seal, or a frangible seal. Various types of seals are
available, such as a single seal, a double seal, or an insulating
seal, or the like. Various sealing techniques are known in the art
to form each seal, and a combination of sealing techniques may be
utilized. The seals may be a heat weld formed by applying heat and
compression, or an ultrasonic seal formed using vibrational energy,
or a combination of heat and ultrasonic seals. It should be
appreciated that a previous seal may be absorbed during the sealing
process.
[0043] The side seal may be an overlap seal, whereby the side seal
extends along the side edge of the panel and a predetermined
distance along the upper edge, and a closing seal for the upper
edge overlaps the side seal. An angled top seal 42 may also be
applied at this time. Advantageously, the seals may be shaped. The
seal may have a curvilinear shape so as to avoid sharp radiuses at
the interior corners of the pouch. A seal having an interior edge
that is rounded facilitates removal of the product.
[0044] Various sealing techniques are contemplated. For example, an
ultrasonic sealing process may be used. In another example, a heat
weld that includes the application of heat and compression is
applied. In still another example, the edges are sealed using a
seal bar or forming plate having a plasma coating. One advantage of
the plasma coating is that the line speed may increase. Another
advantage is that the coating makes the surface of the seal bar or
forming plate more resilient. When the seal bar is heated, the
coating expands due to this resiliency. The shear stress on the
inner edge of the seal is reduced; resulting in reduced creepage of
the material and greater durability of the seal. The plasma coating
reduces the opportunity for potential damage to the material during
the sealing step. In this example, the plasma coating is a smooth,
hard plastic that mimics glass. Since the outer layer of material
is not weakened, there is no creepage of the outer layer.
[0045] A seal bar or forming plate may be used to apply any of the
seals. An example of a seal bar is a generally rectangular member.
The seal bar may include a cavity used to create an air pocket, or
to conform to the shape of a member. The seal bar or forming plate
may have a plasma coating that makes the surface of the seal bar or
forming plate more resilient. When the seal bar is heated, the
coating expands due to this resiliency. The shear stress on the
inner edge of the seal is reduced; resulting in reduced creepage of
the material and greater durability of the seal. The plasma coating
reduces the opportunity for potential damage to the material during
the sealing step. In this example, the plasma coating is a smooth,
hard plastic that mimics glass. Since the outer layer of material
is not weakened, there is no creepage of the outer layer. An
advantage of the plasma coating is that the line speed may
increase.
[0046] In still another example of a sealing technique, the side
seal is a two-step seal formed using more than one seal bar. One
seal bar may include the previously described seal bar cavity for
forming an air pocket in the sealed portion. An example of a
two-step seal is disclosed in commonly assigned U.S. patent
application Ser. No. 11/551,071. The two-step seal advantageously
avoids the generation of ketones due to application of heat to the
material. The first or inner seal is a low temperature seal. The
second or outer seal is a high temperature seal. The second seal is
spaced apart from the first seal by a predetermined distance, to
create an air gap. The first seal is a tack seal, such as 6 mm
wide, and is of a sufficient temperature so as to melt the layers
of material and tack the edges together. The predetermined distance
between the first and second seal is 1/2-1 mm. The second seal is
applied at a higher temperature and pressure than the first seal.
As a result, any gas, such as steam, ketones, aromatics or the
like, is pushed in an outwardly direction, out through the open
edges of the panels, and not into the pouch. Thus, the first seal
prevents entry of contaminates into the pouch to avoid organoleptic
contamination. The heat weld may include a heat weld followed by a
cold weld.
[0047] In an example, a feature, such as the fitment 34, as
previously described, may be sealed within the walls of the pouch
10, such as between the upper edges 16. The fitment may be sealed
using an ultrasonic seal, or a heat weld, or by a combination of
ultrasonic seal and heat weld, as previously described. An example
of an ultrasonic seal for a fitment is disclosed in commonly
assigned U.S. patent application Ser. No. 11/195,906, which is
incorporated herein by reference. Accordingly, the base portion of
the fitment is sealed between the walls of the pouch using an
ultrasonic seal, a heat seal, and then a cool seal. The heat seal
melts a layer of the pouch material, and the material flows around
the sealing ribs on the base portion, and fills in any void between
the base portion and the wall of the pouch. The cool seal sets the
seal and provides an attractive finish to the overall seal.
Advantageously, fewer stations are required to seal the fitment
between the walls of the pouch, since a tack seal is
eliminated.
[0048] The methodology advances to block 120, and each of the
pouches formed in the roll width of material are separated from
each other in a cutting operation. For example, each section of
material may be first separated along its width, or along the side
edge of the panel. The section is then separated into individual
pouches. In this example, the width of unrolling represents the
side edges of the finished pouch. The material is cut into a pouch
10 using a known cutting apparatus, such as a laser or punch or the
like. The cutting apparatus forms a single cut in the material to
separate the pouches. The length of the pouch 10 is controlled by
the distance between the cuts.
[0049] Alternatively, consecutive pouches 10 are separated using a
double cut process, whereby two cuts are made at the same time to
separate the adjoining edges of the consecutive pouches at the same
time. Advantageously, forming two pouches during the cutting
operation effectively doubles the assembly line speed.
[0050] The methodology advances to block 125 and the pouches 10 are
finished. For example, an edge may be further trimmed to achieve a
desired shape. In another example, the edge of the pouch may be
trimmed to accommodate an opening means 28. It may be advantageous
for the pouch corners to have a radius, to eliminate right angles
at the corners. In another example, two legs are formed during the
trimming operation, in order to recess the fitment. The hanging
aperture 44 may be formed at this time. This operation may be
performed using a cutter or a die cut or the like.
[0051] In another example of a finishing operation, a crease or
guide pocket may be formed in a top portion of each wall 12, 14 in
a creasing operation, in order to facilitate opening and filling of
the pouch. An example of a method of forming a crease in a wall to
facilitate opening the pouch is disclosed in commonly assigned U.S.
patent application Ser. No. 10/310,221, which is incorporated
herein by reference. In still another example of a finishing
operation, the sleeve is applied over the individual pouch and
shrunk to fit using an application of heat to the pouch.
[0052] The methodology advances to block 130 and the premade pouch
10 is discharged from the form machine. The completed pouch may
include any combination of the above-described features. Further,
the pouch may be filled through an open edge, i.e. upper or lower,
or through the fitment.
[0053] The methodology advanced to block 25. The pouch is then
transported to the filling machine. The pouches may be loaded into
a carrier and transferred to a filling machine. It should be
appreciated that the filling machine may be integral with the pouch
forming machine, or a separate machine. This portability increases
the flexibility of the pouch and may result in a manufacturing cost
savings. The premade pouch may be lifted from a box, magazine,
vacuum belt and placed into the grippers by a robot device, as
shown in FIG. 9.
[0054] The pouch is unloaded from the carrier and placed in a
holder for moving the pouch between stations. An example of a
holder is a cup or base or puck having a shape corresponding to the
shape of the pouch. Alternatively, the pouch 10 may be held using
grippers (not shown) or a rail as is known in the art. The
methodology advances to block 140.
[0055] In block 140, the pouch 10 is opened in an opening
operation. Various techniques are conventionally known in the art
for opening the pouch 10. For example, the guide pocket formed by
the crease in the front wall 12 and back wall 14 facilitates
opening of the pouch. A nozzle (not shown) may be mechanically
lowered into the guide pocket to direct a stream of compressed gas
into the guide pocket, to force the walls of the pouch 10 away from
each other. An example of a gas is carbon dioxide or nitrogen or
the like. The blowing station may include a manifold, with a hood
extending over the top of the edges of the pouch as known in the
art. The manifold has rows of apertures (not shown) formed above
the upper edges 16 of the pouch 10. The hood is placed over the
pouch 10 to assist in maintaining the air pressure in the pouch 10.
The supply of pressurized gas is directed through the aperture to
form a plurality of jets of pressurized gas or air. The jets are
directed downwardly at the diamond-shaped openings formed at the
upper edges 16 to assist in overcoming the surface tension of the
pouch and assist in separation of the walls 12, 14. A diving rod
(not shown) may then be used to make sure the pouch 10 is fully
opened. If the pouch has a fitment, gas may be injected through the
spout fitment. After the pouch is opened, it may be injected with
super-saturated steam to eliminate any pathogens or the like.
[0056] In block 145, the pouch 10 is filled with the product 58 in
a filling operation. For example, a fill tube is lowered into the
pouch a predetermined distance and the product 58 is dispensed into
the opened pouch. The pouch 10 may be filled through an open edge,
or through the spout 40 using the fill tube. If the pouch 10 is
large, the pouch 10 may be filled at more than one station. The
product 58 is preferably dispensed at a predetermined temperature,
depending on the type of product. The fill tube may be raised out
of the pouch at a predetermined rate as the product is dispensed.
For example, the fill tube may be removed just ahead of the filling
product 58.
[0057] If the product 58 is naturally carbonated, such as wine,
beer or the like, the pouch is preferably filled while immersed in
a nitrogen atmosphere. If the product is not naturally carbonated
and carbonation is desirable, it is immersed in a carbonator to
introduce carbon dioxide into the product. For example, carbon
dioxide is introduced into cold water or juice to provide a
carbonated beverage. The product 58 may contain a mixture of up to
four volumes of carbon dioxide. It should be appreciated that the
carbon dioxide masks any undesirable taste from ketones and other
solvents released during the sealing process. The carbon dioxide
also increases the pressure within the product so that the walls of
the pouch are rigid after the top is sealed. The product 58 is
preferably filled at a temperature ranging from 29.degree. F. to
ambient temperature. The filled pouch may have oxygen removed from
the pouch. For example, the pouch may be flushed with carbon
dioxide.
[0058] The pouches 10 may be moved to a station where any oxygen in
the pouch residing above the product is removed, if necessary. This
can be done by providing a hood or diving nozzle where oxygen is
either evacuated or replaced with carbon dioxide or nitrogen into
the pouch to displace the oxygen. A diving nozzle may be used to
inject the gas.
[0059] In block 150, the filled pouch 10 is closed. For example, if
the pouch is filled through open edges, the open edge of the pouch
is closed by sealing the edges together. The first or closing seal
52 may be an ultrasonic seal, or an ultra pulse seal, or a heat
weld or the like. The closing seal along an upper edge may overlap
a side edge seal as shown at 54. If the pouch holds a carbonated
beverage, the pouch may be sealed as described in commonly owned
PCT Patent Application No. PCT/US03/034396, which is incorporated
herein by reference. A second cosmetic seal 56 may be applied above
the first seal 52 for a carbonated product. The second seal 56 may
be a heat weld. For a carbonated seal, some of the product may be
trapped between the first and second seals. This is advantageous
since there is no gas in the head space, i.e. the region between
the product and the heat seal, and less pouch material is required.
Another cosmetic seal may be applied across the first and second
closing seals. If desired, an end of the seam may be tacked down in
this operation as shown at 24.
[0060] Alternatively, the pouch 10 is filled through the spout
fitment 34 and the cap 36 is applied to close the pouch 10. The cap
36 may be a tamper-evident cap for a carbonated product, containing
an arrangement of thread and grooves as described in copending U.S.
patent application Ser. No. 11/551,071, as previously described.
The cap 36 contains the product in the filled pouch 10, to prevent
leakage of the product from the pouch 10. The complementary
arrangement of threads and grooves in the cap and spout provides
for the controlled release of pressure from the pouch.
[0061] In an example of a push-pull cap, the plug is preassembled
to the push-pull cap and the plug and push-pull cap are pushed onto
the spout and retained by the spout. A tamper-evident outer cap may
be disposed over the tube or slidable cap and fixedly retained by
the tube spout fitment as previously described. It should be
appreciated that the tamper-evident outer cap may be pre-assembled
to the slidable cap. This operation is advantageous because it is
fast, and cost efficient since it can be done at a high speed. In
the example of an open-ended external tube, the open end of the
tube is sealed by applying a closing seal to the upper edges of the
cap. The closing seal may be an ultrasonic seal, or an ultra pulse
seal, such as a heat weld or the like.
[0062] In an example of a zipper opening means, the open upper edge
of the pouch is closed by engaging the zipper teeth. A closing seal
may be applied to the portion of the pouch outboard of the zipper,
to further seal the upper edges 16 together using a closing sealing
process as previously described.
[0063] The methodology advances to block 155 and the pouch 10 is
finished in a finishing operation. For example, the edges of the
pouch 10 are trimmed to achieve a predetermined shape. In addition,
the pouch 10 may be cooled at a cooling station, where the pouch 10
is cooled using a conventionally known cooling technique.
Optionally, the sleeve may be placed over the filled pouch and
shrunk to fit over the pouch by applying heat. The sleeve layer
forms an outer layer of the pouch.
[0064] In block 160 the filled pouch 10 is discharged from the
machine. A plurality of pouches may be placed in a package for
sales or shipping purposes.
[0065] It should be appreciated that the pouch may undergo other
processing steps, such as an upstream oxygen purging station, a
downstream oxygen purging station, pasteurization or the like. For
example, the filled pouch 10 may be pasteurized in an integral
retort chamber (not shown) that heats and then cools the pouch 10.
The pouch 10 may be tested, such as burst testing or the like prior
to packaging for shipping. These additional processing steps may
take place at a station on the form/fill/seal apparatus, or on
another apparatus.
[0066] It should be appreciated that the order of steps may vary
depending on the pouch and its features. Also, a particular
manufacturing station may perform one or a plurality of operations,
to enhance the efficiency of the methodology and apparatus.
[0067] Referring to FIG. 9, an example of a form-fill-seal machine
200 for carrying out the method described with respect to FIG. 8 is
illustrated. Various styles of machines 200 are contemplated for
forming or filling and sealing the pouch 10, such as a flat bed,
conveyor or the like. An example of such a machine is manufactured
by Nishibe, such as the model number SBM500, SMB600 or SMB700. The
machine 200 may include form stations 210 and/or fill-seal stations
258. It should be appreciated that a particular manufacturing
station may perform one or a plurality of operations, to enhance
the efficiency of the methodology and apparatus. The stations may
be arranged in a linear manner, rotary manner, or a combination
thereof.
[0068] The machine includes a base 216 and a transport device 212
that transports the material through the various stations. Various
styles of transport devices are contemplated, and a particular
machine may include more than one style. An example of a transport
device is a conveyor, rollers, a turret or the like. The roll of
material 204 is initially mounted along a horizontally oriented
axis, and is unrolled along at a material feed station.
[0069] The machine 200 includes an alignment station 218 that
aligns the unrolling material 204. For example, at the alignment
station 218, the material rolls pass through sensing device, such
as an optical reader, that identifies a predefined point on the
material 204. This predefined point may be a registration mark on
the material, or the edge of the material 204. The machine 200
utilizes the registration marks to automatically adjust the
orientation of the unrolling material position along an axis. For
example, rollers 220 are used to adjust the position of the
unrolling material .+-.2 degrees relative to a vertically oriented
center axis.
[0070] The machine may include a fitment application station 222
that applies an opening means 28, such as a zipper fitment to the
unrolling material at a predetermined location on the material. The
machine includes a feeder mechanism 223, which supplies the opening
means to the machine. In this example, a feeder mechanism 223
supplies the unrolling material roll with the opening means at a 90
degree angle to the direction of material 204 flow. It should be
appreciated that the opening means may be simultaneously applied
across all lanes in the predetermined panel location.
[0071] The machine includes a cutting station 224 where the
material is cut into a predetermined number of sections. For a
pouch made from two panels of material, one of the sections is
rotated 180 degrees, and the first and second sections of this
example are positioned such that inner sides face one another. The
sections are used to form the front panel and back panel of the
pouch, respectively.
[0072] The machine may include a feature insertion station that
adds a feature, as previously described, between the facing sheets
of material. The facing sections are transferred along the conveyer
to a sealing station.
[0073] The machine includes a station 228 that applies a rib 50 and
seals the edges of the pouch. Various techniques are known in the
art for this purpose, and more than one technique may be used. The
rib 50 may be thermoformed. The edge seal may be a heat weld formed
by applying heat and compression, or an ultrasonic seal formed
using vibrational energy, or a combination of heat and ultrasonic
seals. In addition, a previous seal may be absorbed during the
sealing process.
[0074] The sealing station may include one or more seal bars 229 to
form the rib or to apply the seal. In an example, there are two
opposed seal bars, and the pouch fits between the seal bars. The
seal bar may include a surface that corresponds to a predetermined
shape or the seal or rib. The sealing station 228 may form the
seams joining the edge of each panel to delineate each pouch. In
this example, the side edges of each of the pouches along the width
of material are heat-sealed. By precise alignment of the material
sheets, the width of the side edge seam may be reduced, such as 4
mm, with a tolerance of .+-.1 mm.
[0075] The machine includes a cutting station 230 and the sealed
panels are separated into individual pouches. For example, the
pouch is separated along an edge seam. The pouch may also be
separated from the unrolling material along the upper edge and
lower edge. The cut may be a double cut, so as to separate two
pouches at one time. It should be appreciated that the pouches 10
are fully formed, and are now ready for filling.
[0076] The machine includes an unloading station 232. The transport
device transfers the individual pouches to an unloading station
232, wherein the individual pouches are removed. The pouches may be
placed into a receptacle, such as a holder, or magazine or the
like. In this example, the pouches may be placed directly on a
fill-seal line 258 associated with the machine, using a robotic
transfer device 252.
[0077] For a form-fill-seal machine, the line speed between the
form stations 210 and the fill-seal stations 258 can be coordinated
to output filled pouches at a predetermined rate, and such
coordination may increase the overall pouch production rate. The
fill-seal line 258 includes a pouch receiving station 234 for
receiving the pouch that includes a pouch carrier 262 that moves
the pouch, arranged in a predetermined manner, through each of the
stations in the fill-seal line 258. The fill-seal stations may be
associated with a second frame 284. The stations of the fill seal
line 258 of the machine 200 may be arranged in various
configurations, such as a linear manner, or a circular manner. An
example of a circular transport means is a rotational transport
table. The linearly arranged stations may be further oriented
transversely or vertically. Various types of pouch carriers are
available, such as a holder 262 or a gripper, a combination thereof
or the like. An example of a holder 262 is a cup-shaped member, as
disclosed in commonly assigned U.S. patent application Ser. No.
10/336,601, which is incorporated herein by reference. Another
example of a holder is a pair of opposed edge grippers 264 that
each hold a corresponding side edge of the pouch. The side edge
grippers 264 may be operatively connected to an actuating device
for displacing the side edge gripper to open the pouch. The holder
262 is operatively connected to a transport device 282 for moving
the pouch carrier between stations.
[0078] The machine includes an opening station 236, in order to
separate the upper edges of the pouch for filling. The opening
station 236 may include panel grippers 266 that grip the outside
panels of the pouch. The opening station 236 may also includes a
pouch opening device for fully opening the pouch. An example of a
pouch opening device is disclosed in commonly assigned U.S. patent
application Ser. No. 11/933,784 which is incorporated herein by
reference.
[0079] After the pouch is fully opened, a stream of heated air may
be directed toward the upper edges of the pouch, or through the
spout. In addition, a nozzle may be mechanically lowered into the
pouch opened 10. The nozzle is secured to a gas supply means. For
example, a stream of compressed gas downwardly into the pouch to
further force the walls of the pouch 10 away from each other to
further the pouch as shown at 238. An example of a gas is carbon
dioxide or nitrogen.
[0080] In addition, the opening station 236 may include a manifold,
with a hood extending over the top of the edges of the pouch. The
manifold has rows of apertures (not shown) formed above the upper
edges of the walls of the pouch. The hood is placed over the pouch
to assist in maintaining the air pressure in the pouch. The supply
of pressurized gas is directed through the aperture to form a
plurality of jets of pressurized gas or air. The jets are directed
downwardly at the diamond-shaped openings formed at the upper edges
to assist in overcoming the surface tension of the walls and assist
in separation of the walls. A diving rod may then be used to make
sure the pouch is fully opened. Steam or another type of sterilizer
may be utilized to clean an inside wall of the opened pouch.
[0081] The opened pouch moves to a filling station 240, and the
pouch is filled with the product. For example, a product is stored
in a storage device, and one end of a feed line is in communication
with the product in the storage device. The other end of the feed
line is secured to a nozzle that dispenses a predetermined amount
of product into the opened pouch. The product may be dispensed
directly through the opened edges of the pouch or through the
spout. The feed line is operatively controlled by an actuator that
lowers the nozzle into the opened pouch, and dispenses the product
into the opened pouch. The nozzle may be raised at a predetermined
rate out of the pouch that corresponds to the rate of filling the
pouch. The controlled delivery of product may reduce any overspray.
Depending on the size of the pouch, there may be multiple fill
nozzles or fill stations.
[0082] If carbonation is desired, and the product is naturally
carbonated, such as beer or soda or the like, the pouch may be
filled while immersed in a nitrogen atmosphere. If the product is
not naturally carbonated, it may be immersed in a carbonator to
introduce carbon dioxide into the product. For example, carbon
dioxide is introduced into cold water or juice to provide a
carbonated beverage. The product may contain a mixture of up to
four volumes of carbon dioxide. It should be appreciated that the
carbon dioxide may also mask any undesirable taste from ketones and
other solvents released during the sealing process. The carbon
dioxide also increases the pressure within the product so that the
walls of the pouch 10 are rigid after the top is sealed. The
product is preferably filled at a temperature ranging from
29.degree. F. to ambient temperature. The carbonation is also
advantageous as a microbiocide that can enhance the flavor or
prevent mold or contamination.
[0083] The machine includes a gas removal station for removing any
oxygen from the pouch as shown at 242. The gas removal station may
include a hood that evacuates the oxygen, or a diving nozzle that
delivers a gas, such as carbon dioxide or nitrogen, or liquid
nitrogen or the like, into the pouch to displace the oxygen.
[0084] The machine includes a closing station 244 that closes the
pouch. In an example of a pouch includes a zipper fitment, the
zipper is closed using a closing apparatus that engages the zipper,
and a portion of the pouch outboard of the zipper may be sealed. In
another example of a pouch filled through the open edges of the
pouch, the closed edges of the pouch are sealed using a closing
seal. The closing seal may be a thermal seal. For example, a
moveable heat sealing member is positioned over the upper edge of
the pouch to seal the upper edges together through the application
of heat or heat and pressure. Another example of a closing seal for
a product utilizes an ultrasonic sealing process that includes a
first closing seal. The ultrasonic seal may include sound waves and
is formed using a horn and anvil.
[0085] The machine may include a second closing station for
applying a second closing seal. The second closing seal may be
applied using a heat seal means to form a second heat seal spaced
apart a predetermined distance from the first closing seal. It
should be appreciated that the second closing seal may be spaced
slightly outboard of the first closing seal. The second
heat-sealing station is conventional and utilizes heat or a
combination of heat and pressure to form the seal. The second
closing seal may also be a cosmetic seal or another type of seal,
such as ultrasonic, ultra pulse or the like. The first and second
seals are applied for a carbonated product as disclosed in commonly
assigned Patent Application No. PCT/US03/34396, which is
incorporated herein by reference.
[0086] If the pouch 10 is filled through the spout fitment, the
pouch 10 is closed by securing a cap 36 to the spout 34 using a cap
application device. The cap 36 may have a tamper-evident feature.
In addition, the cap 36 may contain a tracking device 26.
[0087] The machine includes a removal station 246 for finishing and
removing the pouch from the machine 200. A feature, such as a
hanging aperture 44, may be formed at this time using a cutting
device, such as a punch. In another example of a finishing
operation, the edges of the pouch 10 may be trimmed to achieve a
desired shape using a cutting device.
[0088] The machine includes a pouch transfer device such as a
robotic transfer device for removing the pouches 10 from the
machine 200. The pouch may be placed into a box or moved to another
device or machine for additional processing.
[0089] It should be appreciated that the automated machine 200 may
include other operations. For example, the filled pouch may be
transferred to another transport device, or otherwise collected.
Alternatively, other stations may include a straw pierceable
opening station, an upstream oxygen purging station, downstream
oxygen purging station, or the like. In another example, the pouch
is transferred to a packaging machine, which may be integral with
the fill-seal machine or a separate line. Still another example of
additional processing is the pouch may be transferred to a
pasteurization station. Pasteurization enhances the shelf life of
the product. The pouch is inserted into an enclosed chamber. For
example, a combination of steam and water is used to heat the pouch
to a predetermined temperature for a predetermined period of time
to pasteurize the product contained within the pouch. The package
is then cooled. In certain instances, it may be desirable to apply
steam to sterilize the pouch 10 and to wet the inner surface of the
walls to facilitate handling.
[0090] The finished pouch is available for use. It should be
appreciated that the ribs 50 provide structural rigidity to the
filled pouch 10, and the pouch 10 stands upright unassisted even as
the product is removed.
[0091] The present invention has been described in an illustrative
manner. It is to be understood that the terminology which has been
used is intended to be in the nature of words of description rather
than of limitation.
[0092] Many modifications and variations of the present invention
are possible in light of the above teachings. Therefore, the
present invention may be practiced other than as specifically
described.
* * * * *