U.S. patent application number 13/852310 was filed with the patent office on 2013-10-31 for packaging for flowable solids.
The applicant listed for this patent is The Iams Company. Invention is credited to Laura Lynn Heilman, Leonard Joseph Keller, Benito Alberto Romanach, Lawrence Andrew Schumacher, Deborah Sue Slovut.
Application Number | 20130287323 13/852310 |
Document ID | / |
Family ID | 48237255 |
Filed Date | 2013-10-31 |
United States Patent
Application |
20130287323 |
Kind Code |
A1 |
Slovut; Deborah Sue ; et
al. |
October 31, 2013 |
Packaging for Flowable Solids
Abstract
A package for large volumes of flowable solids may comprise 2 or
more distinct packages of smaller volume. The 2 or more distinct
packages may be bound together to minimize changes in center of
gravity during handling. The packages may be bound together by an
overwrap. The overwrap may have discontinuities. A method of
packaging large volumes of flowable solids by temporarily reducing
effective headspace to minimize changes in center of gravity during
handling.
Inventors: |
Slovut; Deborah Sue;
(Madeira, OH) ; Schumacher; Lawrence Andrew;
(Trenton, OH) ; Keller; Leonard Joseph; (Villa
Hills, KY) ; Heilman; Laura Lynn; (Petersburg,
KY) ; Romanach; Benito Alberto; (Mason, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Iams Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
48237255 |
Appl. No.: |
13/852310 |
Filed: |
March 28, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61616759 |
Mar 28, 2012 |
|
|
|
Current U.S.
Class: |
383/84 ; 206/497;
53/482 |
Current CPC
Class: |
B65D 2571/00716
20130101; B65B 7/08 20130101; B65D 2571/00679 20130101; B65D 71/08
20130101; B65D 33/1658 20130101; B65D 2571/00685 20130101; B65D
33/008 20130101; B65D 2571/00672 20130101; B65D 2571/00061
20130101 |
Class at
Publication: |
383/84 ; 206/497;
53/482 |
International
Class: |
B65D 33/16 20060101
B65D033/16; B65B 7/08 20060101 B65B007/08; B65D 71/08 20060101
B65D071/08 |
Claims
1. A package comprising: a first pliable bag containing a first
flowable solid and a headspace; and a second pliable bag containing
a second flowable solid and a headspace; wherein the first pliable
bag and the second pliable bag are bound together to reduce an
effective headspace in the package while the bags are bound.
2. The package of claim 1, wherein the first pliable bag and the
second pliable bag are stacked such that one side of the first
pliable bag faces a corresponding side of the second pliable bag,
and the opposing sides of the first pliable bag and the second
pliable bag are substantially covered by an overwrap.
3. The package of claim 2, wherein the overwrap comprises shrink
wrap.
4. The package of claim 2, wherein the overwrap comprises stretch
film.
5. The package of claim 2, wherein the overwrap reduces an
effective headspace in the first pliable bag by at least 75%.
6. The package of claim 2, wherein the overwrap reduces the
effective headspace in the first pliable bag and an effective
headspace in the second pliable bag, each by at least 75%.
7. The package of claim 2, wherein the overwrap is continuous.
8. The package of claim 2, wherein the overwrap is transparent.
9. The package of claim 2, wherein the overwrap is opaque.
10. The package of claim 2, wherein the overwrap comprises an
easy-open feature.
11. The package of claim 1, wherein the first pliable bag and the
second pliable bag are folded to reduce the effective headspace in
the bags before they are bound.
12. The package of claim 11, wherein the first pliable bag and the
second pliable bag are folded over at a top or a bottom.
13. The package of claim 11, wherein the first pliable bag and the
second pliable bag are folded at gussets, creases, darts, or other
constructed fold lines to reduce an effective headspace of the
bag.
14. The package of claim 1, wherein the first pliable bag and the
second pliable bag each contain between 8 and 50 pounds of a
flowable solid.
15. A package comprising: a pliable bag containing at least 10
pounds of a flowable solid; a headspace comprising at least 20% of
a volume of the pliable bag; wherein the pliable bag is folded to
reduce the effective headspace of the bag and the fold is frangibly
secured.
16. The package of claim 15, wherein the pliable bag has a fold,
and the fold is secured by a securement selected from the group
consisting of tape, adhesive, overwrap, mesh, mechanical-fit, or
combinations thereof.
17. A method of making a heavy package of flowable solids easier to
handle, comprising: providing a pliable bag containing between 40
and 120 pounds of a flowable solid; reducing an effective headspace
of the pliable bag by folding or compressing the pliable bag; and
frangibly securing the pliable bag in the folded or compressed
condition.
18. The method of claim 17, wherein the effective headspace of the
pliable bag, after reduction, is less than 5% of a volume of the
pliable bag.
19. The method of claim 17, wherein the pliable bag is frangibly
secured in the folded or compressed condition by a securement
selected from the group consisting of tape, adhesive, overwrap,
mesh, mechanical-fit, or combinations thereof.
Description
FIELD OF THE INVENTION
[0001] This application relates generally to packaging for flowable
solids, such as processed cereal or dry pet foods.
BACKGROUND OF THE INVENTION
[0002] Flowable solids, such as processed breakfast cereal or dry
pet food, is often packaged in a pliable bag. The bag may be the
final packaging for a consumer who purchases the product in a
store, or the bag may be further packaged in a box or other outer
package. The use of bags, including bags comprising specialized
materials or laminates of materials with specialized properties,
are generally efficient in protecting dry products from moisture or
contamination over the product's shelf-life. An outer package
around the bag, such as a cardboard or laminate box, may be used to
protect the bag from punctures or tears during shipping and
handling, or may be used to provide a more aesthetically pleasing
presentation, as the cardboard may be more amenable to uniform
printing than the inner bag.
[0003] This arrangement works well for packages of relatively small
volume or mass. For example, breakfast cereals are typically
available in a bag-in-box package in sizes ranging from about 1
ounce to about 70 ounces (approximately 0.06 to 4.4 pounds, or 0.03
to 2 Kg). However, in some instances, it may be desirable to
package a flowable solid, such as a food product, in significantly
larger and/or heavier packages. For example, dog food is often sold
in bags weighing approximately 5 to 40 pounds (2.3 to 18 Kg), or
more. At the higher end of this range, over perhaps 30 pounds (13.6
Kg), the bags can become difficult to handle, even for generally
healthy shoppers. At 50 pounds (22.7 Kg) even relatively large,
strong consumers may have difficulty manipulating the bags. For
example, it may be difficult to lift bags from a store shelf or
display, which may be nothing more than a shipping pallet stacked
with product in some "warehouse" or discount stores, to a shopping
cart; or from a shopping cart to a vehicle, such as the trunk of a
car; or from a vehicle into a home, which may involve carrying the
product up or down stairs. This difficulty may be exacerbated for
smaller shoppers, for whom a 50-pound bag may represent a
significant portion of the shopper's body weight; for shoppers who
have limited strength or mobility; or for shoppers who are
accompanied by children or are otherwise distracted or rushed.
However, it may be highly inefficient to purchase food in smaller
quantities. For example, some very large or very active dogs may
consume over 2 pounds of food per day for a single dog, and
multi-dog households or institutions, such as animal shelters or
boarding facilities, may use correspondingly greater amounts of
food, making it impractical to buy food in packages of less than 30
pounds.
[0004] There remains a need for a package for relatively large
amounts of a flowable solid which is easy to handle, even for
shoppers of average or below average size and/or strength.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of an exemplary bag comprising
a flowable solid.
[0006] FIG. 2A is a perspective view of an exemplary particle of a
flowable solid.
[0007] FIG. 2B is a perspective view of an exemplary particle of a
flowable solid.
[0008] FIG. 3 is a perspective view of an exemplary package
comprising three distinct bags of flowable solid.
[0009] FIG. 4 is a perspective view of an exemplary package
comprising two distinct bags of flowable solid.
[0010] FIGS. 5A-5E illustrate measures associated with the Drape
Measurement Method.
[0011] FIG. 6 is a chart showing the average activation of
different muscle groups while lifting various packages into or out
of a shopping cart.
[0012] FIG. 7 is a chart showing the average activation of
different muscle groups while lifting various packages from a
pallet.
[0013] FIGS. 8A-D are illustrations of how a bundle package might
be handled by an opening.
[0014] FIGS. 9A-D are illustrations of how a bundle package might
be handled without using an opening.
[0015] FIG. 10 is a chart showing the average activation of
different muscle groups while handling a bundle package with or
without using an opening.
[0016] FIGS. 11A-B are perspective views of stacking configurations
for palletizing product.
DETAILED DESCRIPTION OF THE INVENTION
[0017] As used herein, "flowable solid," refers to a composition
which, although not liquid or gaseous, will tend to flow or stream
from a container when poured. This definition is sometimes used in
the food industry or other applications involving powder or
particulate handling, and should not be confused with the
alternative use of the term "flowable solid" to refer to
substances, like glass, which are thought of as solids, but will
noticeably flow over prolonged periods of time. Glass and similar
highly viscous liquids or semi-solids can be "flowable solids" as
used herein, however, "flowable solids" as used herein embraces
other materials, including compositions that are flowable as an
aggregate of particles but are not flowable in the same sense as
glass.
[0018] As used herein, "headspace" refers to the interior volume of
a package which is not occupied by a flowable solid. The headspace
may contain predominantly air (e.g., atmospheric gas) or an inert
gas, possibly mixed with moisture and/or volatile compounds that
evolve from the flowable solid.
[0019] In some aspects, this disclosure relates to a package which
facilitates the handling of relatively large volumes and/or weights
of flowable solids. The package may comprise 2 or more distinct
sub-packages bound together. The 2 or more distinct sub-packages
may be bound together in a manner which inhibits the movement of
the flowable solid within the packages. By inhibiting the movement
of the flowable solid, the package may be easier for a single
person to move or manipulate the package.
[0020] Flowable solids are often packaged in flexible containers,
such as bags. Flexible containers may be convenient for one or more
of several reasons. A bag, particularly, but not exclusively, a bag
containing synthetic polymers, specialized materials, or laminates
of materials having specialized properties, may be efficient in
protecting the flowable solid from moisture, oxygen, or other
potential causes of degradation. In some cases, this protection may
be important to preserving the texture, flavor, efficacy, or even
safety of the flowable solid. For example, food products exposed to
excessive moisture may be more vulnerable to potentially harmful
microbial growth during storage.
[0021] A pliable bag may also be useful in storing a flowable
solid. Because the contents can move relative to the package, and
the package itself can change shape somewhat, a flowable solid
stored in a pliable bag provides some flexibility in where the bag
can be stored. For example, a bag of flowable solids might be
stored "upright" or on its side, or might be deformed from its
intended shape (e.g., generally rectangular) so as to fit in space
available in a vehicle, closet, pantry, garage, secondary container
(such as a box, chest, or tub), or other space, where a rigid
container of the same nominal dimensions as the pliable bag would
not conform to the available space. Further, a pliable bag may be
helpful in dispensing the flowable solid from the bag. The bag may
be lifted or tilted from one end to empty or partially empty the
bag. In some instances, the pliability of the bag may be useful in
controlling the amount of product emptied from the bag when it is
lifted or tilted. For example, the pliable bag may be deformed to
partially segregate a portion of the product inside the bag before
the bag is partially emptied. Alternately, a scoop or measure may
be inserted into an opening in the bag to remove product from
inside the bag.
[0022] These advantages in storing or dispensing a flowable solid
from a pliable bag require that the flowable solid have some
ability to move or shift position within the pliable bag. For
example, a pliable bag filled to its volumetric capacity, or a
vacuum-packed pliable bag, would not be as efficient in adapting to
differently shaped storage spaces, and could not be deformed to
segregate a portion of the product inside the bag before it is
dispensed, at least not without difficulty. Unfortunately, when the
flowable solid can move within the package, the package is more
difficult to handle. That is, if the bag allows the product to move
when the bag is manipulated, then the flowable solid may move when
the bag is picked up. Depending on how the flowable solid moves
within the bag, this could significantly change the shape of the
bag upon handling and the location of the center of gravity with
respect to the handling points in the bag. In some instances, the
shape and the center of gravity may change repeatedly as the bag is
lifted and/or manipulated. That is, the shopper or handler must
adjust to a change in the center of gravity upon initial lifting of
the bag, and may have to adjust to on-going shifts in the center of
gravity (and/or moment of inertia, among other aspects) as the bag
is moved or carried. This requires additional strength, balance,
and coordination relative to a package of similar weight with fixed
kinetics. Multiple options have been explored for addressing this
problem. Smaller packages of flowable solid can be provided. This
does not solve the variable center of gravity problem, but it does
allow a shopper or handler of more limited strength, balance, or
coordination to handle the package. Unfortunately, this may require
purchasing several packages instead of one package, which may be
inconvenient. For example, instead of handling one bag, the shopper
or handler must move several bags. This may also complicate
storage, since it may be difficult to neatly and stably stack
multiple pliable bags of flowable solids. Another approach is to
vacuum pack a large bag, but this does not fully remove the
tendency for the bag to fold or change shape upon handling, and
vacuum pack can lead to kibble particles being impressed on the
plastic laminate from the inside which can create not only an
unappealing bumpy look but also the possibility of accidental
perforations that would work against the integrity of the package.
Another approach is to provide a rigid outer package, such as a
reusable tote or sturdy cardboard box. However, unless the tote or
cardboard box is filled to its volumetric capacity, the flowable
solid can still shift inside, although perhaps less than in a
comparably filled, pliable bag. Thus, this could reduce, but does
not necessarily eliminate, the difficulty of handling a large
volume of flowable solid. Further, a rigid outer package may defeat
many of the advantages of using a pliable bag, and, if the outer
package is used as an adjunct to, rather than a replacement for,
the pliable bag, the rigid outer package may also have an
undesirable environmental impact. Even if the rigid outer package
is recyclable, as additional packaging it will add weight to the
product. This additional weight may be small for any individual
package, but significant over many dozens or hundreds of packages,
and may, therefore, increase fuel consumption and greenhouse gas
emissions when the product is shipped to distributors, retail
centers, and the like.
[0023] It has been surprisingly found that these disadvantages can
be overcome by tightly bundling two or more pliant bags containing
flowable solids, and that the tightly bundled bags are preferred
over alternative approaches. Although it seems that a rigid outer
container would potentially present a more aesthetically pleasing
appearance and simplify handling, focus groups indicated that
prototype bundle packs as described below are easier to pick up,
easier to move, and would be easier to store. In addition, focus
groups indicated that the ability to separate the bags in the
bundle pack and open them separately, at different times, may
present advantages in preserving the freshness of a large volume of
product or be perceived as preserving the freshness of a large
volume of product, where the product may be used over days or
weeks, rather than all at once.
[0024] FIG. 1 shows an exemplary bag 10. Bag 10 may be pliable, and
may contain a flowable solid 22 and a headspace. Bag 10 may have a
closure 32, which may be any suitable closure, such as a portion of
bag 10 which is folded over and adhered to itself, a zip-type
closure, a press-fit closure, a heat seal, a cold pressure seal, an
ultrasonic seal, and the like. The headspace may make up between 5%
and 30%, or more, of the volume of the bag. The headspace of the
bag may be determined by calculating the volume of the bag from its
dimensions, emptying the flowable solid from the bag, and measuring
the volume of the flowable solid. The volume of the bag is
calculated to include any space within the bag which is or could
normally (without packaging failure) be available for the flowable
solid to move into. For example, if the bag has gussets which are
folded but not secured, the volume of the bag should include the
volume available when the gussets are unfolded. The headspace is
calculated as the volume of the bag minus the volume of the
flowable solid. Because the flowable solid may settle somewhat
differently within a measuring vessel each time the flowable solid
is poured into a measuring vessel, the volume of the flowable solid
should be measured at least 3 times and the average volume
measurement used to calculate the headspace.
[0025] The "effective headspace" of the bag refers to the volume of
headspace that is available or open to the flowable solid; that is,
the free space in the bag that is available to allow the flowable
solid to move or shift position. Thus, if the bag is folded,
creased, compressed, or otherwise arranged such that flowable solid
cannot enter what would otherwise be open volume or headspace in
the bag, the effective headspace is calculated using only the
dimensions of the bag that are free or open to accept flowable
solid.
[0026] Bag 10 may comprise at least 8 pounds, or at least 10
pounds, or 8 to 50 pounds, or 10 to 50 pounds, or 20 to 50 pounds,
or 25 to 50 pounds, of flowable solid 22. The flowable solid may be
a fine particulate, having an average particle diameter greater
than about 5 micrometers, or may be in "macro" particles, such as
pellets or kibble 38 having average particle diameters up to about
40 mm, or any other size, provided that the particles are flowable
when tipped or poured.
[0027] The average diameter is measured as the diameter 36 of the
smallest sphere (represented by circle 34) which would circumscribe
the entire particle, as shown in FIGS. 2A and 2B, and calculated
from 10 randomly selected particles. The shape of the particles is
inconsequential, so long as the particles are flowable when tipped
or poured. In some instances, it may be desirable to keep the total
weight of the flowable solid in the package to 50 pounds or less,
to increase the number of shoppers who should be able to handle the
package without assistance, and to decrease the risk of injury
which may occur from trying to handle excessive weights. In other
instances, it may be acceptable to provide packages comprising up
to 100 pounds, or up to 120 pounds, of flowable solid. For example,
larger packages may be acceptable in settings where it is expected
that two or more people may handle the packages cooperatively, or
where mechanical assistance devices may be available for handling
the packages.
[0028] The materials and construction of bag 10 may be adapted to
the composition inside the bag. As an example, a dry pet food
kibble may be packaged inside a bag as described in U.S.
Application Publication No. 2011/0027418, titled "Animal Food
Having Low Water Activity". Multiple alternative constructions are
possible and do not limit the applicability of the package as
disclosed. Without limitation, the bag may comprise natural or
synthetic fibers or materials, may be waterproof or water
resistant, and may be reusable or disposable. The bag may comprise
a single layer or multiple layers of material, and any single layer
may itself be a single, uniform material or may be a laminate of
like or dissimilar materials. The bag may, in addition to
comprising the flowable solid, comprise dessicants, humectants,
antioxidants, buffers (such as acids, bases, or salts thereof), or
other active ingredients, within the bag or on the surface
(interior, exterior, or both) of the bag, to help maintain the
flowable solid in a desired condition, physically and/or
chemically, during production, shipping, handling, storage, and/or
use. In one specific embodiment, the bag may be constructed from a
plastic laminate having an outer layer of polyethylene terapthalate
(PET) and an inner layer of a co-extruded blend of linear low
density polyethylene, medium polyethylene, and linear low density
polyethylene. In this embodiment, the bag has a Water Vapor
Transmission Rate of 6.times.10.sup.-6 g*ply/d/cm.sup.2/mmHg.
[0029] Two or more bags, such as 10a, 10b, 10c of flowable solid
(not shown), may be bound together by an overwrap 28 to form a
package 20. FIGS. 3 and 4 show two or three bags, however, it
should be understood that additional bags can be included in
package 20, such that package 20 contains three bags, or four bags,
or even five bags. The bags 10a, 10b, 10c, if not uniform in all
dimensions (e.g., not roughly spherical or cubical) may be laid
side-to-side to along their longest axis. Pairing the bags 10a, 10b
along their longest side may facilitate applying overwrap 28, and
may also make package 20 easier to handle, particularly if, as in
FIG. 3, one side of bags 10a, 10b, 10c is significantly longer than
the other sides. As shown, bags 10a, 10b, 10c are of the same size,
however, it is possible to use overwrap 28 to manage two or more
bags of different sizes.
[0030] Overwrap 28 may be a plastic film, such as that used for
pallet wrapping, and may be blown or cast, and of any desired
gauge. Overwrap 28 may have stretch or shrink properties to help
bundle bags 10a, 10b tightly together, to minimize the movement of
flowable solid 22a, 22b within bags 10a, 10b, even when package 20
is moved or moving. Overwrap 28 may comprise paper, paperboard, or
fiberboard or other materials, for example, such materials may be
incorporated into a shrink or stretch material, as by laminating a
label or paperboard structure onto a shrink or stretch material.
Overwrap 28 can be transparent, translucent, or opaque, and may be
colorless, tinted, or richly colored. Overwrap 28 may be different
in different portions of the overwrap. For example, part of
overwrap 28 may be transparent, and part may be opaque, or
different parts of overwrap 28 may have different colors, tints,
printing, and the like. Overwrap 28 may tend to adhere to itself,
or may be sealed to itself through any suitable means, including
heat sealing, cold pressure sealing, adhesive sealing (including
applied glue or the use of adhesive tape), ultrasonic sealing, and
the like, at one or more seals. Overwrap 28 may include one or more
perforations, peel-away strips, pull tabs, or other easy-open
features to help remove overwrap 28 when package 20 arrives at its
final destination. Overwrap 28 may be printed or may have labels or
other indicia applied to its outer surface to identify the flowable
solid 22 inside package 20, or overwrap 28 may be designed to as
not to interfere with indicia on bags 10a, 10b which include
information, such as the identity of flowable solid 22, that may be
relevant to a shopper or someone handling package 20. The selection
of the overwrap material may be such that it will not substantially
adhere to outer material of the individual bags to be bundled, so
as to enable easy removal of the overwrapped material upon opening
of the package and prevent any damage to the appearance or
integrity of the individual bags comprised in the package.
Non-limiting examples of material combinations may include a paper
substrate inner package combined with a polyolefin or polyethylene
shrink film or a plastic (e.g. PET/PE, PET/BPOA/PE, PET/mBOPP/PE,
or the like with PET outer layer) film structure with a polyolefin
or polyethylene shrink film. An example of non-compatible material
could be paper bags with a plastic film label to bundle the
products resulting in bag destruction when removing the plastic
film label.
[0031] In some cases, non-vacuum packed bags, even those with
little headspace, may allow the flowable solid to move. The freedom
to move may increase the more the shape of the bag deviates from
the shape of a sphere, as less-spherical packages require more bag
surface area for a given volume. For example, a flat rectangular
bag may have nearly twice as much surface area as a spherical bag
of the same volume. An overwrap may be used to create a package
that is closer to a sphere than the individual bag(s). In some
embodiments, the excess surface area of an overwrapped package as
compared to the surface area of a sphere of equal volume is less
than 50% of the surface area of the sphere, preferably less than
40%, or preferably less than 35%, while also preferably more than
10%, preferably more than 20%, or preferably more than 25%, for
improved ergonomics. The excess surface area of an overwrapped
package, as compared to the surface area of a sphere of equal
volume, may be between 25% and 35%.
[0032] Overwrap 28 may compress the bag(s) in the package,
stiffening the bundle. This stiffening may reduce changes to the
shape of the bundle and changes to the location of its center of
gravity upon handling, which would facilitate predictable handling.
Stiffness can be measured using the Drape Measurement Method
described below. As measured a lower drape measurement is
indicative of a more rigid (e.g., stiffer) package. In some
embodiments, the package may have a drape measure less than 0.8,
preferably less than 0.6, preferably less than 0.4, preferably less
than 0.2.
[0033] Overwrap 28 may be left open at one or more ends of package
20, as shown in FIGS. 3 and 4. These openings 40 may serve as
hand-holds when picking up or manipulating package 20. In some
embodiments, excess material may be bunched or rolled at the ends
of package 20 to form rudimentary grips. In some embodiments, the
ends of package 20 may be augmented with additional material like
or unlike overwrap 28, to provide distinct grips. Augmented grips
may be cushioned or formed of a "cushiony" material, such as foam,
to make grasping and lifting package 20 more comfortable on the
handler's hands. Augmented grips may be formed or shaped to
accommodate a hand or fingers and thus be more comfortable on the
handler's hands. At a minimum, if opening(s) 40 are augmented, the
ends may be "padded," rounded, or otherwise designed to help
distribute the force of lifting package 20 over more than the
narrow strip of overwrap 28 which might otherwise form the end of
package 20. That is, augmented ends may be used to reduce the
pressure on the hands of a handler of package 20. Alternately,
overwrap 28 may be placed such that openings 40 expose an end of
one or more bags within package 20, so that the end of the bag may
serve as a grip or handle. For example, a handler of package 20 may
slide his or her hands in between two bags within package 20, and
lift package 20 by the bag within package 20. If openings 40 are
used to handle package 20 of bags of equal size, the length of
overwrap 28 may be greater than the length of the bags within
package 20, and less than the length plus the height of the bag, to
leave a suitable opening 40 for grasping package 20.
[0034] Package 20 may comprise one or more stiffening inserts. Such
inserts may be, for example, heavy-duty cardboard or other stiff,
durable members. The inserts may help to prevent the bag(s) inside
package 20 from sagging in between the points where the package is
gripped by a shopper or handler. An insert may be particularly, but
not exclusively, useful if the bag(s) inside package 20 still have
significant effective headspace after folding and/or bundling. If
used, an insert may be printed or ornamented to provide useful
information, attract attention, or provide an aesthetically
pleasing appearance for the package. In some embodiments, no
stiffening insert or member is present. In some embodiments, the
rigidity of package 20 is increased over the bag(s) inside package
20 only by decreasing the effective headspace of the bag(s), as by
folding and/or bundling the bags. In some embodiments, the rigidity
of package 20 is increased over the bag(s) inside package 20 by
restricting the movement of the headspace location, as by tightly
bundling the bag(s) with a compressive overwrap 28. In another
embodiment the rigidity of package 20 is increased over the bag(s)
inside package 20 by restricting the movement of the headspace
location and decreasing the effective headspace of the bag(s), as
by folding and/or tightly bundling the bags. In some embodiments,
package 20 excludes a pallet or other durable shipping aid, but may
be placed, stacked, or stored on a pallet or other durable shipping
aid. For example, package 20 may not comprise a pallet or other
durable shipping aid within overwrap 28, if present.
[0035] When placed in an overwrap, a bundle of individual laid down
bags stacked vertically one over the other has a lower bulge to
equivalent gusset height ratio than a comparative single individual
bag of equivalent designed footprint and weight as the bundle. This
may result in improved pallet fit and design options as well as a
better package readability and/or recognition for the consumer to
see information about the product, such as the name or type of
product, or other information on the label. In particular, the use
of a bundle pack as described herein may enable the safe vertical
stacking of packages on a pallet at heights or in configurations
which are not possible with comparable individual bags. These
bundle packs may be further secured to the pallet and/or to one
another on a pallet, as by shrink wrap, overwrap, bands or belts,
as is often done for palletized product. Nonetheless, the bundle
pack enables different stacking patterns and stacking heights than
comparable individual bags. In an individual bag, where a flowable
solid is able to move due to headspace in the package, the
individual packages can shift during palletization, leading to
uneven heights within a vertical layer of packaging. Further, the
flowable solid may move in response to the placement of other
individual packages nearby. When there is capacity for movement
within the palletized product, the palletized product may become
unstable and fall over. This limits the configurations and/or
stacking heights which can be safely used with conventional,
individual packages of flowable solids.
[0036] Conforming the dimensions of the packs, as by using a
bundled package as described herein, may also enable stacking the
packages while they are vertical. Being able to stack the packages
vertically enables different palletizing or stacking patterns. As
shown in FIGS. 11A and 11B, reorienting packages 200 of the same
size on a pallet 210 can result in the addition of one or more
packages 200 to the pallet 210. FIG. 11A shows a stacking
configuration which yields 35 packages per pallet. FIG. 11B shows
an alternative stacking configuration for packages having the same
dimensions as those in FIG. 11A, but the stacking configuration of
FIG. 11B yields 36 packages per pallet. When shipping many
packages, an increase of even 1 or 2 packages per pallet can
contribute to reduced material use (e.g., fewer pallets, and less
overwrap or banding material to secure product to the pallet for
transportation), reduced shipping costs (more packages per pallet
means more packages per truck, train car, boat, or other mode of
transportation), and reduced carbon emissions associated with
shipping the products.
[0037] In an individual bag of substantial weight, which might be
stored in relatively low positions in a shopping area, the bulge
along the sides of the package may reduce the visibility of label
information on the bottom of the bulge. That is, the bulge,
possibly in concert with a standing person's line of sight due to
the position of the package on a shelf or display, may render some
of the label information difficult or impossible to see, or to see
clearly. Of course, if a bag is stored in a relatively high
position, label information on the top of the bulge may be
relatively inaccessible. The equivalent gusset height of a bundle
of individual bags stacked vertically is determined as the sum of
the individual gusset heights of each of the bags in the bundle.
The gusset height, GH, of an individual bag is determined as the
actual distance between edge creases in the gusset in a flat
position. This should not be confused with the distance between
edge creases when the bag is full and bulging. The bulge is
determined as the difference between the width of a laid down bag
filled with flowable solid, Wf, and the designed bag width as
measured between edge creases in a flat position (or empty bag),
We, so Bulge=Wf-We.
[0038] In some embodiments, a package may comprise an equivalent
gusset height above 5 inches, preferably above 7 inches, preferably
above 9 inches, or preferably above 11 inches, and/or less than 26
inches, preferably less than 24 inches, preferably less than 22
inches, preferably less than 20 inches. In some embodiments, a
package may comprise a bulge to equivalent gusset height less than
0.6, preferably less than 0.4, preferably less than 0.2. In one
embodiment a bundled pack comprising three laid down bags stacked
vertically one over the other has an equivalent gusset height of 9
inches and a bulge to equivalent gusset height ratio of 0.16. In
another embodiment a bundled pack comprising four laid down bags
stacked vertically one over the other has an equivalent gusset
height of 14 inches and a bulge to equivalent gusset height ratio
of 0.18. In another embodiment a bundled pack comprising three laid
down bags stacked vertically one over the other has an equivalent
gusset height of 15 inches and a bulge to equivalent gusset height
ratio of 0.31.
[0039] When placed in overwrap 28, the effective headspace in bags
10a, 10b may be reduced in order to form a solid, brick-like
package that does not experience the shifting center of mass and
moment of inertia that bags 10a, 10b might. If the bag is gusseted
or darted, this may manifest as partially or completely closed
gussets or darts 42, as shown in FIG. 3. Alternately, or in
addition, there may be creases or folds in the material elsewhere
along the bag surface, either in pre-defined or more-or-less random
locations as the bags are bound into package 20. That is, the bag
structure or the overwrap process or both may be designed to fold
or crease the bag in specific locations, or the bag may be allowed
to fold or crease without intentional direction (although a uniform
and/or mechanized process for preparing a package may make this
less than truly random).
[0040] In some embodiments, the bags may be folded over so that the
material in the bag that would enclose headspace rather than
flowable solid is folded back on itself prior to forming package
20, as shown in FIG. 4. If the bags, as a result of printing, other
indicia, or structure, have a top and a bottom, the bags may be
folded over at the top, at the bottom, or along the sides of the
package. If the bags are folded, they may be secured in the folded
position by a securement means, such as tape, adhesive (including
cohesives), overwrap, mesh, mechanical fit, or combinations
thereof. The securement may be frangible. With reference to the
securement, frangible means that the securement may be broken or
disabled without opening or damaging the bag or its contents. For
example, if tape is used to secure the bags, the tape may have a
sufficiently low adhesion force to the bags that the tape can be
easily removed without stripping the bag of any functional or
cosmetic outer layer. That is, the tape and the bag may be mutually
selected so that, after removing the tape, the bag will serve any
intended barrier function (e.g., as a barrier to moisture, oxygen,
pests, children, etc.) and the tape will not disrupt labeling or
indicia that might be useful in identifying the contents of the
bag, reading instructions for using the contents of the bag, or the
like. A frangible securement, in addition to protecting the
function of the bag(s) in the package, may be helpful in enabling a
shopper or handler to access the benefits of a pliable bag having a
headspace, when those benefits would exceed the benefits of having
a lower effective headspace. For example, it may be desirable to
provide a package with a low effective headspace to make it easier
to lift the package into a shopping cart, vehicle, or other
conveyance, and desirable to provide a pliable bag with an open
headspace that is easier to conform to available storage space, or
to use to pour or dispense the contents of the bag once the bag has
been moved to its ultimate location.
[0041] The securement, such as an overwrap, may cover substantially
all of the bag(s). For example, the overwrap may cover 80% or more
of the surface area of the bag(s) as stacked. The overwrap may be
continuous or discontinuous. For example, if the overwrap is a
stretch wrap, tape(s) or strap(s) which is(are) wound around the
bag(s) several times, it is not necessary that the overwrap touch
or overlap across the entire side surface of the bag(s), so long as
the overwrap is sufficient to secure the intended effective
headspace of the package. If a mesh is used to secure the package,
the mesh structure may overlay 80% or more of the surface area of
the bag(s) as stacked (i.e., of the surface area taken along the
perimeter of the package, excluding the surface area of facing
sides of the bags in a multi-bag package), even if the
discontinuities in the mesh mean that a much smaller portion of the
surface area of the bags is "covered" or obscured by the mesh. The
overwrap may be a single piece or continuous web of material, such
as stretch wrap applied from a single roll source, or may be
comprised of two or more pieces of material, such as two or more
webs of stretch wrap. If the overwrap comprises two or more pieces
of material, the pieces may be joined, overlapped, or affixed to
one another, in parts or in whole (e.g., some pieces joined to
other pieces, but not all pieces joined directly or indirectly, or
all pieces joined directly or indirectly, as by joining one piece
to another, which is joined to yet another piece, which is joined
to yet another piece), or the parts may not be joined, overlapped
or affixed to one another.
[0042] The securement may secure the bag(s) in a condition with an
effective headspace at least 75% less than the headspace of the
bag(s) when they are not folded, secured, or bound. In some
embodiments, the securement may secure the bag(s) in a condition
with an effective headspace at least 95% less than the headspace of
the bag(s) when they are not folded, secured, or bound. One, more
than one, or all of the bags in a package may be bound in a
condition which results in an effective headspace at least 75%, or
at least 95%, less than the headspace of the bag when it is not
folded, secured, or bound. In some embodiments, a single bag
containing a large volume of flowable solid, such as at least 40
pounds, or at least 50 pounds, or at least 55 pounds of flowable
solid, is folded and secured to reduce effective headspace. Such a
single-bag package may present some benefits of a package
comprising two or more bags, such as improved handling, and may not
present any drawback in terms of freshness if, for example, the
contents of the bag may be used at once, with no leftover material
to be stored for later use. The bag or bags, whether packaged
individually or in a multi-bag package, may comprise features to
help preserve the contents of the bag after the bag is opened, such
as a resealable opening (e.g., an opening equipped with adhesives,
cohesives, or press-fit/zip-style closures that can be opened,
reclosed, and opened again).
[0043] The flowable solids in different bags in a package may be
the same or different compositions. For example, one flowable solid
may be one flavor of dog food, and a second flowable solid may be a
different flavor of dog food. As a more specific example, a first
flowable solid may be dry dog food kibble flavored with lamb and
rice, and a second flowable solid may be dry dog food kibble
flavored with chicken and rice. In other embodiments, different
flowable solids may be complimentary or adjunct products, such as
cat food and cat litter, or dog food and dog treats, or a food
product to support nursing mothers and a food product suitable for
weaning infants/puppies/kittens, or breakfast cereal and
freeze-dried fruits, or combinations of different dehydrated foods,
candies, chemicals, or the like.
[0044] This disclosure describes flowable solids with most frequent
reference to pet foods, such as dry dog food. However, the packages
and packaging methods described may be useful with regard to a
variety of flowable solids, including human foods, such as
breakfast cereals, other processed foods, candies, vegetables, and
breads (particularly, but not exclusively, rounds, mini-loaves,
rolls, or muffins); household chemicals, such as salt (as for a
water softener or de-icing purposes), detergents, and pesticides;
agricultural products, such as seeds, mulch, pebbles, processed or
pelleted fertilizers (in contrast, unprocessed manure, for example,
may clump and resist flowing when dispensed from a bag),
pesticides, or fungicides, and other soil additives; or industrial
products in solid, particulate form, such as extrusion resins.
Although the potential benefits are described largely in relation
to an individual shopper or consumer in a shopping center, vehicle,
or home, it should be appreciated that similar handling benefits
may accrue when products are handled in a workplace or other
setting, including stores, farms, loading docks, manufacturing
areas, and the like, where individuals may be called upon to
manually manipulate relevant volumes of a flowable solid.
Drape Measurement Method
[0045] The drape measure is indicative of the ability of a package
to retain its shape upon handling, and measures an amount of
deformation of the package upon placing it on a test stand. FIGS.
5A-5E illustrate the set-up for performing this method, as
described below.
[0046] The test stand 100 comprises a horizontal surface 101
located above a floor surface 102 a minimum distance H equivalent
to the longest dimension of the package to be measured, and
supported in that location by any means that would enable surface
101 to support the weight of the package to be measured. Surface
101 further comprises a straight end edge 103. The stand further
comprises a horizontal ceiling surface 104 with ability to move up
and down and ability to slightly compress a package placed between
surface 101 and ceiling surface 104 with a weight approximately
equivalent to that of the package being measured, or within 10% of
the weight of the package. A weight 107 can be used to approximate
the weight of the package.
[0047] Before a package is measured, three orthogonal surfaces are
chosen on the package that would naturally correspond to a front,
side, and bottom surfaces of the package. The largest of such
surfaces is labeled S1, the smallest surface is labeled S3 and the
remaining surface is labeled S2. If two surfaces are equal and
larger than the third, then those two are labeled S1 and S2, and
the third labeled S3. If two surfaces are equal and smaller than
the third, then those two surfaces are labeled S2 and S3 and the
third labeled S1. If all three surfaces are equal, then any one
surface can be S1, another S2 and the last one S3.
[0048] The package is placed a first time on surface 101 such that
surface S1 is fully supported by surface 101, and oriented such
that the longest length of surface S1 is perpendicular to straight
end edge 103. Ceiling surface 104 is lowered over the package so
that it slightly compresses the package between surface 101 and
ceiling surface 104 with a weight approximately equivalent to that
of the package being measured, or within 10% of the weight of the
package. The distance D (105) between the surface 101 and ceiling
surface 104 is recorded as D1. The package is now slid over the
surface 101 and towards straight end edge 103 such that the center
of gravity of the package rests over the straight end edge 103 and
such that only half of the surface S1 of the package is now
supported by surface 101. Ceiling surface 104 must be large enough
to completely cover, at a minimum, the portion of the package that
remains on surface 101, and exerts a weight approximately
equivalent to that of the package being measured, or within 10% of
the weight of the package, to prevent the package being measured
from pivoting around the straight end edge 103 and falling from
surface 101 prematurely. At this point the portion of the package
that is not supported by surface S1 may be inclined as per the
force of gravity to bend 5 over the straight end edge 103 towards
floor surface 102. The maximum vertical distance, V (106), that the
package reaches from a horizontal plane including surface 101
towards floor surface 102 is recorded as V1. If the package does
not get to cross the horizontal plane that includes surface 101,
then V1 is equal to 0. The drape measure, DM, is now calculated as
V1 divided by D1, so DM=V1/D1. All dimensions are measured with the
same unit of length, such 10 that the DM ratio is adimensional (or
dimensionless). The drape measure is reported as an average of 3
measurements.
Example 1
[0049] The following table shows drape measurements taken for three
bags of various weights, and for two different kinds of bundles,
showing how the bundles have a much lower drape 15 measure as
compared to individual bags. This is indicative of a stiffer
package prepared only with laminate materials.
TABLE-US-00001 Actual Weight Length Width D 1 V 1 Sample
Description (LB) (IN) (IN) (IN) (IN) DM 15 lb-Side Lay Flat Large
Bag 15.2 21.77 12.84 3.3 4.4375 1.3447 Gusseted Bag 26 lb-Side Lay
Flat Large Bag 26.45 25.75 16.627 4.264 4.5625 1.0700 Gusseted Bag
33 lb Side Lay Flat Large Bag 33.3 23.848 19.018 4.0875 6.5625
1.6055 Gusseted Bag 3-10.5 lb Bag Lay Flat Large Bags 32.35 19.1
14.35 8.05 1.0625 0.1320 Bundle in bundle 3-12 lb Bag Stand Up Bags
in 36.3 18.169 10.049 9.845 1.4725 0.1496 Bundle bundle
Example 2
[0050] A focus group of shoppers who frequently purchase 50-pound,
pliable bags of dog food are shown four packaging configurations.
The first is a package as described above, with 3 bags each
containing about 16.6 pounds of dog food and secured to each other
via a substantially continuous overwrap with discontinuities at two
ends of the package. The second configuration is a rigid cardboard
container shaped like a cube, with partial oval cut-outs in two
sides of the cube that serve as handles. The third configuration is
a roughly cube-shaped bag, sometimes called a Smart Cube. The
fourth configuration is a conventional 50-pound bag of dog food.
The focus group was given the opportunity to view, touch, and
handle each package, as each group member desires. The focus group
indicated that the package as described above appears to be easier
to store and better for protecting the freshness of the food after
the bag or package it opened. The focus group further indicated
that the package as described above is easier to lift and
manipulate than the other packages.
Example 3
[0051] Electromyography was used to measure muscle activation in
adult human volunteers lifting comparable weights of dog food in
different package configurations. Electromyography (EMG) is a
technique of measuring muscle activation by recording the
electrical potentials that cause muscle fiber contraction.
Specifically, EMG measures the electrical signals that are sent by
the brain through the nerve to the motor units in the muscles. The
motor units use the electrical signal to contract muscle fibers
which are spread throughout the muscle. The more motor units
stimulated, the more muscle fibers contract, creating a stronger
contraction. Muscle activation results can be used to compare the
effort required to lift a load, as well as which muscle group(s)
are activated. High muscle forces in the hands and arms can cause
pain and fatigue.
[0052] EMG was measured by placing two electrodes on the skin above
the muscle of interest about 1-2 cm apart from one another. Female
subjects were selected from a pool of volunteers aged 18-95 who
purchase single pack pet foods of approximately 35 pounds.
Volunteers were excluded from the study for medical conditions
which contraindicated lifting 35 pounds or EMG (e.g., allergies to
latex, adhesives, or gels used in the test, use of a pacemaker or
hearing aid, open wounds in areas where EMG sensors would be
placed, recent acute injury, or recent surgery). Measurements were
taken to calibrate Maximum Voluntary Contraction (MVC). Results
were reported in % MVC for each volunteer, to account for
differences in muscle structure and strength between
individuals.
[0053] Each volunteer was asked to handle, in randomized order, a
bundle pack of dry dog food as shown in FIG. 3, weighing a total of
35 pounds, a large single pack of commercially available dry dog
food weighing 33 pounds, and a cardboard box of dry dog food
weighing 33 pounds. For each handling exercise, the volunteer was
asked to lift the package from a 5-inch pallet (to simulate lifting
the package from an endcap display or low shelf), transfer the
package to a shopping cart, remove the package from the shopping
cart, and place the package on a meeting room table (to simulate
placing the package in an automobile trunk). The order of handling
the different packages was randomized--some subjects lifted the box
first, some subjects lifted the bundle pack first, and some
subjects lifted the individual bag first. Percent MVC was measured
for each activity by each volunteer at the shoulder (Medial
Deltoid), upper arm (Biceps Brachii and Triceps Brachii), and
forearm (Flexor Carpi Ulnaris). The results are shown in FIG. 6
(handling the packages relative to a shopping cart) and FIG. 7
(handling the packages relative to a pallet). FIGS. 6 and 7 show
that the percent MVC for the bundle pack was comparable to or
better than the single pack and box even though it was slightly
heavier. In addition, qualitative ergonomic observations included
less back bending when lifting the bundle pack compared to the
alternatives (which explains why the arm muscle activation was
slightly higher in some circumstances). Also, volunteers of shorter
stature had to lift the single pack and box above their chest to
place those packages into and lift those packages from a shopping
cart, but did not have to do so with the bundle pack.
[0054] Handling the bundle pack by openings 40 provided further
benefits in terms of reducing stress on the back. Examples of
handling the bundle pack by openings 40 are shown in FIG. 8.
Examples of handling the bundle pack other than by openings 40 are
shown in FIG. 9. Average percent MVC for various muscle groups when
handling the bundle pack by openings 40 or in another manner are
shown in FIG. 10. Handling the bundle pack by openings 40 increases
the use of the triceps and decreases the use of the biceps and
forearm, which is ergonomically preferred.
[0055] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0056] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0057] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *