METHOD FOR MANUFACTURING A STRIP OF PACKAGES FOR STORING INDIVIDUAL PORTION OF FOOD OR BEVERAGE, AND STRIP OF PACKAGES THUS OBTAINED

Abstract

The invention deals with a method for manufacturing a strip (100) of packages (30, 40), the method comprising steps of:—Providing a first shell (10) comprising a first part (11) of a first cavity (31) comprising a rim (12), and a flange (13);—Providing a second shell (20) comprising a first part (21) of a second cavity (41) comprising a rim (22), and a flange (23);—Positioning the first part (11) of the first cavity aside the first part (21) of the second cavity with one part of the flange (13) of the first shell overlapping one part of the flange (23) of the second shell; and—Linking the part of the flange (13) of the first shell to the part of the flange (23) of the second shell. The invention also deals with a corresponding strip (100) of packages (30, 40).

Claims

1. Method for manufacturing a strip of packages, the method comprising steps of: Providing a first shell comprising a first part of a first cavity comprising a rim, and a flange extending from the rim and surrounding the first part of the first cavity; Providing a second shell comprising a first part of a second cavity comprising a rim, and a flange extending from the rim and surrounding the first part of the second cavity; Positioning the first part of the first cavity aside the first part of the second cavity with one part of the flange of the first shell overlapping one part of the flange of the second shell; and Linking the part of the flange of the first shell to the part of the flange of the second shell.

2. Method according to claim 1, in which the flange of each of the first shell and second shell comprises a front surface, and the front surface of the flange of the first shell is linked to the front surface of the flange of the second shell.

3. Method according to claim 1, in which the flange of the first shell comprises a reverse surface, and the reverse surface of the flange of the first shell is linked to a front surface of the flange of the second shell.

4. Method according to claim 1, further comprising a step of closing at least the first cavity.

5. Method according to claim 4 in which the step of closing at least the first cavity comprises steps of: Providing a first complementary shell comprising a second part of the first cavity and comprising a rim, and a flange extending from the rim and surrounding the second part of the first cavity; Forming the first cavity by positioning the second part of the first cavity facing the first part of the first cavity; and Sealing the flange of the first complementary shell to the flange of the first shell.

6. Method according to claim 1, in which the flange of the first shell comprises a ring surrounding the rim and at least one tab extending from the ring, and the step of linking the part of the flange of the first shell to the part of the flange of the second shell comprises a step of linking the tab of the flange of the first shell to the part of the flange of the second shell.

7. Method according to claim 1, in which the step of providing a first complementary shell comprises a step of providing a closing strip comprising at least the second part of the first cavity and a second part of the second cavity; and the method further comprises a step of positioning the second part of the first cavity facing the first part of the first cavity and positioning the second part of the second cavity facing the first part of the second cavity, and a step of sealing the closing strip to the first shell and second shell at least around the first part of the first cavity and the first part of the second cavity.

8. Method according to claim 1, comprising a step of providing a portion of food or beverage precursor, and placing the portion in the first part of the first cavity.

9. Package strip comprising at least a first package and a second package which is linked to the first package, the first package comprising a first cavity and the second package comprising a second cavity, the first package comprising at least a first shell comprising a first part of the first cavity and a flange extending from the first part of the first cavity, and the second package comprising at least a second shell comprising a first part of the second cavity and a flange extending from the first part of the second cavity, the package strip further comprising at least a bond between the first package and the second package, linking the first package to the second package, the bond comprising one part of the flange of the first shell overlapping one part of the flange of the second shell.

10. Package strip according to claim 9, in which the first package comprises a first complementary shell comprising a second part of the first cavity and a flange extending from the second part of the first cavity, and the second package comprises a second complementary shell comprising a second part of the second cavity and a flange extending from the second part of the second cavity.

11. Package strip according to claim 9, in which the package strip comprises a closing strip comprising at least the second part of the first cavity and the second part of the second cavity.

12. Package strip according to claim 9, in which one package of the package strip comprises a portion of food or beverage precursor which is inside the cavity of the package.

13. Package strip according to claim 9, in which one shell is made of a paper-based structure material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0119] Additional features and advantages of the present invention are described in, and will be apparent from, the description of the presently preferred embodiments which are set out below with reference to the drawings in which:

[0120] FIG. 1 is a perspective view of shells which are arranged to be linked one to each other according to one example embodiment of the invention;

[0121] FIG. 2 is a cross sectional view of two packages linked together according to one example embodiment of the invention;

[0122] FIG. 3 is a cross sectional view of a package strip comprising two packages linked together according to another example embodiment of the invention;

[0123] FIG. 4 is a top view of packages linked together according to one example embodiment of the invention;

[0124] FIG. 5 is a top view of a package strip according to one example embodiment of the invention;

[0125] FIG. 6 is a top view of shells according to other example embodiments of the invention;

[0126] FIG. 7 is a perspective view of shells according to FIG. 6 which are arranged to be linked one to each other according to another example embodiment of the invention;

[0127] FIG. 8 is a diagrammatical side view of a package strip which is wound with the portions arranged in quincunx between two adjacent layers of the package strip;

[0128] FIG. 9 is a perspective view of a casing comprising a wound package strip as illustrated in FIG. 8; and

[0129] FIG. 10 shows an illustration of a food or beverage preparation apparatus receiving a casing as in FIG. 9, comprising a wound package strip for individually dispensing one portion from one package of the package strip.

DETAILED DESCRIPTION OF THE DRAWINGS

[0130] Food or beverage precursor's portions are packed into a primary packaging, also called “flowpack”, which is a flexible strip comprising tens of packages, each comprising a cavity, for example between twenty and thirty packages, often about 24 packages, each cavity of them receiving one pearl of product, i.e. one portion of product (beverage precursor).

[0131] Hence the flowpack may be considered as a flexible strip comprising a plurality of individual packages.

[0132] Manufacturing such a package strip can raise difficulties, in particular when they are made of paper-based material, for example in order to provide at least recyclable packages.

[0133] To this end, FIGS. 1 to 4 shows example embodiments of a manufacturing method according to the invention.

[0134] In FIG. 1, a first shell 10 and a second shell 20 are provided.

[0135] The first shell 10 comprises a first part 11 of a first cavity 31 comprising a rim 12, and a flange 13 extending from the rim 12 and surrounding the first part 11 of the first cavity 31.

[0136] In the illustrated embodiment, the first part 11 of the fist cavity 31 is a part of a sphere, in particular a half-sphere, and as a consequence, the rim 12 has a circular shape.

[0137] In addition, the flange 13 has an annular shape, surrounding the first part 11 of the first cavity 31.

[0138] In a similar manner here, the second shell 20 comprises a first part 21 of a second cavity 41 comprising a rim 22, and a flange 23 extending from the rim 22 and surrounding the first part 21 of the second cavity 41.

[0139] In the illustrated embodiment, the first part 21 of the second cavity 41 is a part of a sphere too, in particular a half-sphere, and as a consequence, the rim 22 has a circular shape too.

[0140] In addition, the flange 23 has an annular shape too, surrounding the first part 21 of the second cavity 41.

[0141] In the illustrated embodiments, the geometry of each cavity part is based on a half sphere. However, the rim may not be perfectly circular: a diameter along the main axis of the package strip can be a little greater than the diameter across, for example it is of about 24.3 mm while the transverse diameter is of about 23.3 mm. The resulting shape is a slightly ovoid base of each half-sphere, aiming to facilitate a release of the pearl out of the cavity after a cutting step of the package to open it.

[0142] Here, the first shell 10 and the second shell 20 are identical.

[0143] Any of the first shell 10 and the second shell 20 can be formed from a paper-based material, preferably a barrier paper-based material.

[0144] For example, the material can be a stretchable paper-based structure with a thickness comprised between 100 μm and 200 μm, for example of about 162 μm.

[0145] As the forming process of the base material induces a stretching of the material, it results an irregular decrease of the material thickness. Even if the decrease is difficult to predict, it can be estimated that the material can be 60% of its original thickness on the top a half-sphere and comes back progressively to its original thickness on the flat part of the shell, for example on the flange.

[0146] One shell can thus be formed, for example embossed, from a corresponding blank.

[0147] For example, one shell is formed of oxygen and/or vapor impervious material such as a laminate including at least one gas barrier layer. The material forming the shell (all films and layers) is preferably at least recyclable, for example it may be biodegradable, or even possibly compostable.

[0148] The term “compostable” means that the material is substantially broken down within a few months or weeks. When it is industrially composted, the material is at least about 90% composted under specific conditions within six months as determined by the method of ISO14855 or EN13432.

[0149] The laminate may comprise a seal layer such as PLA, PBA, PBS, copolyester of adipidic acid, 1, 4-butanediol and dimethyl terephthalate (PBAT), polylactic acid (PLA), polyvinyl butyral (PVB), poly(vinyl acetate-ethylene) (VAE), poly(ethylene-vinyl acetate) (EVA) and combinations thereof. It may comprise an oxygen barrier layer such as EVOH, PVOH, SiOx, cellophane, metal and combinations thereof. An example of laminate can be PLA/EVOH/PLA. In these examples, PLA may be replaced by PBA, PBS, PPS, copolyester of adipidic acid, 1, 4-butanediol and dimethyl terephthalate (PBAT), polyvinyl butyral (PVB), poly(vinyl acetate-ethylene) (VAE), poly(ethylene-vinyl acetate) (EVA) and combinations thereof. EVOH may also be replaced by PVOH and/or SiOx.

[0150] To manufacture a strip of packages on this basis, shells or individual packages made of shells assembled together are positioned end to end.

[0151] Such linking can be of any kind, for example sealing, gluing, mechanically attaching or fastening etc.

[0152] The linking of two items may be made on a plan or with a relief portion in order to improve the link. This is clearly valuable when sealing or gluing the different parts.

[0153] For example, the first shell 10 and the second shell 20 are positioned such that the first part 11 of the first cavity 31 is aside the first part 21 of the second cavity 41 with one part of the flange 13 of the first shell 10 overlapping one part of the flange 23 of the second shell 20, as illustrated by a dotted line in FIG. 1.

[0154] In addition, in this figure, a front surface of the flange 13 of the first shell 10 is facing a front surface of the flange 23 of the second shell 20.

[0155] Thus, the first shell 10 and the second shell 30 are facing each other but their cavity parts are offset from each other, i.e. they are not forming one same cavity, but are arranged to define two different cavities 31, 41.

[0156] The shells 10, 20 are here considered to be on each side of a plane which would be defined by the front surface of the flanges 13, 23.

[0157] When shells are joined end to end in this manner, they are considered as in staggered rows.

[0158] When providing a first shell 10 and a second shell 20 as described above, the method can then comprise a step of linking a part of the front surface of the flange 13 of the first shell 10 to a part of the front surface of the flange 23 of the second shell 20.

[0159] The shells are then arranged as illustrated in FIG. 2.

[0160] According to another arrangement, a reverse surface, opposite the front surface, of the flange 13 of the first shell 10 is facing the front surface of the flange 23 of the second shell 20.

[0161] In such embodiment, the first shell and the second shell are extending one from the other. In other words, the shells are on a same side of a plane which would be defined by the front surface of the flanges.

[0162] When shells are joined end to end in this manner, they are considered as in one row.

[0163] When providing a first shell 10 and a second shell 20 as described above, the method can then comprise a step of linking a part of the reverse surface pf the flange 13 of the first shell 10 to a part of the front surface of the flange 23 of the second shell 20.

[0164] The shells are then arranged as illustrated in FIG. 3.

[0165] The method may also comprise a step of closing one cavity of one package.

[0166] Referring again to FIG. 1, the method according to an example embodiment of the invention, can also comprise a step of providing a first complementary shell 14 which comprises, in a similar manner, a second part 15 of the first cavity 31 and a rim 16, and a flange 17 extending from the rim 16 and surrounding the second part 15 of the first cavity 31.

[0167] The first cavity 31 can then be formed by positioning the complementary shell 14 such that second part 15 of the first cavity 31 faces the first part 11 of the first cavity 31.

[0168] Then, the flange 17 of the first complementary shell 14 can be sealed to the flange 13 of the first shell 10, thus forming one first package 30 of a package strip.

[0169] In this embodiment, the second part 15 of the first cavity 31 is a half-sphere too, so that the rim 16 has a same shape as the rim 12 of the first shell 10.

[0170] In the illustrated embodiment, the flange 17 of the first complementary shell 14 has a width smaller than a width of the flange 13 of the first shell 10.

[0171] As better illustrated in FIGS. 2 and 3, this enables to avoid additional layer thickness in a junction portion between two packages linked to each other.

[0172] In these figures, a second package 40 is thus formed by linking the second shell 20 to a second complementary shell 24 which comprises, in a similar manner, a second part 25 of the second cavity 41 and a rim 26, and a flange 27 extending from the rim 26 and surrounding the second part 25 of the second cavity 41.

[0173] For example, the shells of one package 30, 40 are sealed together around their corresponding cavity 31, 41 by a sealing area surrounding the cavity 31, 41, for example an annular seal.

[0174] Thus, for example, one package comprises the sealing area.

[0175] The shape of each sealing area is here a ring with an inner diameter of about 36 mm with a width of 2 mm.

[0176] Each sealing ring is preferably centered with the center of each cavity with an accuracy of +/−0.5 mm.

[0177] A gap between the outer shape of a cavity, the rim, and the inner line of the sealing area is defined as a cutting area of the package, which should stay clear for the travel of the dispenser's blade.

[0178] The cutting area has here an inner diameter comprised between 28 mm and 31 mm, for example it is of 29.36 mm, and an outer diameter comprised between 30 mm and 38 mm, for example it is of about 34 to 36 mm.

[0179] Such cutting area preferably has a width of at least 1 mm, for example from 1 mm to 5 mm.

[0180] As shown in FIGS. 2 to 5 for example, the package strip comprises half-cavities sealed together around each cavity, aiming to encapsulate in a tight manner beverage precursors (pearls) into the cavities.

[0181] Before sealing, each package 30; 40 encloses one portion of food or beverage precursor.

[0182] Each portion may contain a few grams of food or beverage precursors, for example, in the case of a beverage precursor, 5 to 6 grams, corresponding to at least one serving of beverage. The beverage precursor is preferably a compacted beverage precursor made of compacted powder. Preferably, the beverage precursor contains essentially roast-and-ground coffee. The beverage precursor may also comprise a mix of roast-and-ground coffee and soluble coffee or a mix of roast-and ground coffee and milk powder. The beverage precursor may also comprise soluble coffee, milk powder or a chocolate based compacted powder. For example, one portion may be suitable for preparing one cup of coffee.

[0183] The portions are preferably spherical. In the present description, the term “spherical” encompasses also designs such as multiple facets (e.g. like a “football” shape) or a sphere having truncated faces of diameter less than the diameter of the sphere or slightly ovoid or oval or egg shapes. A preferred shape is however a ball with circular cross-sections.

[0184] Other shape may be envisaged for the portions like a square or a diamond shape, a parallelepipedal shape, a triangular shape, an ovoid etc. . . .

[0185] In the proposed example, an inner nominal diameter of one cavity is comprised between 22 mm and 25 mm, for example here about 23.3 mm which corresponds to the outer nominal diameter of the packed portion.

[0186] Packages 30, 40 are bonded together in order to create the full strip, as shown in FIGS. 4 and 5.

[0187] In FIG. 4, packages 30 and 40 are closed (after insertion of a beverage precursor portion) and linked to each other, either as illustrated in FIG. 2 or in FIG. 3.

[0188] However, to ensure a better-looking aspect of the package strip and a better interaction with the beverage preparation device, the method may also comprise a step of cutting an edge along at least one side of the packages 30, 40.

[0189] As shown in FIG. 5, a cutting footprint of the package strip corresponds to a “wave” shape which helps to save the material usage and to ensure a good-looking aspect of the packaging.

[0190] For example, the distance in between two pearls (from center to center) is comprised between 45 mm and 49 mm, for example about 47 mm+/− 0.5 mm.

[0191] For example, an overall length of the package strip having 24 pearls (individual portions) is comprised between 1000 mm and 1250 mm, for example it is about 1128 mm.

[0192] For example, a maximum width of the package strip is comprised between 35 mm and 40 mm, for example it is about 38 mm.

[0193] FIG. 6 shows another example of embodiment of shells according to the invention.

[0194] The shells of FIG. 6 differs in particular from the previous ones in the form of the flange.

[0195] For example, a shell can comprise a flange which comprises ring 13_1 and one tab 13_2 extending from the ring, or even a ring 13_1 with two tabs 13_2, for example diametrically aligned one to the other, for example along a longitudinal direction of the strip once the shell is assembled to a complementary shell to form a package.

[0196] For example, during assembling of the shells, the tabs should be aligned, one to the other, within a tolerance of angle of less than 1°, preferably less than 0.5°.

[0197] FIG. 7 shows a possible assembling of a first shell 10_1 with a first complementary shell 14_1 before assembling with a second shell 20_3. In view of the preceding disclosure, one can envisage various options in the assembling process of these shells having at least one tab.

[0198] According to another example embodiment which is not illustrated the package strip may comprise a closing strip comprising at least the second part of the first cavity and the second part of the second cavity.

[0199] In this case, the cavities of such a closing strip can be flatter, so that they can be more easily formed in a strip although they are made of paper-based material.

[0200] Therefore, the packages may have a flatter shape, for example a half sphere shape.

[0201] FIG. 8 shows a package strip 100 comprising tens of packages 30, 40 as described above.

[0202] As shown in FIG. 8, a package strip 100 as described above can be easily wound in superimposed layers, with the portions of one package 30, 40 arranged in quincunx between two adjacent layers of the package strip 100.

[0203] In an advantageous embodiment, the distance d between two neighboring packages 30, 40 may be larger than a diameter of one cavity, so that a folding of two layers is eased.

[0204] Such wound package strip 100 can then be packed in a casing 200 as diagrammatically shown in FIG. 9.

[0205] The casing 200 is generally made of a paper-based material.

[0206] It is usually relatively rigid to protect the package strip 100 received therein.

[0207] The casing 200 may be shaped as a box with an overall parallelepipedal form. For example, it has a narrow rectangular bottom and top, two large side walls and narrower front and rear walls.

[0208] The casing 200 may optionally comprise a transparent window provided on at least one of the large sidewall and/or top to enable to visualize the band of portions inside.

[0209] The casing 200 may further comprise at least one openable gate which forms an opening for allowing the package strip to be progressively withdrawn from the casing during dispensing, e.g. delayered or unwound, with one portion at a time.

[0210] The openable gate may be positioned in a corner or nearby, said top front corner of the casing 200.

[0211] FIG. 10 shows an example embodiment of a food or beverage preparation apparatus 300.

[0212] Such apparatus may be mainly as one described in WO 2019/219523 or WO 2019/219524.

[0213] The apparatus comprises a seat to receive a casing 200 as described in connection with FIG. 9, with the opening of the casing close to a portion removing assembly of the apparatus.

[0214] The portion removing assembly preferably comprises a portion capturing rotary drum 301 driven in rotation in a stepwise fashion by a driving assembly.

[0215] The portion capturing rotary drum comprises a plurality of receiving holes 302 formed in an outer annular wall 303 of the drum 301.

[0216] The receiving holes 302 are individually dimensioned and arranged at distance one another so as to match with the distance d between neighboring packages 30, 40 of the package strip 100.

[0217] As the portions are captured by the receiving cavities moving step-wisely, the package strip 100 is progressively withdrawn from the casing 200.

[0218] The apparatus 300 further comprises package opening means 304 such as a cutting tool arranged for opening the cavities of one package by cutting along one cutting line in at least one side of one package to remove each portion individually. The cutting tool may be driven by a linear motorized actuator configured for moving the cutting tool reciprocally between a retracted position and a cutting position. The cutting tool may be formed as a cylinder of diameter slightly larger than the diameter of one beverage portion and may comprise at least one blade arranged circumferentially on the free edge of the cylinder. Preferably, the cutting tool is arranged to cut the strip 100 on at least 200° or preferably between 300 and 340° about the portion to provide sufficient opening of the cavity and facilitate ejection of the portion while keeping the package material in one piece.

[0219] The apparatus 300 may further comprise portion ejection means 305 for expulsing the portion from the cavity after the package is cut open. The portion ejection means 305 may take various forms. In the illustrated example, the portion ejection means 305 comprises a cam which is stationary arranged on an internal bearing which is arranged co-centrically relative to the rotary drum 301. The cam is preferably positioned angularly, e.g. an angle of 50-80 degrees after the cutting tool, to push the portion outside the corresponding cavity as the drum 301 rotates (as illustrated in FIG. 10 in clockwise direction R).

[0220] The apparatus 300 may further comprise a chute or the like, arranged for gently receiving and transporting by gravity or otherwise (e.g. air pressure), the portion to a food or beverage preparation device to prepare the food or beverage.

[0221] Then, the apparatus 300 preferably comprises at least one container to receive the used package material on one side and the organic residue (food or beverage precursor portion after use) on another side, which eases recycling and composting of waste.