METHOD OF MANUFACTURING AND FILLING A PACKAGE AND CORRESPONDING PACKAGE

Abstract

The present invention relates to a method of manufacturing and filling a package with a powdered nutritional product, such as infant nutrition or milk formula, the method comprising providing a thermoformed tub having sidewalls and a base defining a product receiving space, filling the product receiving space with the powdered nutritional product, and sealing a membrane across an open mouth of the tub to seal the product therein; and folding a carton blank with a plurality of panels around the filled tub to form a carton sleeve, wherein the carton sleeve comprises a peripheral wall enclosing at least the sidewalls of the tub.

The invention also relates to a package for such a powdered nutritional product manufactured according to this method.

Claims

1. A method of manufacturing and filling a package with a powdered nutritional product, the method comprising: a) providing a thermoformed tub having sidewalls and a base defining a product receiving space, filling the product receiving space with the powdered nutritional product, and sealing a membrane across an open mouth of the tub to seal the product therein; b) folding a carton blank with a plurality of panels around the filled tub to form a carton sleeve, wherein the carton sleeve comprises a peripheral wall enclosing at least the sidewalls of the tub.

2. The method according to claim 1, wherein the carton blank comprises a bottom panel and side wall panels and wherein after folding the carton blank to a sleeve, the sleeve encloses the sidewalls and at least a part of the base of the tub.

3. The method according to claim 1, wherein step b) further comprises gluing the panels to the tub.

4. The method according to claim 1, wherein step b) further comprises connecting the panels to each other.

5. The method according to claim 2, wherein step b) further comprises gluing the bottom panel to the base of the tub.

6. The method according to claim 1, wherein step b) comprises applying a lateral displacement to panels to bring them into engagement with the sidewalls of the tub after folding towards the sidewalls of the tub.

7. The method according to claim 1, wherein step b) further comprises providing the carton blank from a carton blank magazine holding multiple carton blanks.

8. The method according to claim 1, wherein step b) further comprises centring the carton blank and the thermoformed tub with respect to each other.

9. The method according to claim 1, wherein step a) further comprises fitting a lower rim to an upper edge of the tub.

10. The method according to claim 9, wherein step a) further comprises fitting a lid assembly to the tub, the lid assembly comprising an upper rim and a recloseable lid.

11. The method according to 10, wherein the upper rim and the lower rim are mechanically connected together in an interference fit.

12. The method according to claim 1, wherein step a) takes place in a high care zone defined by a supra-atmospheric pressure and a filtered atmosphere.

13. The method according to claim 12, wherein step b) takes place outside the high care zone.

14. The method according to claim 1, wherein filling the product receiving space with the powdered nutritional product takes place in a low oxygen atmosphere.

15. The method according to claim 14, wherein the low oxygen atmosphere comprises a carbon dioxide atmosphere.

16. The method according to claim 1, wherein the tub has a wall thickness of between 0.10 mm and 0.50 mm.

17. The method according to claim 1, wherein the carton blank has a weight of between 50 g/m.sup.2 and 400 g/m.sup.2.

18. The method according to claim 1, wherein the tub and the sleeve have tapered sidewalls, with a taper of between 1 and 7.

19. The method according to claim 1, wherein the membrane comprises a weakened tear line defining an opening region, and a pull tab.

20. A package for a powdered nutritional product manufactured by a method comprising: a) providing a thermoformed tub having sidewalls and a base defining a product receiving space, filling the product receiving space with the powdered nutritional product, and sealing a membrane across an open mouth of the tub to seal the product therein; b) folding a carton blank with a plurality of panels around the filled tub to form a carton sleeve, wherein the carton sleeve comprises a peripheral wall enclosing at least the sidewalls of the tub.

21. (canceled)

22. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The features and advantages of the invention will be further appreciated upon reference to the following drawings of a number of exemplary embodiments, in which:

[0051] FIG. 1 shows a package for powdered nutritional products manufactured according to the method of the invention.

[0052] FIG. 2 shows a semi-finished package for assembly of the package of FIG. 1 in an exploded view.

[0053] FIG. 3 shows a carton blank and the semi-finished package of FIG. 2 for assembling the package of FIG. 1.

[0054] FIG. 4 shows side panels of the carton blank of FIG. 3 folded towards the thermoformed tub; and

[0055] FIG. 5 shows a schematic flow diagram of the production of the package of FIG. 1.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0056] FIG. 1 shows in perspective view a package 1 manufactured according to the present invention. The package 1 is in its completed state and includes a tub 2, enclosed by a sleeve 4, and a lid assembly 3.

[0057] FIG. 2 shows a partially exploded view of the tub 2 and the lid assembly 3 showing further a membrane 6, a lower rim 8, an upper rim 10 and a lid 12 forming a first assembly part 1 of the package 1. The tub 2 is thermoformed of a laminate of inner and outer relatively thin polypropylene material layers and an intermediate EVOH barrier layer. It includes a base 14 and a peripheral wall 16 defining a product containing space 20, i.e. the tub 2 is filled with a powdered nutritional product 21 before the membrane 6 is connected over the open mouth 15 of the tub. The peripheral wall 16 extends to an upper edge 18 having an outwardly directed flange 19.

[0058] Lower rim 8 is formed as a flat annular ring of a similar dimension to the outwardly directed flange 19. The lower rim 8 is injection moulded of polypropylene, although it will be understood that other appropriate materials could also be employed. The upper rim 10 and lid 12 form the lid assembly 3 and are also formed of injection moulded polypropylene. The upper rim 10 is designed to mechanically engage with the lower rim 8 in an interference fit including snap connectors, not shown. The seal 6 includes a tear line 22 defining an opening region 24 and includes a pull tab 26.

[0059] The production line 40 of the package 1, of which a flow diagram is shown in FIG. 5, is divided into a number of zones, defined as a first low-care zone 41, a high-care zone 42, a second low-care zone 43 and a third low-care zone 44. The tub 2, lower rim 8, lid assembly 3 and membrane 6 are all delivered via the first low-care zone 41, to the high-care zone 42. It is noted that the tubs 2 are pre-formed, size-stabilised thermoformed tubs that have been formed at least 48 hours previously. In the high-care zone 42, after initial cleaning and flushing operations have been performed, the tub 2 is filled with milk powder 21. Subsequently, membrane 6 is applied to close the product containing space 20 and hermetically seal the milk powder within the tub 2. Afterwards, lower rim 8 is applied over the membrane 6 onto the outwardly directed flange 19 at the upper edge 18 of the peripheral wall 16 and subsequently welded into position.

[0060] Thereafter, the lid assembly 3 is applied onto the lower rim 8 and clicked into position.

[0061] At this point, all of the components that enter into contact with the milk powder 21 are enclosed within a semi-finished package 1, shown in FIG. 2. This can now proceed from the high-care zone 42 into the second low care zone 43. It will be understood that only the processes relevant to the present invention have been described at this point and that many other further operations may take place within the high-care zone 42, including cleaning, inspecting, testing and the like.

[0062] Within the second low-care zone 43 the sleeve 4 will be formed around the semi-finished package 1 to form a final package 1 as will be described in further detail below. The final package 1 is passed to the third low-care zone 44 for onward shipment.

[0063] FIG. 3 shows a perspective view of a blank 28 used to form the sleeve 4 and the filled and sealed tub 2 centered on a bottom panel (not shown) of the blank 28. The blank material is polyethylene (PE) coated, high-quality card of 300 g/cm.sup.2. The blank 28 defines a number of side panels 30 and the bottom panel (not shown), corner sections 32 and connection tabs 34.

[0064] FIG. 4 shows a perspective view of the assembly of the package 1 by first folding side panels 30 towards the side walls 16 of the tub 2. Before folding the side panels 30 a layer of adhesive, or glue, is provided in an adhesive area 31. After connection of the side panels 30 to the side walls 16 by the adhesive, connection tabs 34 are folded towards the side walls 16 and connected to the side walls 16 by gluing.

[0065] Secondly, the side panels 30 are provided with a layer of adhesive, or glue, provided in an adhesive area 33. Side panels 30 are then folded towards the side walls 16 of the tub 2 and connected to both the connection tabs 34 and the tub 2 by gluing. Upon folding the side panels 30, the corner sections 32 fold around the rounded corners of the tub 2. The blank 28 is now formed into a sleeve 4 that encloses the tub 2 by covering the side walls 16 and the base 14 and which supports the relatively thin walls of the tub 2. The adhesive is a hot-melt adhesive available as TECHNOMELT SUPRA 325 HT from Henkel AG and having an application temperature of between 160 C. and 190 C.

[0066] It will be understood that although it has been indicated that the adhesive is applied in the designated adhesive areas 31, 33, this may be applied at any desired location using an appropriate robotic glue actuator and may even be applied to the walls of the tub itself.

[0067] Thus, the invention has been described by reference to certain embodiments discussed above. It will be recognized that many modifications in addition to those described above may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, these are examples only and are not limiting upon the scope of the invention.

LIST OF PARTS

[0068] 1. Final package

[0069] 1. Semi-finished package

[0070] 2. Tub

[0071] 3. Lid assembly

[0072] 4. Sleeve

[0073] 6. Membrane

[0074] 8. Lower rim

[0075] 10. Upper rim

[0076] 12. Lid

[0077] 14. Base

[0078] 15. Open mouth

[0079] 16. Peripheral wall

[0080] 18. Upper edge

[0081] 19. Flange

[0082] 20. Product containing space

[0083] 21. Powdered product

[0084] 22. Tear line

[0085] 24. Opening region

[0086] 26. Pull tab

[0087] 28. Blank

[0088] 30. Side panel

[0089] 31. Adhesive area

[0090] 32. Corner section

[0091] 33. Adhesive area

[0092] 34. Connection tabs

[0093] 40. Production line

[0094] 41. First low-care zone

[0095] 42. High-care zone

[0096] 43. Second low-care zone

[0097] 44. Third low-care zone