An apparatus and method for forming a plurality of individually folded and rolled wipe products, which allows for multiple individually folded and rolled wipe products to be processed concurrently, and which maintains moisture in the wipe product during manufacturing.

A sheet processing device includes a first conveyance passage, a first conveyor, a second conveyor, a folder, a second conveyance passage, and circuitry. The circuitry is configured to (1) cause the first conveyor and the second conveyor to convey the sheet nipping the sheet to warp the sheet between the first conveyor and the second conveyor, (2) guide the warped sheet to form a first fold on the sheet by the folder and circulate the sheet to the first conveyance passage, (3) cause the first conveyor and the second conveyor to convey the sheet while nipping the sheet again to warp the sheet between the first conveyor and the second conveyor, (4) guide the warped sheet to form a second fold on the sheet by the folder, and (5) cause the second conveyor to convey the sheet with the first fold and the second fold.

A bale of stock packaging material includes a continuous tube of paperboard material, the continuous tube of paperboard material being flattened and folded back and forth on itself into a fan-folded bale. The continuous tube of paperboard can be a single piece of paperboard with two opposed edges that are folded to overlap with each other. The paperboard material can include a corrugated layer. The opposed edges can be adhered together to form a single seam that runs lengthwise along the continuous tube of paperboard. The adhesive can be applied between the two edges which can join to form the single seam.

A bale of stock packaging material includes a continuous tube of paperboard material, the continuous tube of paperboard material being flattened and folded back and forth on itself into a fan-folded bale. The continuous tube of paperboard can be a single piece of paperboard with two opposed edges that are folded to overlap with each other. The paperboard material can include a corrugated layer. The opposed edges can be adhered together to form a single seam that runs lengthwise along the continuous tube of paperboard. The adhesive can be applied between the two edges which can join to form the single seam.

A sheet processing device includes a first conveyance passage, a first conveyor, a second conveyor, a folder, a second conveyance passage, and circuitry. The circuitry is configured to (1) cause the first conveyor and the second conveyor to convey the sheet nipping the sheet to warp the sheet between the first conveyor and the second conveyor, (2) guide the warped sheet to form a first fold on the sheet by the folder and circulate the sheet to the first conveyance passage, (3) cause the first conveyor and the second conveyor to convey the sheet while nipping the sheet again to warp the sheet between the first conveyor and the second conveyor, (4) guide the warped sheet to form a second fold on the sheet by the folder, and (5) cause the second conveyor to convey the sheet with the first fold and the second fold.

A bale of stock packaging material includes a continuous tube of paperboard material, the continuous tube of paperboard material being flattened and folded back and forth on itself into a fan-folded bale. The continuous tube of paperboard can be a single piece of paperboard with two opposed edges that are folded to overlap with each other. The paperboard material can include a corrugated layer. The opposed edges can be adhered together to form a single seam that runs lengthwise along the continuous tube of paperboard. The adhesive can be applied between the two edges which can join to form the single seam.

A method and apparatus for pleating or otherwise shaping a web are described herein. The method and apparatus may have numerous applications. In some embodiments, the method and apparatus are used in the formation, filling, and sealing of unit dose packages for consumer products. A method and apparatus for forming sealing two moving webs together, which webs have portions that are non-planar are also described herein.

A bale of stock packaging material includes a continuous tube of paperboard material, the continuous tube of paperboard material being flattened and folded back and forth on itself into a fan-folded bale. The continuous tube of paperboard can be a single piece of paperboard with two opposed edges that are folded to overlap with each other. The paperboard material can include a corrugated layer. The opposed edges can be adhered together to form a single seam that runs lengthwise along the continuous tube of paperboard. The adhesive can be applied between the two edges which can join to form the single seam.

A method and apparatus for forming patterns on sheet material are disclosed. The method comprises a continuous lateral stretch process for producing zero- or near zero-curvature structures. In a preferred embodiment, the method comprises pre-gathering the sheet material in the lateral direction to form longitudinal corrugated folds and then feeding the corrugated material through one or more sets of oscillating formers, preferably articulating discs, to impart folding in the lateral direction. Optionally, the sheet material may be fed through one or more sets of patterned rollers.

A method and apparatus for forming patterns on sheet material are disclosed. The method comprises a continuous lateral stretch process for producing zero- or near zero-curvature structures. In a preferred embodiment, the method comprises pre-gathering the sheet material in the lateral direction to form longitudinal corrugated folds and then feeding the corrugated material through one or more sets of oscillating formers, preferably articulating discs, to impart folding in the lateral direction. Optionally, the sheet material may be fed through one or more sets of patterned rollers.