A method of forming a tray includes obtaining a blank, positioning the blank in a blank feeder assembly of a system for forming a tray, moving the blank from the blank feeder assembly to a nipping assembly, and moving the blank to a tray forming assembly, the tray forming assembly including a tray forming apparatus. The method further includes positioning the blank between a first tray forming portion of the tray forming apparatus and a second tray forming portion of the tray forming apparatus, the first tray forming portion includes a forming block that defines an interior, and the second tray forming portion includes a tray forming member, and driving the forming block into engagement with the blank and the tray forming member such that the blank and the tray forming member are at least partially received in the interior of the forming block to form a tray.

A method of making a preassembled display with automatic stackable supports (PDASS) is described. A PDASS may include two or more blanks (for example pieces of corrugated paperboard) that are joined together, for example to initially form a knocked down flat (KDF). The PDASS may include an insert formed from a single blank, where the single insert blank, when the whole display is erected, automatically erects and provides asymmetric supports that form at opposing corners of the outer blank.

A converting machine is used to convert sheet material into packaging templates for assembly into boxes or other packaging. The converting machine includes a converting assembly that performs transverse conversion functions and longitudinal conversion functions on the sheet material to create the packaging templates. A fanfold crease sensing mechanism detects the presence and location of fanfold creases in the sheet material. Based on the location of the fanfold creases, the fanfold creases are either cut out of the sheet material, or the sheet material is cut to adjust the position of the fanfold crease in a packaging template.

A packing method and unit (26) for producing a rigid package (1) with a hollow rib (12; 13); an end portion of a blank (21) is folded about a contrasting body (36; 39) onto a panel (11′) of the blank (21) to form the hollow rib (12; 13); a fastening tab (16; 19), which forms the end part of the end portion, is glued to the panel (11′) to stabilize the hollow rib (12; 13); and the contrasting body (36; 39) is extracted from the hollow rib (12; 13) once the end portion is folded.

A method of forming a container from a blank of sheet material using a machine is provided. The blank includes a bottom panel, two side panels, two end panels, and a reinforcing panel assembly extending from a first side panel. The machine includes a hopper station, a corner post forming station, and a plunger station. The method includes rotating the reinforcing panel assembly upwardly toward the first side panel as the blank is transported from the hopper station to the corner post forming station, forming a corner wall and a reinforcing end tab by folding reinforcing panels about fold lines as the blank is transported through the corner post forming station, rotating the side panels and the end panels to be substantially perpendicular to the bottom panel by directing the blank through the plunger station, and coupling the reinforcing end tab to an end panel to form the container.

A blank of sheet material for forming a container includes a front panel, a top panel, a rear panel, and a bottom panel coupled together in series by a plurality of generally parallel fold lines. The blank also includes a pair of front side panels extending from opposing side edges of the front panel, a pair of top side panels coupled to opposing side edges of the top panel, and a pair of bottom side panels coupled to opposing side edges of the bottom panel. A side tab extends from each bottom side panel along a tab perforation line. Each side tab is configured to couple to one of the front side panels in a face-to-face relationship. A face of each of the top panel, the bottom panel, the pair of top side panels, and the pair of bottom side panels is devoid of perforation lines extending therethrough.

A box gluing device for attaching a glue tab of a box blank to an opposing panel when the box blank is folded so the glue tab is position at an edge of the box blank. The gluing device includes a support structure upon which a gluing apparatus and a support plate are mounted. The gluing apparatus a glue dispensing nozzle for applying glue on one or more surfaces of the box blank. The box blank can be moved through the gluing device to attach the glue tab to the opposing panel. As the box blank moves through the gluing device, a guide rail orients the glue tab in a desired manner while glue is applied to the box blank, and a roller assembly presses the glue tab and the opposing panel together with the glue therebetween. Alternatively, the gluing device can include a clamp arm that holds the box blank in place while glue is applied, and a folding bar that folds the glue tab onto the opposing panel after glue is applied.

In a folder-gluer, push-out forces by an air cylinder and a push-out spring mechanism are set such that: (1) when downstream portions of first and fourth panels are passing through a second bending plate, the second bending plate is pushed outwardly in a width direction by the push-out forces to extend the downstream portions of the first and fourth panels in the width direction; and (2) when upstream portions of the first and fourth panels are passing through the second bending plate, the second bending plate is pushed back inwardly in the width direction by the resistance force applied to the second bending plate by the first and fourth panels so as not to extend the upstream portions in the width direction, and wherein the push-out forces are not varied by a control while the first and fourth panels are passing through the second bending plate.

A multivariable perforated adjustable height box is provided with improved folding, bending, and separation of adjacent panels. The multivariable perforated adjustable height box may include a box, columns, rows, glue tabs, column scores, row scores, perforations, cuts, skips, and bundle breakers. Perforation patterns may be irregular, angled, shifted, or otherwise configured to increase usability, strength, and/or other aspects of the packaging. A method to produce a packaging device with improved folding, bending, and separation of adjacent panels using the multivariable perforated adjustable height box is also provided.

A box assembly includes an exterior piece including a middle portion; a connecting segment coupled to the middle portion by a fold line; and a end segment coupled to the connecting segment by a fold line, the connecting segment positioned substantially perpendicular to the middle portion and the end segment; an interior piece positioned within the exterior piece, the interior piece including a side panel, a space defined between the middle portion and the side panel, the interior piece defining a cavity, the end segment extending into the cavity, the end segment coupled to the side panel; and an insulator positioned at least partially within the space.