BAG-IN-BOX PACKAGE

Abstract

The invention relates to a bag-in-box package (1) being made of a material composition which is recyclable in the paper recycling stream. The package (10) comprises: a box (10) made of a cellulose fiber material, and a bag (30) comprising cellulose-based material and having an oxygen and moisture barrier function. The bag (30) is placed at least partially inside the box (10) and non-detachably connected to the box (10).

Claims

1. A bag-in-box package being made of a material composition which is recyclable in the paper recycling stream, comprising: a box made of a cellulose fiber material, and a bag comprising cellulose-based material and having an oxygen and moisture barrier function, wherein the bag is placed at least partially inside the box and non-detachably connected to the box.

2. The bag-in-box package according to claim 1, wherein the bag is made of a multi-layered bag structure comprising: a first layer made of or comprising cellulose-based material, and a second layer made of a material having an oxygen and/or moisture barrier function.

3. The bag-in-box package according to claim 2, wherein the first layer is the outermost layer of the multi-layered bag structure facing to an outside of the bag.

4. The bag-in-box package according to claim 2, wherein the second layer comprises a coating, wherein the coating is selected from the group consisting of a metallization coating, an SiOx based coating, an AlOx based coating, and combinations thereof.

5. The bag-in-box package according to claim 2, wherein the second layer comprises a multi-layered barrier structure.

6. The bag-in-box package according to claim 5, wherein the second sub-layer is sandwiched by the first layer and the first sub-layer.

7. The bag-in-box package according to claim 2, wherein the second layer comprises polyethylene, and wherein the second layer comprises metalized oriented polypropylene.

8. The bag-in-box package according to claim 2, wherein the first layer has a thickness in the range of 20-100 m.

9. The bag-in-box package according to claim 1, wherein the bag comprises cellulose fiber material.

10. The bag-in-box package according to claim 1, wherein the box is made of cardboard as cellulose fiber material.

11. The bag-in-box package according to claim 1, wherein the overall content of cellulose fiber in the material composition is greater than 70 wt. %.

12. The bag-in-box package according to claim 1, wherein the bag is connected to the box by an adhesive.

13. The bag-in-box package according to claim 1, wherein the box comprises a reclosable lid for selectively releasing an opening section of the bag for accessing the content in the bag or discharging the content from the bag-in-box package.

14. The bag-in-box package according to claim 1, wherein the bag is glued to the box.

15. A method for manufacturing a bag-in-box package being made of a material composition which is recyclable in the paper recycling stream, comprising: a1. Providing a bag material comprising cellulose-based material and having an oxygen and moisture barrier function, a2. Filling a space delimited by the bag material, a3. Sealing the bag material to close the space, a4. Providing a bag comprising the filled and closed space, wherein providing the bag preferably includes cutting the bag material, b1. Providing a box material made of cellulose fiber material, b2 Folding the box material into a box, c1. Placing the bag at least partially inside the box, and c2. Connecting the bag to the box in a non-detachable manner.

16. The method according to claim 15, further comprising: c3. Closing and preferably sealing the box so as to house the bag connected to the box completely inside the box.

17. The method according to claim 15, wherein steps a1 to a4 are carried out on a vertical form fill sealing (VFFS) machine.

18. The method according to claim 15, wherein steps b1, b2, c1, and c2 are carried out in a horizontal cartoning machine.

19. The method according to claim 15, wherein the method further comprises: applying an adhesive to the box and/or the bag so as allow the bag be non-detachably connected to the box in step c2.

Description

[0042] In the following, the invention is described exemplarily with reference to the enclosed figures, in which

[0043] FIG. 1 is a schematic perspective view of a bag-in-box package according to a preferred embodiment;

[0044] FIG. 2 is a schematic cross-sectional detailed view of an embodiment of the layers forming a wall section of the bag; and

[0045] FIG. 3 is a flowchart illustrating a method for manufacturing a bag-in-box package according to a preferred embodiment.

[0046] FIG. 1 shows a preferred embodiment of a bag-in-box package 1 (in the following: package). The package 1 comprises a box 10. The box 10 may comprise one or more walls, such as one or more side walls 11, 12 and/or a front wall 13 and/or a back wall 14. The box 10 may comprise a bottom 15 from which the one or more walls may extend. The one or more walls may comprise a printing surface. The box 10 may comprise a space 16 that may be delimited by the one or more walls and/or the bottom 15. In a cross-sectional view, the one or more walls may form a rectangular shape that the limits the space 16.

[0047] The box 10 may comprise an opening 17 that is preferably defined by the (rim of) the one or more walls. Via the opening 17, the space 16 can be accessed, e.g. for placing something inside the box 10.

[0048] The box 10 may comprise a reclosable lid 18. The lid 18 may be connected via a hinge to the body of the box 10; preferably, the lid 18 is connected (e.g. by the hinge) to one of the walls of the box 10, such as to the back wall 14. The lid 18 is arranged to move between an open position and a closed position. In the closed position, the lid 18 preferably covers the opening 17, whereas in the open position the lid 18 exposes the opening 17 in order to allow for an access via the opening 17 to the space 16. In the closed position, the lid 18 is preferably flush with and/or connected to the front wall 13, such as an edge or rim of the wall 13. To facilitate opening of the lid 18 (i.e. moving the lid 18 from the closed position into the open position), the wall 13 may comprise a recessed portion 13.1 that is preferably comprised by an (upper) edge of the wall 13. Via the recessed portion 13.1, a user may easily grip a (lower) edge of the lid 18 in order to move the latter away from the wall 13 and thus into the open position.

[0049] The lid 18 may be adapted to receive, in a detachable manner, an object such as an object that can be used in connection with a content of the box 10. Preferably, the lid 18 comprises a space 18.1 adapted to at least partially contain the object. The lid 18 may comprise one or more walls that delimit the space 18.1. The one or more walls may comprise a (back) wall that is connected, via the hinge, to the back wall 14 of the box 10. The object may be a tool or a cutlery object. In the preferred embodiment shown in FIG. 1, the object is a spoon 18.2. The lid 18 may comprise an attachment structure that is suitable for attaching the object to the lid 18 and/or inside the space 18.1. For example, the attachment structure may be designed to attach the object to the lid 18 by a snap fit or a form and/or frictional fit.

[0050] The box 10 may have a parallelepiped shape. For example, the box 10 may have the shape of a cuboid or a cube.

[0051] The box 10 is made of a cellulose fiber material. Preferably, the box 10 is made of cardboard as cellulose fiber material. The cardboard may have a grammage in the range of 100-500 g/m.sup.2. Preferably, the box 10 is made of cardboard with a grammage from 200-400 g/m.sup.2, in particular 300-400 g/m.sup.2, e.g. 350 g/m.sup.2. According to a particularly preferred embodiment, the box is made from cardboard having the grade GD2. The grade GD2 is one of several grades defined in DIN 19303 Paperboard-Terms and grades, which is the European classification for the quality of paperboard. The box 10 may be made from folding a (single sheet of) the box material. The box material is then made of (or essentially consists of) the cellulose fiber material, such as cardboard or paperboard.

[0052] The package 1 further comprises a bag 30. The bag 30 may comprise one or more walls, such as one or more side walls 31, 32 and/or a front wall 33 and/or a back wall 34. The bag 30 may comprise a bottom (not shown), wherein the one or more walls preferably extend from the bottom. The bag 30 may comprise a space 36, which may be delimited by the one or more walls and/or the bottom. Inside of the space 36 a product such as a nutrition product (infant nutrition, cereals, etc.) can be placed. The product may be provided in several forms, such as in the form of a powder. The bag 30 may have a top 37 so that the one or more walls may extend between the bottom and the top 37. The bag 30 may be closed at the top 37, preferably by sealing. For example, the top 37 may comprise side edges 37.1 which are attached to one another, e.g. by sealing. The top 37 of the bag 30 may be designed for being opened to provide an opening section 37.3 by way of which one can access the space 36. The opening section 37.3 may be defined by at least the side edges 37.1. The opening section 37.3 is suitable for accessing the content in the bag 30 and/or for discharging the content from the bag 30. The bag 30 may preferably be of the pillow pouch type or of the gusset pouch type.

[0053] As shown in FIG. 1, the bag 30 is placed at least partially inside the box 10. This means that the bag 30 may be placed at least partially inside the space 16 of the box 10. As shown, the bag 30 may be placed inside the box 10 in such a way that the bag 30 can project out some way beyond one or more (upper) side edges of the one or more of the walls 11-13, when the lid 18 is in its open position. In other embodiments, the bag 30 may be arranged in such a way that the bag 30 does not project beyond the said (upper) side edges.

[0054] With the lid 18 in the open position, the top 37 or opening section 37.3 of the bag 30 can be released so that one can easily access the content in the bag 30 or the discharge the content from the package 1.

[0055] The bag 30 is non-detachably connected to the box 10. This means that the bag 30 is not only held by being placed at least partially inside the box 10. Rather, by providing the non-detachable connection between the bag 30 and the box 10, there is a further connection that attaches the bag 30 to the box 10. Thereby, the bag 30 is not loosely inserted in the box 10. The non-detachable connection may be provided by an adhesive such as a pressure-sensitive adhesive (for example, TECHNOMELT EM 325 by Henkel may be used as the pressure-sensitive adhesive). In other words, the bag 30 may be glued to the box 10. The non-detachable connection may comprise one or more junctions (i.e., connection points). For example, the bottom and/or one or more of the walls 31-34 of the bag 30 may be non-detachably connected to one or more sections of the box 10, respectively, such as to the bottom 15 and/or one or more of the walls 11-14. The box 10 may comprise an inner surface (e.g. comprised by one or more of the walls 11-14 or the bottom 15), and the bag 30 may comprise an outer surface (e.g. comprised by one or more of the walls 31-34 and fish or the bottom), wherein the adhesive extends between these surfaces in order to non-detachably connect the bag 30 to the box 10. The inner surface of the box 10 may face the space 16 and the outer surface may face away from the space 36 and towards the inner surface of the box 10.

[0056] In one embodiment, the bag 30 is glued to the box 10.

[0057] The bag 30 comprises a cellulose-based material and has an oxygen and moisture barrier function. This means that the bag 30 on the one hand comprises the cellulose-based material and on the other hand is designed to limit the transmission of oxygen and moisture from outside the bag 30 through the bag 30 (such as via its one or more walls) into the inside or space 36 of the bag 30. Such a limitation is in particular desired to extend the shelf life of the product within the bag 30. For example, the moisture may include liquid such as water. The oxygen and moisture barrier function of the bag 30 may be such that a) the oxygen transmission rate is at most 0.15 (cc/m.sup.2/day at a temperature of 23 C. and 50% relative humidity (RH)), preferably at most 0.1, more preferably at most 0.01, and/or b) the moisture (or water) vapour transmission rate is at most 0.15 (g/m.sup.2/day at a temperature of 38 C. and 90% RH), preferably at most 0.1, more preferably at most 0.01.

[0058] Preferably, the cellulose-based material and the oxygen and moisture barrier function of the bag 30 are provided by forming the bag 30 of a multi-layered structure (i.e. a multilayered material). An embodiment of such a multi-layered structure is shown in FIG. 3 and indicated with the reference sign 38. As shown, the multi-layered structure 38 comprises a first layer 38.1 made of or comprising cellulose-based material. The cellulose-based material is preferably made of, or preferably comprises, cellulose fiber material, such as parchment paper, and/or regenerated cellulose material, such as cellophane. Preferably, the first layer 38.1 consists of the cellulose-based material. The first layer 38.1 may be the outermost layer that faces an outside of the bag 30, preferably at least a part of the first layer 38.1 faces an inner surface (e.g. comprised by the one or more walls and/or the bottom) of the box 10.

[0059] The first layer 38.1 is not limited to a specific thickness. Preferably, the first layer 38.1 has a thickness in the range from 20 m to 100 m, preferably from 20 m to 60 m, more preferably from 30 m to 50 m, for example 40 m. In a particularly preferred embodiment, the first layer is made of paper with a grammage between 20-100 g/m.sup.2, preferably between 30-80 g/m.sup.2, more preferably between 35-60 g/m.sup.2, for example 40 g/m.sup.2.

[0060] The multi-layered structure 38 further comprises a second layer 38.2 providing one or more barriers against oxygen and/or moisture. The second layer 38.2 may additionally provide a barrier against other environmental factors such as light. The second layer 38.2 may be the innermost layer of the multi-layered structure 38. The second layer 38.2 may thus face (or may be exposed to) an inside of the bag 30, such as the space 36. The second layer 38.2 is not limited to a specific thickness. Preferably, the second layer 38.2 has a thickness in the range from 40 m to 100 m, preferably from 50 m to 80 m.

[0061] The second layer 38.2 may comprise a multi-layered structure that preferably has a first sub-layer 38.2a and a second sub-layer 38.2b.

[0062] The first sub-layer 38.2a is a sealing layer, i.e. has sealing properties. This allows the bag 30 to be sealed, such as by heat sealing. The bag 30 may be sealed at least at its top 37. The first sub-layer 38.2a may be the innermost layer of the multi-layered structure 38. This means that the first sub-layer 38.2a may comprise an inner surface that faces the inside or space 36 of the bag 38 and thereby may be exposed to the content of the bag 38. The first sub-layer 38.2a may be, or may comprise, polyethylene (PE), preferably low-density polyethylene (LDPE). The first sub-layer 38.2a is preferably thicker than the second sub-layer 38.2b and/or may have a thickness in the range from 40 m to 80 m, preferably from 55 m to 65 m, for example 60 m.

[0063] The second sub-layer 38.2b has the oxygen and/or moisture barrier function. The second sub-layer 38.2b may comprise a coating to provide this function. The coating comprises a metallization coating, an SiOx based coating, an AlOx based coating, or combinations thereof. Preferably, the second sub-layer 38.2b is made of, or comprises, metalized oriented polypropylene (metOPP), preferably metallized biaxially oriented polypropylene (metBOPP). The second sub-layer 38.2b may be an intermediate layer that may be sandwiched between the first layer 38.1 and the first sub-layer 38.2a. Thereby, the first layer 38.1 covers the second sub-layer 38.2b. The second sub-layer 38.2b may have a thickness in the range from 10 m to 40 m, preferably from 15 m to 25 m, for example 18 m.

[0064] As shown in FIG. 3, an (first) adhesion or tie layer 38.3 may be disposed between the first layer 38.1 on the one hand and the second layer 38.2 or the second sub-layer 38.2b on the other hand. The layer 38.3 may comprise a polyurethane-based adhesive. The layer 38.3 may have a thickness in the range from 1 m to 5 m, preferably from 2 m to 4 m, for example 3 m. An (second) adhesion or tie layer 38.4 may be disposed between the first sub-layer 38.2a and the second sub-layer 38.2b. The layer 38.4 may comprise a polyurethane-based adhesive. The layer 38.4 may have a thickness in the range from 1 m to 5 m, preferably from 2 m to 4 m, for example 3 m.

[0065] The package 1 is preferably made of a material composition that has an overall content (or mass fraction) of cellulose fiber of greater than 70 wt. %, or greater than 75 wt. %, or greater than 80 wt. %, or greater than 90 wt. %, or greater than 95 wt. %. In other words, the material composition of the package 1 consists of one or more materials for making the box 10, one or more materials for making the bag 36 and, optionally, one or more materials for providing the non-detachable connection between the box 10 and the bag 36, and has the mentioned cellulose fiber contents. In other words, all parts of the package 1 that are non-detachably connected (directly or indirectly) to one another form a unit that consists of a material composition that preferably has the mentioned overall content of cellulose fiber. Besides the non-detachable connection between the box 10 and the bag 30, all parts of the package 1 that are integral with one another (e.g. due to being folded from the same sheet of material) also represent parts that are non-detachably connected to one another. Accordingly, the object connected to (e.g., received by or contained in) the lid 18, such as the spoon 18.2, does not contribute to the material composition of the package 1, because the object is detachably connected to the box 10.

[0066] The package 1 is thus particularly suitable for being recycled in the paper recycling stream. In the paper recycling stream, the material composition of the package 1 as the waste material may undergo a process (such as re-pulping into fibres) to obtain a material that can be used for a purpose such as for making another item (such as a sheet of paper, not necessarily packaging). The potential fibrous material yield and thus the overall content of cellulose fiber (by weight) in the material composition of the package 1 and the recyclability of the package 1 may be assessed with Requirements and assessment catalogue of the institute cyclos-HTP for EU-wide certification (state 7 Oct. 2019)/Scope of validity according to nation states, see chapter 1) in combination with Minimum standard for measuring the recycling capacity of the ZSVR (state 31 Aug. 2020) and DIN EN 13430.

[0067] In particular, the package 1 has a material composition including materials (in particular for providing the oxygen and moisture barrier function, e.g. the second layer 38.2) that are in the recycling process quantitatively separable by established treatment steps or that are at least considered as having no or a negligible impact on the recyclate properties in practice. Thereby, the paper recycling stream can easily obtain, from the material composition of the package 1, a recyclat (i.e., recycled material), which mainly consists of the cellulose fiber material of the box 10 and of the cellulose-based material (such as cellulose fiber material) of the bag 30. In other words, the design of the package 1 achieves a high recyclability and is thus particularly suitable for the paper recycling stream.

[0068] An example of the package 1 according to a preferred embodiment is described in the following.

[0069] According to this example, the box has a grammage of 350 g/m.sup.2 and a weight of 41.17 g, and the bag (pouch) has a length of 0.24 m and a width (x2) of 0.32 m and is formed of a sheet of material with 0.0768 m.sup.2.

[0070] The further specifications of the multi-layer structure of the bag according to this example are as follows: [0071] First layer: material: paper 40 g/m.sup.2; thickness: 40 m; volume: 0.000003072 m.sup.3; density: 1000000 g/m.sup.3; weight: 3.07 g; [0072] First adhesion or tie layer: material: PU; thickness: 3 m; volume: 2.304E07 m.sup.3; density: 1125000 g/m.sup.3; weight: 0.26 g; [0073] Second sub-layer: material: metBOPP; thickness: 18 m; volume: 1.3824E06 m.sup.3; density: 900000 g/m.sup.3; weight: 1.24 g; [0074] First adhesion or tie layer: material: PU; thickness: 3 m; volume: 2.304E07 m.sup.3; density: 1125000 g/m.sup.3; weight: 0.26 g; [0075] First sub-layer: material: LDPE; thickness: 60 m; volume: 4.608E06 m.sup.3; density: 920000 g/m.sup.3; weight: 4.24 g; [0076] TOTAL: thickness: 124 m; weight: 9.07 g

[0077] The total paper content is thus 41.17 g (box)+3.07 g (bag)=44.24 g. The total plastic content is 0.26 g+1.24 g+0.26 g+4.24 g=6 g. The total weight of the package is 50.24 g.

[0078] Hence, the total paper content in the package according to this example is about 88 wt. %.

[0079] The package may contain a product (e.g. in the form of powder) with a weight of 300 g. However, the weight of the product is not taken into account in the calculation of the total paper content/overall cellulose content.

[0080] The package may contain a spoon with a weight of 2.9 g. However, the weight of the spoon is not taken into account in the calculation of the total paper content/overall cellulose content.

[0081] FIG. 3 shows a preferred embodiment for manufacturing a bag-in-box package being made of a material composition which is recyclable in the paper recycling stream, such as the package 1 describe above. As shown, the method comprises at least steps a1-a4, b1-b2, c1, c2 and prefereably step c3. Steps a1-a4 may be carried out parallel to steps b1-b2.

[0082] Step a1 comprises providing a bag material comprising cellulose-based material, preferably cellulose fiber material and/or regenerated cellulose material, and having an oxygen and moisture barrier function. The bag material may be provided by a roll of film, such as a flat roll of film.

[0083] Step a2 comprises filling a space delimited by the bag material. Step a2 may comprise forming or folding the bag material in order to provide the space. However, forming or folding may be not included so that, for example, the space is provided by connecting (such as by sealing) two sheets of bag material to one another. Step a2 may comprise a first step in which the bag material, e.g. folded, is sealed; thereby, a bottom may be formed that delimits the space from below; the so created seal may comprise a bottom seal. In a subsequent second step, comprised by step a2, the product to be packed is filled into the space. To dispense the product into the space, a dispensing mechanism such as a nozzle may be provided.

[0084] Step a2 may comprise filling the space with a fluid such as a gas. The gas may be filled in order to extend the shelf life of the product filled in the space. In particular, the gas filled into the space may aid in driving out oxygen. Preferably, the gas is an inert gas such as nitrogen.

[0085] Step a3 comprises sealing the bag material to close the space. Step a3 preferably directly follows step a2. The sealing in step a2 may be such that the filled space is closed on all sides; the so created seal, which may be a further seal provided in addition to the said (bottom) seal, may comprise a top seal, i.e. a seal at the top of the bag. Preferably, the further seal forms the (bottom) seal that defines a subsequent space to be filled.

[0086] A sealer such as a heat sealer may be provided to perform sealing.

[0087] Step a4 comprises providing a bag comprising the filled and closed space. Preferably, this step of providing the gap includes cutting the bag material. For example, cutting the bag material may effect that the bag material, which delimits the filled and closed space, can advance as the (sealed) bag formed by the cut off bag material, thereby providing the bag comprising the filled and closed space.

[0088] Step b1 comprises providing a box material made of cellulose fiber material. The box material may be provided pre-cut and thus in a form ready to be folded to provide a box. Providing the box material may be carried out automatically and/or with a box material supply unit.

[0089] Step b2 comprises folding the box material to provide a box. The step b2 may also comprise cutting the box material so as to provide a sheet of box material ready to be folded. In such a case, step b1 does not require to provide the box material in a pre-cut state. Folding the box material may be carried out by using a (automatic) folding mechanism, such as a folding device or machine.

[0090] Step c1 comprises placing the bag, provided with steps a1-a4 above, at least partially inside the box. Such a placing may be carried out by pushing the bag into the box. Such pushing may be carried out by a mechanical mechanism (a mechanical sleeve, arm, etc.) and/or by pressurized air.

[0091] Step c2 comprises connecting the bag to the box in a non-detachable manner. As described above, such a connection may be provided by an adhesive. In a step before step c1, the adhesive may be provided on (an inside of) the box and/or on (an outside of) the bag. For example, step c2 may involve the pushing mechanism used in step c1, which, by its pushing action, aids in providing the non-detachable connection, such as by (slightly) pushing the bag against the box, thereby adhering the bag on the box.

[0092] An optional step c3, which is preferably after step c2, comprises closing and preferably sealing the box so as to house the bag connected to the box completely inside the box.

[0093] Steps a1 to a4 are preferably carried out on a vertical form fill sealing (VFFS) machine.

[0094] Steps b1, b2, c1, c2 and, if present, also step c3 are preferably carried out in a horizontal cartoning machine.

[0095] It should be clear to a skilled person that the embodiments shown in the figures are only preferred embodiments, but that, however, also other designs of a bag-in-box package can be used.