The present invention provides methods and systems for applying a second-piece material to a paperboard cutout that includes a conveyor belt used for transporting the paperboard cutouts, a vacuum belt, at least two metering rolls, a first roller and second roller in a spaced apart and planar relationship, a nip roller positioned adjacent the second roller, and a cutting device. The vacuum belt proceeds over the first roller and the at least two metering rolls meter the second-piece material thereon, the vacuum belt proceeds through a valley between the first roller and second roller, at a predetermined time, the nip roller continues to pull the vacuum belt and the metering rolls pull back slightly and pulling the second-piece material taught and causing the second-piece material to contact the cutting device, and thus cutting the second-piece material.

A system for forming a pressware product comprises rollers, a scoring tool, a scoring station actuator, a forming tool, and a forming station actuator. The rollers pull the web along a path having an angle. The scoring tool receives the material from the rollers and includes a vertically shiftable scoring punch with an edge that extends about an outline of the pressware product and a striker plate. The scoring station actuator shifts the scoring tool to form a slot in the web. The forming tool receives the scored web and includes a vertically shiftable positive mold assembly and negative mold assembly. The forming station actuator shifts the positive mold assembly to press against the web and form the pressware product.

A system for forming a pressware product comprises rollers, a scoring tool, a scoring station actuator, a forming tool, and a forming station actuator. The rollers pull the web along a path having an angle. The scoring tool receives the material from the rollers and includes a vertically shiftable scoring punch with an edge that extends about an outline of the pressware product and a striker plate. The scoring station actuator shifts the scoring tool to form a slot in the web. The forming tool receives the scored web and includes a vertically shiftable positive mold assembly and negative mold assembly. The forming station actuator shifts the positive mold assembly to press against the web and form the pressware product.

A machine (1000) for forming a blank assembly having a blank and a retaining web coupled to the blank includes a deck (1250) coupled to a frame (1002), and a blank transfer assembly (1200) coupled to the frame. The blank transfer assembly is configured to position the blank on the deck. The machine also includes a web transfer assembly (1700) coupled to the frame. The web transfer assembly includes a pick-up assembly (1730) moveable between a first end and a second end of the web transfer assembly. The pick-up assembly is configured to pick up the web proximate the first end and deposit the web proximate the second end in an at least partially overlying relationship with the blank positioned on the deck. A first compression member (1750) is configured to compress a coupling region of the web against the blank on the deck to form the blank assembly.

An adjustable pouch machine comprises a vertical sealer module forms transverse seals between two piles of a pouch web to partially define a plurality of pouches. Rollers selectively tension and relax the web on the vertically oriented wheel, allowing them to drop away from heated lands on emergency and cycle stops. A filler wheel has a plurality of adjustable gripper units mounted directly thereon for transporting independent separate pouches cut from the pouch web. An adjustable knife is selectively provided with changeable knife hub sets to handle a variety of pouch sizes where a filler wheel alternately first fills and seals pouches in a train. Gear linkage accommodates variation in distance between hubs of different sets. Various embodiments, apparatus and methods are described.

An adjustable pouch machine comprises a vertical sealer module forms transverse seals between two plies of a pouch web to partially define a plurality of pouches. Rollers selectively tension and relax the web on the vertically oriented wheel, allowing them to drop away from heated lands on emergency and cycle stops. A filler wheel has a plurality of adjustable gripper units mounted directly thereon for transporting independent separate pouches cut from the pouch web. An adjustable knife is selectively provided with changeable knife hub sets to handle a variety of pouch sizes where a filler wheel alternately first fills and seals pouches in a train. Gear linkage accommodates variation in distance between hubs of different sets. Various embodiments, apparatus and methods are described.

A machine for forming a blank assembly having a blank and a retaining web coupled to the blank includes a deck coupled to a frame, and a blank transfer assembly coupled to the frame. The blank transfer assembly is configured to position the blank on the deck. The machine also includes a web transfer assembly coupled to the frame. The web transfer assembly includes a pick-up assembly moveable between a first end and a second end of the web transfer assembly. The pick-up assembly is configured to pick up the web proximate the first end and deposit the web proximate the second end in an at least partially overlying relationship with the blank positioned on the deck. A first compression member is configured to compress a coupling region of the web against the blank on the deck to form the blank assembly.

A system for forming a pressware product comprises rollers, a scoring tool, a scoring station actuator, a forming tool, and a forming station actuator. The rollers pull the web along a path having an angle. The scoring tool receives the material from the rollers and includes a vertically shiftable scoring punch with an edge that extends about an outline of the pressware product and a striker plate. The scoring station actuator shifts the scoring tool to form a slot in the web. The forming tool receives the scored web and includes a vertically shiftable positive mold assembly and negative mold assembly. The forming station actuator shifts the positive mold assembly to press against the web and form the pressware product.

A system for forming a pressware product comprises rollers, a scoring tool, a scoring station actuator, a forming tool, and a forming station actuator. The rollers pull the web along a path having an angle. The scoring tool receives the material from the rollers and includes a vertically shiftable scoring punch with an edge that extends about an outline of the pressware product and a striker plate. The scoring station actuator shifts the scoring tool to form a slot in the web. The forming tool receives the scored web and includes a vertically shiftable positive mold assembly and negative mold assembly. The forming station actuator shifts the positive mold assembly to press against the web and form the pressware product.

The present invention provides methods and systems for applying a second-piece material to a paperboard cutout that includes a conveyor belt used for transporting the paperboard cutouts, a vacuum belt, at least two metering rolls, a first roller and second roller in a spaced apart and planar relationship, a nip roller positioned adjacent the second roller, and a cutting device. The vacuum belt proceeds over the first roller and the at least two metering rolls meter the second-piece material thereon, the vacuum belt proceeds through a valley between the first roller and second roller, at a predetermined time, the nip roller continues to pull the vacuum belt and the metering rolls pull back slightly and pulling the second-piece material taught and causing the second-piece material to contact the cutting device, and thus cutting the second-piece material.