A process for producing a flexible container is provided. The process includes: A. providing a rear panel web, a front panel web, a first folded gusset panel web, and a second folded gusset panel web, each panel web having peripheral edges and a bottom face, each bottom face having two opposing tapered edges meeting at a bottom end; B. placing the folded gusset panel webs between the rear panel web and the front panel web, the gusset panel webs opposing each other, the panel webs configured to form a common periphery and the bottom seal area including the bottom end of each panel; C. first sealing the peripheral edges, the tapered edges, and the bottom seal area under a set of heat seal conditions; D. second sealing a portion of the bottom seal area under a second heat seal condition; and E. forming a flexible container.

Methods, systems, and apparatuses of a fluid bubble valve device or element can comprise a plurality of films or webs aligned over the top of each other. For example, two separate webs or film layers of material can be made with two or more different layers of films combined to provide different necessary benefits in manufacturing or forming the valve and sealing to a pouch or package later. The two individual forming webs or film layers are fed into a machine together where channel seals and a bubble pocket are created to form a pathway for a controlled direction for a fluid product to later flow through when the completed pouch or package is used by the consumer. The pocket is formed on both of the two individual forming webs or film layers at the same time. A separate lidding web or layer of material is introduced and sealed over the underside of the bubble pocket to trap air or gas between the lidding layer and the combined individual forming webs or film layers.

Methods, systems, and apparatuses of a fluid bubble valve device or element can comprise a plurality of films or webs aligned over the top of each other. For example, two separate webs or film layers of material can be made with two or more different layers of films combined to provide different necessary benefits in manufacturing or forming the valve and sealing to a pouch or package later. The two individual forming webs or film layers are fed into a machine together where channel seals and a bubble pocket are created to form a pathway for a controlled direction for a fluid product to later flow through when the completed pouch or package is used by the consumer. The pocket is formed on both of the two individual forming webs or film layers at the same time. A separate lidding web or layer of material is introduced and sealed over the underside of the bubble pocket to trap air or gas between the lidding layer and the combined individual forming webs or film layers.

A tape applicator consistent with the present disclosure may include a tape applicator configured for applying a tape, such as a pressure sensitive adhesive tape to a carton (e.g., for sealing and/or assembling the carton). One or more rollers may be utilized to aid in applying the pressure sensitive adhesive tape to a carton. Furthermore, a wiper aids in applying pressure sensitive adhesive tape to a carton (e.g., before and/or after the one or more rollers). The wiper may be a split wiper having a first portion and a second portion, which allows for applying adhesive tape to a carton when the carton is under-packed or over-packed, and thus, the flaps of the carton are not level with respect to each other (e.g., the edges are not located in the same plane).

Methods of making flexible containers that include structural support frames, including methods for sealing such containers.

A substantially paper-based composite container for an off-gassing product includes a paperboard can body having a substantially gas-impervious liner attached to an inner surface thereof, and a pair of substantially paper-based end closures attached to the opposite ends of the can body, each end closure defining a generally cylindrical sealing panel in contact with an inner surface of the can body. Heat-sealable materials are disposed on opposing surfaces of the sealing panel and can body. The sealing panels of the end closures are attached to the can body by heat seals. The heat seal for at least one of the end closures is discontinuous such that at least one vent channel extends through the heat seal so as to establish fluid communication between an interior of the composite container and the environment outside the composite container. The at least one vent channel is operable to vent excess gas pressure from the interior of the container.

A method for sealing and cutting of a flexible material for forming a flexible container comprising a product volume and at least one structural support volume can include feeding at least two flexible material into a sealing apparatus comprising a sealing surface and an opposed anvil surface; contacting a seam region of the at least two flexible material with the sealing surface to form a seal in the seam region and cut the seal to form a seam in a single unit operation. The seal defines one or both of at least a portion of a boundary of the product volume and at least a portion of a boundary of the at least one structural support volume.

Advanced ultrasonic welding components of Applicant's U.S. Pat. No. 8,376,016 are readily incorporated into new form-fill-seal machines, but owners of existing machines utilizing heat-seal stations were unsuccessful at swapping the sealing packages. Retrofit kits to a replace heat sealing stations with an advanced ultrasonic sonotrode and anvil comprise: a housing; a linear rail fixed thereto; first and second bearing carriages being slidable upon the rail; and first and second fluidic muscles. Each of the fluidic muscles is mounted with a first end fixed to a respective housing wall, and a second end fixed to a respective bearing carriage, permitting actuation of each carriage through pressurization/depressurization of the muscles. The advanced anvil and sonotrode may be secured to respective carriages. In-line arrangements of anvil/sonotrode, bearing carriages, the first fluidic and second fluidic muscles provides a narrow profile, permitting side-by-side kit installations for retrofits accomplishing duplex sealing on a horizontal machine.

A method of packaging a series of differently shaped objects. The method includes receiving a first object to be packaged and identifying a first length of a stock packaging material suitable for enclosing the first object. The method continues by creating, with a bag making machine, a first bag from the stock packaging material having approximately the first length, which leads to substantially enclosing the first object in the first bag. Then the method continues by receiving a second object to be packaged, the second object having a shape or size different from the first object. A second length of the stock packaging material suitable for enclosing the second object is identified. The method continues by creating, with the bag making machine, a second bag from the stock packaging material having approximately the second length, followed by substantially enclosing the second object in the second bag.

A substantially paper-based composite container for an off-gassing product includes a paperboard can body having a substantially gas-impervious liner attached to an inner surface thereof, and a pair of substantially paper-based end closures attached to the opposite ends of the can body, each end closure defining a generally cylindrical sealing panel in contact with an inner surface of the can body. Heat-sealable materials are disposed on opposing surfaces of the sealing panel and can body. The sealing panels of the end closures are attached to the can body by heat seals. The heat seal for at least one of the end closures is discontinuous such that at least one vent channel extends through the heat seal so as to establish fluid communication between an interior of the composite container and the environment outside the composite container. The at least one vent channel is operable to vent excess gas pressure from the interior of the container.