U.S. patent application number 15/315787 was filed with the patent office on 2017-04-20 for method of manufacturing and filling a package and corresponding package.
This patent application is currently assigned to N.V. Nutricia. The applicant listed for this patent is N.V. Nutricia. Invention is credited to Sjors Floris Crusius.
Application Number | 20170107002 15/315787 |
Document ID | / |
Family ID | 51033456 |
Filed Date | 2017-04-20 |
United States Patent
Application |
20170107002 |
Kind Code |
A1 |
Crusius; Sjors Floris |
April 20, 2017 |
METHOD OF MANUFACTURING AND FILLING A PACKAGE AND CORRESPONDING
PACKAGE
Abstract
The present invention relates to a method of manufacturing and
filling a package with a powdered nutritional product, such as
infant nutrition or milk formula, the method comprising providing a
thermoformed tub having sidewalls and a base defining a product
receiving space, filling the product receiving space with the
powdered nutritional product, and sealing a membrane across an open
mouth of the tub to seal the product therein; and folding a carton
blank with a plurality of panels around the filled tub to form a
carton sleeve, wherein the carton sleeve comprises a peripheral
wall enclosing at least the sidewalls of the tub. The invention
also relates to a package for such a powdered nutritional product
manufactured according to this method.
Inventors: |
Crusius; Sjors Floris;
(Utrecht, NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
N.V. Nutricia |
Zoetermeer |
|
NL |
|
|
Assignee: |
N.V. Nutricia
Zoetermeer
NL
|
Family ID: |
51033456 |
Appl. No.: |
15/315787 |
Filed: |
June 4, 2015 |
PCT Filed: |
June 4, 2015 |
PCT NO: |
PCT/NL2015/050402 |
371 Date: |
December 2, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 2543/00722
20130101; B65D 2543/00435 20130101; B65D 2251/009 20130101; B65D
2251/0093 20130101; B65B 1/02 20130101; B65D 43/169 20130101; B65D
2543/00527 20130101; B65B 31/028 20130101; B65D 2543/00787
20130101; B65B 43/145 20130101; B65D 25/36 20130101; B65B 7/28
20130101; B65B 1/04 20130101; B65D 2543/00685 20130101; B65D
2543/00194 20130101; B65D 2543/00611 20130101; B65D 2577/2091
20130101; B65B 11/004 20130101; B65D 2543/00537 20130101; B65D
2543/00842 20130101; B65D 51/247 20130101; B65D 2251/0021 20130101;
B65D 2251/0028 20130101; B65D 2577/205 20130101; B65D 51/20
20130101; B65D 2543/00296 20130101; B65B 31/025 20130101 |
International
Class: |
B65B 1/04 20060101
B65B001/04; B65D 25/36 20060101 B65D025/36; B65D 51/20 20060101
B65D051/20; B65B 7/28 20060101 B65B007/28; B65B 11/00 20060101
B65B011/00; B65B 31/02 20060101 B65B031/02; B65B 43/14 20060101
B65B043/14; B65D 43/16 20060101 B65D043/16; B65D 51/24 20060101
B65D051/24 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 5, 2014 |
NL |
PCT/NL2014/050361 |
Claims
1. A method of manufacturing and filling a package with a powdered
nutritional product, the method comprising: a) providing a
thermoformed tub having sidewalls and a base defining a product
receiving space, filling the product receiving space with the
powdered nutritional product, and sealing a membrane across an open
mouth of the tub to seal the product therein; b) folding a carton
blank with a plurality of panels around the filled tub to form a
carton sleeve, wherein the carton sleeve comprises a peripheral
wall enclosing at least the sidewalls of the tub.
2. The method according to claim 1, wherein the carton blank
comprises a bottom panel and side wall panels and wherein after
folding the carton blank to a sleeve, the sleeve encloses the
sidewalls and at least a part of the base of the tub.
3. The method according to claim 1, wherein step b) further
comprises gluing the panels to the tub.
4. The method according to claim 1, wherein step b) further
comprises connecting the panels to each other.
5. The method according to claim 2, wherein step b) further
comprises gluing the bottom panel to the base of the tub.
6. The method according to claim 1, wherein step b) comprises
applying a lateral displacement to panels to bring them into
engagement with the sidewalls of the tub after folding towards the
sidewalls of the tub.
7. The method according to claim 1, wherein step b) further
comprises providing the carton blank from a carton blank magazine
holding multiple carton blanks.
8. The method according to claim 1, wherein step b) further
comprises centring the carton blank and the thermoformed tub with
respect to each other.
9. The method according to claim 1, wherein step a) further
comprises fitting a lower rim to an upper edge of the tub.
10. The method according to claim 9, wherein step a) further
comprises fitting a lid assembly to the tub, the lid assembly
comprising an upper rim and a recloseable lid.
11. The method according to 10, wherein the upper rim and the lower
rim are mechanically connected together in an interference fit.
12. The method according to claim 1, wherein step a) takes place in
a high care zone defined by a supra-atmospheric pressure and a
filtered atmosphere.
13. The method according to claim 12, wherein step b) takes place
outside the high care zone.
14. The method according to claim 1, wherein filling the product
receiving space with the powdered nutritional product takes place
in a low oxygen atmosphere.
15. The method according to claim 14, wherein the low oxygen
atmosphere comprises a carbon dioxide atmosphere.
16. The method according to claim 1, wherein the tub has a wall
thickness of between 0.10 mm and 0.50 mm.
17. The method according to claim 1, wherein the carton blank has a
weight of between 50 g/m.sup.2 and 400 g/m.sup.2.
18. The method according to claim 1, wherein the tub and the sleeve
have tapered sidewalls, with a taper of between 1.degree. and
7.degree..
19. The method according to claim 1, wherein the membrane comprises
a weakened tear line defining an opening region, and a pull
tab.
20. A package for a powdered nutritional product manufactured by a
method comprising: a) providing a thermoformed tub having sidewalls
and a base defining a product receiving space, filling the product
receiving space with the powdered nutritional product, and sealing
a membrane across an open mouth of the tub to seal the product
therein; b) folding a carton blank with a plurality of panels
around the filled tub to form a carton sleeve, wherein the carton
sleeve comprises a peripheral wall enclosing at least the sidewalls
of the tub.
21. (canceled)
22. (canceled)
Description
BACKGROUND OF THE INVENTION
[0001] Field of the Invention
[0002] The present invention relates to the manufacturing of
packages and in particular to the manufacturing of packages for
powdered nutritional products such as infant nutrition or milk
formula. The invention also relates to such a package.
[0003] Description of the Related Art
[0004] Powdered material, such as infant milk formula, has been
sold in various forms of package for many years. Metal cans were
initially the preferred container as they were relatively easy and
cheap to produce and could be sealed for long term storage. The
seal comprised an aluminium foil across the mouth of the container
that was removed on first use. As a single container would be used
for an extended period, the containers were provided with
re-closable plastic lids which gripped over the outer rim of the
metal can. A measuring scoop was frequently included with the
container, either packaged separately or within the can itself.
Such cans are however relatively heavy and expensive to
produce.
[0005] More recently, alternative packaging forms have become
available which improve on the existing cans. These include
laminate container bodies and plastic hinged lid and rim
structures, which may be glued to the container body. One such
package is described in US 2008041861, having a seal for initially
closing the package and a space between the seal and an upper edge
of the container for partially receiving the scoop prior to use.
The container part may consist of a laminate of carton, metal foil
and plastic material. A further similar package is shown in
WO2010071424. A disadvantage of composite packages is that they may
be difficult to recycle. Proposals for multi-component packages
have been made that allow disassembly for separate recycling but
until the present, suitable manufacturing processes capable of
achieving such packages have been absent.
[0006] It has been known to manufacture multi-component packages by
providing a carton around a thermoformed containers prior to
filling the container, for example by the use of a mandrel to
support the container and form the carton around the container or
by using a mould to support the carton prior to lining the carton
with a thermoformed container. A disadvantage of such
multi-component packages it that this way of manufacturing is
undesirable for high-care products, such as infant formula. In the
light of these requirements, it would be desirable to provide a
package capable of being assembled in a manufacturing process that
can be disassembled for recycling purposes. It would also be
desirable to provide a method by which such a package could be
manufactured.
BRIEF SUMMARY OF THE INVENTION
[0007] According to the invention, there is provided a method of
manufacturing and filling a package with a powdered nutritional
product, the method comprising: [0008] a) providing a thermoformed
tub having sidewalls and a base defining a product receiving space,
filling the product receiving space with the powdered nutritional
product, and sealing a membrane across an open mouth of the tub to
seal the product therein; [0009] b) folding a carton blank with a
plurality of panels around the filled tub to form a carton sleeve,
wherein the carton sleeve comprises a peripheral wall enclosing at
least the sidewalls of the tub.
[0010] If both parts of the packaging are manufactured separately
both the inner tub and the outer sleeve will have dimensions that
fall within tolerances. As the sleeve is slid over the inner tub,
the sleeve will have to be able to receive even the largest inner
tub within these tolerances. This may lead to a relatively small
inner tub in a relatively large sleeve, such that the sleeve does
not give as much support to the inner tub as desired. Additionally,
the finish of such a combination of a relatively large sleeve and a
small tub is unsightly, due to the gaps that appear along the edges
and at the corners. Folding the carton blank around the filled tub
has the advantage that a sleeve formed from the carton blank
engagingly encloses the thermoformed tub independent of the outer
dimensions of the thermoformed tub. By folding the carton blank
around the filled inner tub, the sleeve fittingly encloses the
inner tub leading to a more acceptable final product. Additionally,
the close fit between these two components provides maximum support
to the inner tub, which is particularly important in the case of
tubs having relatively thin walls.
[0011] Additionally, mandrels or male moulds to hold the
thermoformed tub in shape can be omitted due to the form retention
of the thermoformed tub by the powdered nutritional product. Adding
mandrels or male moulds to a manufacturing machine is costly.
Moreover, the thermoformed tub has inner dimensions falling within
tolerances and even the smallest of the thermoformed tubs should
fit over the male mould. This may lead to less support by the male
mould in case of a relatively large thermoformed tub, such that the
mould cannot give the support desired while folding the carton
blank around the tub. More importantly, it is only possible to use
a mandrel within the tub prior to filling. As will be described
further below, for processes where filling takes place under
high-care conditions, it may not be desirable for the carton sleeve
to enter into the high-care zone and it is thus excluded that a
mandrel based assembly be used.
[0012] According to a surprising effect of the present invention,
it is believed that improved shape retention and support during
folding the carton blank around the tub may be achieved due to the
fact that the tub is filled with a powdered nutritional product,
such as baby formula or infant nutrition. Powdered products such as
baby formula or other powdered milk products tend to have higher
resistance to deformation due to the flow properties of the powder,
i.e. they may compress to a denser state or consolidate rather than
flow out upon application of an external pressure , contrary to
fluids. The consolidated product then can act as a shape retainer
while folding the carton blank around the filled tub. This
resistance to deformation results in a pressure force against the
inner wall of the tub, thereby supporting the tub and retaining its
shape. For other products such as liquids or granulated products,
the content may not provide adequate resistance during a folding
process and the resulting product may be less than adequate.
[0013] The bulk density of the powdered nutritional product may be
between 0.4 and 0.7 g/ml, preferably between 0.45 and 0.6 g/ml.
[0014] According to the present method, the tub is filled with the
powdered material prior to folding the carton sleeve around the tub
and the product thus provides additional support to the peripheral
wall of the tub. Additionally, the contents of the tub can exert an
outward counter-force on the sleeve during the folding operation,
thereby promoting the attachment between the tub and the sleeve. In
addition, the membrane is provided over the top edge of the tub
before folding the sleeve around the tub to give extra support to
the tub and to protect the product from the environmental
atmosphere. With the method according to the invention, it is
believed that mandrel-less assembly of a multi-component package is
achieved, while being able to maintain the high-care standards for
the nutritional product.
[0015] The membrane seal may comprise a metal foil or may be a
plastics-only foil. It may be removed in its entirety prior to use
or may comprises a weakened tear line defining an opening region,
and a pull tab. The membrane may be provided at various locations
but most preferably, the membrane is sealed across the upper edge
of the container. In particular, it will be understood that
thermoformed tubs generally have an outwardly extending flange
forming the upper edge and the membrane may be sealed across the
flange. In an alternative embodiment, the membrane may be sealed to
the lower frame to close the opening. In that case, the skilled
person will understand that the connection between the lower frame
and the upper edge of the container must be a sealed
connection.
[0016] Preferably, the carton blank comprises a bottom panel and
side wall panels and wherein, after folding the carton blank to a
sleeve, the sleeve encloses the sidewalls and at least a part of
the base of the tub. Such a sleeve provides additional support to
the base of the thermoformed tub. More preferably, the carton blank
is formed as a single piece blank with a plurality of panels.
[0017] The composite package can benefit from improved strength and
the carton sleeve can be easily printed. Because the sleeve is
added at a late stage in the production cycle, the sleeve design or
language may be changed, even after the tub has been filled. For
recycling, the sleeve and tub can be separated and disposed of as
required.
[0018] According to another embodiment, step b) further comprises
gluing the panels to the tub after folding towards the tub.
Preferably, step b) further comprises gluing the bottom panel to
the base of the tub. Connecting the panels of the sleeve to the tub
ensures that the sleeve and the tub support each other.
Additionally, the sleeve is formed from the carton blank and covers
an outer surface of the tub in this way.
[0019] Preferably, step b) further comprises connecting the panels
to each other after folding towards the tub, preferably by gluing.
Preferably, the blank has the shape of a cross defining a base and
four side panels. The side panels may be provided with lobes or
tabs that engage with each other and may be glued or otherwise
adhered together.
[0020] Preferably, step b) further comprises centering the carton
blank and the thermoformed tub with respect to each other.
Additionally, step b) may comprise gripping the tub at the lid
assembly for transportation and to have free access to both the
peripheral wall and the base of the tub. The carton blank may then
be connected at the bottom panel to the base of the tub by an
adhesive, such as glue. According to an embodiment, the side panels
are folded towards the tub in pairs of opposite side panels.
Preferably, the side panels provided with tabs are folded first
towards the tub, after which the remaining side panels are folded
towards the tub. The tabs are preferably provided at the side
panels of the blank covering relatively longer side walls of the
tub. In this embodiment, folding the side panels covering
relatively shorter side walls of the tub over and connecting to the
tabs provides more strength to the package. Furthermore, it is
preferred that the tabs have such a length that they do not overlap
each other upon folding around or onto the tub.
[0021] According to a further embodiment, step b) comprises
applying a lateral displacement to the side panels to bring them
into engagement with the sidewalls of the tub after folding towards
the sidewalls of the tub. To firmly connect the side panels of the
sleeve to the tub, a laterally applied force to press the side
panels on the outer surface of the inner tub may be used. Pressure
may be applied at regions at which glue has been applied in order
to cause adhesion at these points. Preferably, pressure is applied
at a centre of the side panels of the sleeve, close to an upper
edge thereof.
[0022] In a preferred embodiment, step b) further comprises
providing the carton blank from a carton blank magazine holding
multiple carton blanks. The filled and sealed thermoformed tub is
provided from the filling and sealing machines to the assembly line
by a carrier device. The carton blank is then provided separately,
preferably from a carton blank magazine or cartridge holding
multiple carton blanks to allow a continuous assembly of the
packages.
[0023] In a preferred embodiment of the method, step a) may further
comprise fitting a lower rim to an upper edge of the tub. This rim
may advantageously assist in strengthening the otherwise relatively
thin thermoformed tub. The lower rim is preferably adhered or
welded on top of the membrane seal although it is not excluded that
it may be connected to the upper edge of the tub directly before
applying the membrane. The lower rim is preferably formed of the
same class of material as the tub such that both may be recycled
together. According to an important aspect of the invention, the
step of applying the lower rim may further comprise centering the
tub with respect to the lower rim prior to connection. In this
manner, the lower rim may subsequently serve as a guide for further
operations on the tub.
[0024] In a further preferred embodiment of the invention, step a)
further comprises fitting a lid assembly to the tub, the lid
assembly comprising an upper rim and a recloseable lid. The upper
rim is preferably circumferential, defining an access opening and
the lid can be hingedly attached to the upper rim for closing the
access opening.
[0025] This allows the tub to be opened by a user by removal of the
membrane seal and subsequently opened and resealed using the lid to
close the access opening. A catch on the front edge of the lid can
engage with a rib on the upper frame to maintain the lid closed.
The lid can comprise a support surface at an outside of the lid
assembly to support a base of another package thereon upon stacking
of the packages.
[0026] In a most preferred embodiment, the upper rim and the lower
rim are mechanically connected together in an interference fit. The
lower rim thus has the function of strengthening the upper edge of
the tub allowing the upper rim and lid to be effectively connected
thereto.
[0027] Of significant importance, for powdered nutritional products
and especially for infant nutrition, all elements of the package
that come into contact with the product must be manufactured
according to strict norms. To address this need, certain
manufacturing steps are preferably carried out in a high-care
environment. Additional components such as scoops and the lid or
closure are also manufactured according to the same standards if
they are to come into contact with the product. According to one
important aspect of the invention, step a) may take place in a
high-care zone. In this context, it is understood that all of the
individual actions included in step a) should take place within
this high-care zone. Thus the package is filled and sealed and all
element surfaces coming into contact with the powdered nutritional
product are only exposed to the high-care zone.
[0028] For the purpose of the present invention, high-care is
intended to denote that the environment is at an over pressure with
respect to atmospheric pressure, preferably an overpressure of
between 5 Pa and 50 Pa, more preferably an overpressure of between
5 Pa and 30 Pa, most preferably between 5 Pa and 20 Pa. The
temperature in the high-care zone is preferably kept between
18.degree. C. and 25.degree. C., more preferably between 19.degree.
C. and 23.degree. C. and the relative humidity is preferably
controlled between 20% RH and 80% RH, more preferably between 30%
RH and 60% RH, most preferably between 35% RH and 50% RH. Also, the
atmosphere within the high-care environment is preferably filtered
to remove particulates, such as with a HEPA (High-efficiency
particulate absorption) filter including a H10 filter or higher
according to EN 1822:2009.
[0029] Preferably, all components entering into contact with the
product are cleaned by sterile, ionized air jet and checked with a
vision system for imperfections or foreign bodies.
[0030] Furthermore, the package is filled in a low-oxygen
atmosphere. This may include flushing with nitrogen and/or carbon
dioxide before and during the filling procedure and prior to
applying the membrane. Nevertheless, the skilled person will
understood that other criteria may be applied to this zone if
required e.g. by local regulations.
[0031] Using a low-oxygen atmosphere, in particular a carbon
dioxide atmosphere, during filling has the advantage that the
powdered material is relatively dry compared to ambient atmosphere.
Furthermore, after filling, certain powders absorb the carbon
dioxide causing a slight underpressure in the package. Therefore
the powder can be consolidated even further than under ambient
atmosphere, such that the form retaining function of the contents
of the tub is enhanced.
[0032] As bloating of food comprising container is generally
associated with spoilage of the contained food, such an impression
is preferably avoided as much as possible. Due to the relatively
thin thermoformed tub, the package of the present invention may be
more sensitive to a bloated appearance than containers made of
thicker, more rigid plastic, e.g. formed by injection moulding.
Thicker, more rigid plastic walls are less susceptible to the force
exerted by the content of the containers than the relatively thin
thermoformed peripheral wall of the tub. It is therefore preferred
that the thermoformed tub is filled with powdered material having a
particular temperature. This may be of particular importance in
case the finished package contains infant formula or food since
such shelf-stable products are placed under less conditioned
circumstances on the shelf in stores in contrast to packages
containing fresh products such as yoghurt. Thus, in a preferred
embodiment, the powdered nutritional product has a temperature
between 10 to 30.degree. C., more preferably between 15 to
25.degree. C. when the tub is filled therewith.
[0033] Preferably, a scoop is provided within the package and may
be located above the membrane seal prior to use. It is also
conceivable that a scoop is integrally formed with the lid
construction and separated at first use. In either case, the scoop
is preferably also included within the package in step a) and may
therefore also be handled exclusively in the high-care zone.
[0034] In a preferred embodiment, the scoop is positioned above the
membrane seal when the sleeve is folded around the tub, whereby a
distance between the scoop and the membrane seal is limited to less
than 4 mm, preferably less than 3 mm, most preferably less than 2
mm. Limiting the distance between the spoon and the membrane seal,
i.e. limiting excess space in the package, is beneficial for
reducing plastic waste.
[0035] A further important point in defining the actions carried
out in the high-care zone is to specify that step b) takes place
outside the high-care zone. These actions may thus be characterised
as ones that may not be permitted within the high-care zone. In
particular, carton handling may be associated with considerable
process debris and should be kept separate from the actions taking
place in step a). For the purpose of the present invention,
low-care is intended to denote that the environment thereof is kept
at ambient conditions. This includes ambient pressure, meaning no
overpressure situation is created. Furthermore, the temperature in
the low-care zone is preferably less strictly controlled compared
to the high-care conditions, meaning that the temperature in the
low-care can be between 12.degree. C. and 30.degree. C., more
preferably 15.degree. C. and 26.degree. C. Particulate filtration
may be installed in the low-care area or installed for flow of air
into the low-care zone but HEPA filtration is preferably not
implemented to save costs
[0036] It will be understood that the gluing can be a construction
step in erecting the carton blank and/or an assembly step in
joining the tub to the sleeve. Preferably the connection between
the tub and the sleeve can easily be broken to allow for
disassembly on recycling of the package after use. The glue is
preferably a hot-melt adhesive and is applied at locations on the
inner surface of the carton blank and/or on the outer surface of
the inner tub before folding the respective panels towards the
filled thermoformed tub.
[0037] According to a still further aspect of the invention, the
tub is a pre-formed, size-stabilised tub of thermoplastic material.
In the present context, pre-formed is understood to require that
the tub has been formed at least 24 hours and preferably at least
48 hours prior to filling. This allows for residual stresses within
the tub, due to the thermoforming process, to be relaxed.
[0038] The invention is particularly applicable to thin-walled tubs
and in particular to tubs defining a single compartment. Such tubs
may be relatively inexpensive due to the use of minimal amounts of
plastics. Additional strength is provided by the carton sleeve.
[0039] Preferably, the tub has a wall thickness of about 0.10 mm to
0.50 mm, preferably between 0.15 and 0.40 mm. It will be understood
by the skilled person that, due to the thermoforming process, the
wall thickness may not be uniform over the whole tub. In
particular, the upper edge of the tub may form a flange having
greater thickness and stiffness. The tub may be manufactured of any
appropriate material capable of being thermoformed. A most suitable
material is polypropylene. However, other polymer materials such as
polyethylene terephthalate (PET) or polyethylene (PE) can be used
as well. Multi-layer materials may also be used, subject to the
requirements of recycling.
[0040] Most preferably, the tub comprises a multi-layer laminate
including a central barrier layer having reduced oxygen
transmission, i.e. forming a barrier to oxygen, such as EVOH or the
like.
[0041] As indicated above, the strength of the package may be
achieved by the combined strengths of the tub and the sleeve. The
sleeve thus also has a structural function in addition to providing
a printable surface. Preferably, the carton used for the blank has
a weight of between 50 g/m2 and 400 g/m2, preferably from 100 g/m2
to 300 g/m2. The wording carton blank is defined as a blank
comprising carton material. The blank material can further comprise
other suitable materials, such as a coating to protect the outer
surface against environmental influences. In general, the carton
blank material has greater weight and thickness than the sidewalls
of the tub. It may have a wall thickness of between 0.10 mm to 0.50
mm and may even have a wall thickness of 0.6 mm. The carton blank
may have a thickness that is at least twice the wall thickness of
the sidewalls.
[0042] According to the invention, the tub and the sleeve support
each other in order to provide a wall structure that is stronger
than would be the case for each of the elements when taken alone.
It will be understood that the sleeve base may be either open or at
least partially closed. It will be understood that the weight of
the powder contents can assist in pressing the sidewalls into
contact with the sleeve. The sidewalls of the inner tub and the
sleeve are preferably slightly tapered. The taper of the outer
sleeve and/or tub may be between 1.degree. and 7.degree.,
preferably around 3.degree.. An advantage of such a tapered shape
is that the tubs can be stacked inside one another.
[0043] Additionally, a top edge of the sleeve may be at a distance
different from the top edge of the tub. In order for the sleeve to
adequately support the tub, the top edge of the sleeve does not
necessarily have to coincide with the top edge of the tub. When a
relatively small distance is maintained between the top edges, the
tolerances of the respective heights of the tub and the sleeve can
be accommodated such that the support of the sleeve to the tub can
be optimized. This distance may be at most 5.0 mm, preferably 2 mm,
more preferably 1 mm, whereby the sidewalls are supported up to the
top edge, without the tub actually being suspended from its top
edge.
[0044] The membrane used to seal across the open mouth of the tub
may be any conventional membrane of metal foil or plastic film or
combination thereof. The membrane may function as a seal to protect
the product from the environmental atmosphere, i.e. forms a barrier
against oxygen, and preferably moisture. Preferably, the membrane
comprises a weakened tear line defining an opening region, and a
pull tab for removing the membrane prior to use. The membrane may
seal to an inside surface of the sidewalls.
[0045] Most preferably however, the tub comprises an outwardly
extending flange at the top edge to which flange the membrane is
connected.
[0046] The invention also relates to a package for a powdered
nutritional product , the package being manufactured according to
any of the embodiments of the method as described above. The
resulting package may be easy to produce and dispose of Other
advantages will be apparent on the basis of the further description
below.
[0047] The invention is particularly applicable to infant formula
and most preferably the package is filled with powdered infant milk
formula.
[0048] Preferably, a scoop is provided within the package and may
be located above the membrane seal prior to use. It is also
conceivable that a scoop is integrally formed with the lid
construction and separated at first use.
[0049] According to a still further aspect of the invention, the
process is particularly applicable to wide access packages of the
type wherein the tub is rectangular and has an access opening with
a minimum dimension of at least 70 mm, more preferably around 100
mm and an area of at least 100 cm.sup.2. The overall length of the
package may be between 150 mm and 250 mm, preferably about 185 mm.
The width of the package may be between 100 mm and 150 mm,
preferably around 120 mm. The package may be available in multiple
heights according to volume required, varying from 80 mm to 150 mm.
In this context, rectangular is understood to include square and
does not exclude the presence of rounded corners. The volume of the
package may be between 0.8 litre or 800 ml and 3 litres, or 3000
ml, preferably around 1.5 litres, or 1500 ml. Such wide access
packages are particularly susceptible to the problems of wall
strength.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The features and advantages of the invention will be further
appreciated upon reference to the following drawings of a number of
exemplary embodiments, in which:
[0051] FIG. 1 shows a package for powdered nutritional products
manufactured according to the method of the invention.
[0052] FIG. 2 shows a semi-finished package for assembly of the
package of FIG. 1 in an exploded view.
[0053] FIG. 3 shows a carton blank and the semi-finished package of
FIG. 2 for assembling the package of FIG. 1.
[0054] FIG. 4 shows side panels of the carton blank of FIG. 3
folded towards the thermoformed tub; and
[0055] FIG. 5 shows a schematic flow diagram of the production of
the package of FIG. 1.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0056] FIG. 1 shows in perspective view a package 1 manufactured
according to the present invention. The package 1 is in its
completed state and includes a tub 2, enclosed by a sleeve 4, and a
lid assembly 3.
[0057] FIG. 2 shows a partially exploded view of the tub 2 and the
lid assembly 3 showing further a membrane 6, a lower rim 8, an
upper rim 10 and a lid 12 forming a first assembly part 1' of the
package 1. The tub 2 is thermoformed of a laminate of inner and
outer relatively thin polypropylene material layers and an
intermediate EVOH barrier layer. It includes a base 14 and a
peripheral wall 16 defining a product containing space 20, i.e. the
tub 2 is filled with a powdered nutritional product 21 before the
membrane 6 is connected over the open mouth 15 of the tub. The
peripheral wall 16 extends to an upper edge 18 having an outwardly
directed flange 19.
[0058] Lower rim 8 is formed as a flat annular ring of a similar
dimension to the outwardly directed flange 19. The lower rim 8 is
injection moulded of polypropylene, although it will be understood
that other appropriate materials could also be employed. The upper
rim 10 and lid 12 form the lid assembly 3 and are also formed of
injection moulded polypropylene. The upper rim 10 is designed to
mechanically engage with the lower rim 8 in an interference fit
including snap connectors, not shown. The seal 6 includes a tear
line 22 defining an opening region 24 and includes a pull tab
26.
[0059] The production line 40 of the package 1, of which a flow
diagram is shown in FIG. 5, is divided into a number of zones,
defined as a first low-care zone 41, a high-care zone 42, a second
low-care zone 43 and a third low-care zone 44. The tub 2, lower rim
8, lid assembly 3 and membrane 6 are all delivered via the first
low-care zone 41, to the high-care zone 42. It is noted that the
tubs 2 are pre-formed, size-stabilised thermoformed tubs that have
been formed at least 48 hours previously. In the high-care zone 42,
after initial cleaning and flushing operations have been performed,
the tub 2 is filled with milk powder 21. Subsequently, membrane 6
is applied to close the product containing space 20 and
hermetically seal the milk powder within the tub 2. Afterwards,
lower rim 8 is applied over the membrane 6 onto the outwardly
directed flange 19 at the upper edge 18 of the peripheral wall 16
and subsequently welded into position.
[0060] Thereafter, the lid assembly 3 is applied onto the lower rim
8 and clicked into position.
[0061] At this point, all of the components that enter into contact
with the milk powder 21 are enclosed within a semi-finished package
1', shown in FIG. 2. This can now proceed from the high-care zone
42 into the second low care zone 43. It will be understood that
only the processes relevant to the present invention have been
described at this point and that many other further operations may
take place within the high-care zone 42, including cleaning,
inspecting, testing and the like.
[0062] Within the second low-care zone 43 the sleeve 4 will be
formed around the semi-finished package 1' to form a final package
1 as will be described in further detail below. The final package 1
is passed to the third low-care zone 44 for onward shipment.
[0063] FIG. 3 shows a perspective view of a blank 28 used to form
the sleeve 4 and the filled and sealed tub 2 centered on a bottom
panel (not shown) of the blank 28. The blank material is
polyethylene (PE) coated, high-quality card of 300 g/cm.sup.2. The
blank 28 defines a number of side panels 30 and the bottom panel
(not shown), corner sections 32 and connection tabs 34.
[0064] FIG. 4 shows a perspective view of the assembly of the
package 1 by first folding side panels 30'' towards the side walls
16'' of the tub 2. Before folding the side panels 30'' a layer of
adhesive, or glue, is provided in an adhesive area 31. After
connection of the side panels 30'' to the side walls 16'' by the
adhesive, connection tabs 34 are folded towards the side walls 16'
and connected to the side walls 16' by gluing.
[0065] Secondly, the side panels 30' are provided with a layer of
adhesive, or glue, provided in an adhesive area 33. Side panels 30'
are then folded towards the side walls 16' of the tub 2 and
connected to both the connection tabs 34 and the tub 2 by gluing.
Upon folding the side panels 30, the corner sections 32 fold around
the rounded corners of the tub 2. The blank 28 is now formed into a
sleeve 4 that encloses the tub 2 by covering the side walls 16 and
the base 14 and which supports the relatively thin walls of the tub
2. The adhesive is a hot-melt adhesive available as TECHNOMELT.TM.
SUPRA 325 HT from Henkel AG and having an application temperature
of between 160.degree. C. and 190.degree. C.
[0066] It will be understood that although it has been indicated
that the adhesive is applied in the designated adhesive areas 31,
33, this may be applied at any desired location using an
appropriate robotic glue actuator and may even be applied to the
walls of the tub itself.
[0067] Thus, the invention has been described by reference to
certain embodiments discussed above. It will be recognized that
many modifications in addition to those described above may be made
to the structures and techniques described herein without departing
from the spirit and scope of the invention. Accordingly, although
specific embodiments have been described, these are examples only
and are not limiting upon the scope of the invention.
LIST OF PARTS
[0068] 1. Final package
[0069] 1'. Semi-finished package
[0070] 2. Tub
[0071] 3. Lid assembly
[0072] 4. Sleeve
[0073] 6. Membrane
[0074] 8. Lower rim
[0075] 10. Upper rim
[0076] 12. Lid
[0077] 14. Base
[0078] 15. Open mouth
[0079] 16. Peripheral wall
[0080] 18. Upper edge
[0081] 19. Flange
[0082] 20. Product containing space
[0083] 21. Powdered product
[0084] 22. Tear line
[0085] 24. Opening region
[0086] 26. Pull tab
[0087] 28. Blank
[0088] 30. Side panel
[0089] 31. Adhesive area
[0090] 32. Corner section
[0091] 33. Adhesive area
[0092] 34. Connection tabs
[0093] 40. Production line
[0094] 41. First low-care zone
[0095] 42. High-care zone
[0096] 43. Second low-care zone
[0097] 44. Third low-care zone
* * * * *