Container construction for powdered material

Abstract

A packaging is disclosed for a powdered material comprising a tub for receiving the material, the tub having a base and a peripheral wall with a top edge; an outer sleeve around at least the peripheral wall of the tub, thereby supporting the tub; a removable membrane for separating the powdered material in the tub from the environment; and a lid assembly comprising a peripheral rim for connection over the top edge of the peripheral wall of the tub and defining a wide access opening and a lid, hingedly attached to the rim for reclosing the access opening.

Furthermore, a method of manufacturing a package for a powdered material is disclosed, comprising sliding the tub in the sleeve, such that at least the peripheral wall of the tub is enclosed by the sleeve, whereby the sleeve supports the tub and the tub and sleeve form a container for the powdered material.

Claims

1. A method of packaging a powdered nutritional product under high-care conditions, the method comprising, in a high-care zone having an over-pressure with respect to atmospheric pressure and a filtered atmosphere: providing a thermoformed tub having a base and a peripheral wall with a top edge; filling the tub with the powdered nutritional product; providing a membrane for separating the powdered material from the environment; and sealing the membrane to the peripheral wall of the tub, the method further comprising transferring the filled and sealed tub from the high-care zone to a low-care zone and in the low care zone: providing a sleeve of carton material, enclosing the peripheral wall of the tub with the sleeve, whereby the sleeve supports the tub and the tub and sleeve form a composite container for the powdered material.

2. The method of claim 1, further comprising providing a lid assembly, comprising a peripheral rim defining a wide access opening and a lid, hingedly attached to the rim for reclosing the access opening and connecting the peripheral rim of the lid assembly over the top edge of the tub.

3. The method of claim 2, wherein the lid assembly is connected to the tub in the high-care zone.

4. The method of claim 2, wherein the lid assembly is connected to the tub in the low-care zone.

5. The method of claim 1, wherein the over-pressure in the high-care zone is between 5 Pa and 30 Pa.

6. The method of claim 1, wherein a temperature in the high-care zone is between 19 C. and 23 C. and a humidity is between 35% RH and 50% RH.

7. The method of claim 1, wherein the atmosphere within the high-care zone is filtered with a HEPA filter of H10 or higher according to EN 1822:2009.

8. The method of claim 1, further comprising checking the tub and the membrane with a vision system for imperfections or foreign bodies prior to filling.

9. The method of claim 1, wherein filling takes place in a low-oxygen atmosphere.

10. The method of claim 9, further comprising flushing with nitrogen or carbon dioxide before and during the filling procedure and prior to applying the membrane.

11. The method of claim 1, wherein the tub comprises an outwardly extending flange at the top edge and the membrane is connected across the flange.

12. The method of claim 11, wherein the membrane comprises a weakened tear line defining an opening region, and a pull tab.

13. The method of claim 12, wherein the tear line further defines a peripheral region, permanently connected to the flange.

14. The method of claim 1, wherein the peripheral wall of the tub comprises a laminate comprising polypropylene and including a barrier layer having reduced oxygen transmission.

15. The method of claim 14, wherein the barrier layer comprises EVOH.

16. The method of claim 1, wherein the peripheral wall of the tub has a thickness of between 0.15 and 0.40 mm and the sleeve has a weight of 100 g/m2 to 300 g/m2.

17. The method of claim 1, wherein the powdered nutritional product is infant milk formula.

18. The method of claim 17, further comprising providing a scoop within the package, wherein the scoop is placed onto the membrane within the low-care zone.

19. A package, manufactured according to the method of claim 1.

20. A package of powdered nutritional product manufactured under high-care conditions, the package comprising: a thermoformed tub for receiving the nutritional product, the tub having a base and a peripheral wall of polymeric material with a top edge, the peripheral wall being provided with a barrier layer having reduced oxygen transmission; a quantity of powdered nutritional product within the tub, the product being flushed with nitrogen or carbon-dioxide, whereby substantially no oxygen is present; a membrane, hermetically sealing the powdered nutritional product within the tub from the environment; an outer carton sleeve enclosing and engaging the peripheral wall and base of the tub around its complete periphery; and a lid assembly comprising a peripheral rim for connection over the top edge of the peripheral wall of the tub and defining a wide access opening and a lid, hingedly attached to the rim for reclosing the access opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The features and advantages of the invention will be appreciated upon reference to the following drawings of a number of exemplary embodiments, in which:

[0040] FIG. 1 shows a package according to a first embodiment of the present invention in partly exploded perspective view;

[0041] FIG. 2 shows a perspective view of the embodiment of FIG. 1.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0042] FIG. 1 shows a partially exploded view of a package 1 according to a first embodiment of the invention comprising a container 2 and a lid assembly 9. The lid assembly 9 comprises a circumferential rim 3 for connecting the lid assembly 9 to the container 2 and a lid 4 for reclosing the container 2 after opening. The container 2 comprises a tub 17 and a sleeve 18. The tub 17 has a base 5 and a peripheral upstanding wall 7 having a top edge 6. The top edge 6 of the tub 17 comprises a flange 23 that extends outwardly from the peripheral wall. A membrane 11 is connected to the top edge 6 of the tub 17 at the flange 23 for sealing the powdered product (not shown) from the environment. The sleeve 18 has a further base 19 and a further peripheral upstanding wall 14 with a further top edge 15. Alternatively, the sleeve 18 can comprise only a further peripheral wall, leaving the base 5 of the tub 17 uncovered. The tub 17 has only one compartment 24, which compartment holds the product (not shown).

[0043] In this view it can be seen that the sleeve 18 of carton is provided around the tub 17 of polymer material. The sleeve 18 provides rigidity to the tub 17 and can be easily printed as may be required. The tub 17 and the sleeve 18 support each other in order to provide a wall structure that is stronger than would be the case for each of the elements when taken alone. This support is achieved by an interference fit preventing the tub 17 and the sleeve 18 from sliding out of each other during normal use and ensures that the peripheral wall 7 of the tub 17 is adequately supported. The weight of the powder contents (not shown) can assist in pressing the peripheral wall 7 of the tub 17 into contact with the outer sleeve 18. The peripheral rim 3 fits over the top edge 6 of the tub 17. The peripheral rim 3 and the top edge 6 define an access opening 8. The access opening 8 is sealed with a membrane 11 prior to use. The lid 4 and peripheral rim 3 are arranged to attach onto flange 23 to complete the package 1. To this end, the peripheral rim 3 fits over the flange 23. During manufacture, the tub 17 may first be filled with milk powder (not shown). The membrane 11 may then be connected to the top edge 6 to form a hermetically sealed unit. In a final stage of production, the outer sleeve 18 may be slid over the tub, the sleeve having the desired printing, and the lid assembly 9 may be applied. However, first sliding the sleeve 18 over the tub 17 before conducting the further manufacturing steps is possible as well. The tub 17 is then subsequently sealed with the membrane 11 over the top edge 6 and the lid assembly 9 is subsequently applied onto the top edge 6 at the flange 23.

[0044] FIG. 2 shows the embodiment of FIG. 1 in perspective view. The container 2 has a depth dimension d, measured from its base 5 to a top edge 6 of its peripheral wall 7. It also has a width dimension w and a length dimension 1. The rim 3 forms an access opening 8 providing access to the interior of the container 2. During manufacture, the inner tub 17 is slid into the outer sleeve 18 forming the container 2. The inner tub 17 is then supported by the outer sleeve 18. The top edge 6 of the tub 17 and the top edge 15 of the outer sleeve are at a distance from each other, such that the tolerances in the height dimensions of these container parts may be accommodated. The membrane 11 has a weakening line 21 and a pull tab 20 that may be grasped in order to facilitate its removal along the weakening line 21. As can be seen, the tear line 21 delimits the peripheral region 13 which remains attached to peripheral wall 7 once the central opening region 12 has been removed by pulling of the pull-tab 20. In use, the package 1 is opened by hinging back the lid 4 along hinges 16 to reveal the access opening 8. The pull tab 20 may then be grasped in order to rupture the membrane 11 along the line of weakness 21. The opening region 12 may then be removed, leaving a peripheral region 13 connected to the peripheral wall 7 and exposing the powdered material (not shown). A scoop (not shown) is used to perform dosing of the powdered material. After use of the product, the lid 4 is reclosed.

[0045] In the embodiment of FIGS. 1 and 2, the base of the container 2 has a profile (not shown) that is complementary to the depression 22 on the lid. During storage or display, packages 1 may be stacked one upon the other whereby the base 5, 19 of one package 1 engages with the lid 4 of a package 1 beneath. On use, the user removes the membrane 11 and uses a scoop to dispense product. The lid 4 subsequently serves to close the access opening 8.