A system for making a sheet of paper into a folded article is disclosed that includes multiple folding units and a turn unit for changing the travel path of the folded article. At least one of the folding units creates a fold in the folded article in a direction that is perpendicular to a fold created by another one of the folding units. The turn unit alters the travel direction of the folded article so that downstream folding units can be arranged in a manner that saves floor space. Also disclosed herein is a method of folding a sheet of paper that includes conveying the sheet of paper along perpendicular travel paths after the sheet of paper has been folded.

A web has a series of cut outs that define bridging portions therebetween. A method for folding the web includes providing the web to a first conveyor, folding the web about a folding wheel to define a folded edge that extends through the series of cut outs, transferring the web to a second conveyor having an included angle of 15 to 40 degrees in relation to the first conveyor, folding the web about a folding bar to maintain the folded edge, and spanning at least one cut out with the folding bar and contemporaneously contacting at least two bridge portions with the folding bar to maintain the folded edge of the web about the folding bar as the web passes the folding wheel edge.

A flap folding arrangement is disclosed. The flap folding arrangement includes an axially extending rim that initially contacts a flap of a product to partially fold the flap as the product is dropped from a feed conveyor into a first pocket of a rotator pan. A controller is adapted to rotate the rotator pan away from a first position which drives the flap into contact with a flap-folding flange and a radially extending rim until the product is positioned at a second position under a flap-folding gate. The controller is adapted to drive a product discharger into contact with the product to drive the product out of the first pocket and away from the folding assembly after rotation of the rotator pan.

A folding arrangement including a flap lifting assembly located at a drop conveyor discharge end and including a pivoting arm with a flap engaging surface that is movable between a first, flap-lifting position and a second, pass-through position is provided. A folding assembly includes a receiving conveyor with a receiving conveyor feed end positioned below the drop conveyor discharge end, and a folding finger above the receiving conveyor feed end. The product-substrate combination is driven by the drop conveyor into contact with the flap engaging surface in the first position to lift the flap as the product-substrate combination is discharged from the drop conveyor discharge end towards the receiving conveyor feed end, and the folding finger contacts the flap of the product-substrate combination to complete folding of the flap to a second angled position onto the product as the product-substrate combination pivots the flap engaging surface to the second position.

A method and apparatus for constructing a tubular assembly (24) comprising an inner portion (21) and a further portion (22) surrounding the inner portion, the further portion being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus (100) comprises an assembly station (106) having a wall (122). The apparatus (100) comprises means for advancing the inner portion (21) along a first path (111) extending past the wall, and means for advancing the strip (50) along a second path (112) and causing the strip to encircle the wall and thereby wrap about and surround the inner portion (21). The two marginal side portions (53) are disposed in overlapping relation on the side of the wall opposed to the first path (111). The apparatus (100) further comprises a system (131) for affixing the two longitudinal marginal side portions (53) together in overlapping relation to assemble the strip (50) into a tubular configuration about the inner portion (21), whereby the strip in the tubular configuration provides the further portion (22).