Abstract: A form, fill and seal packaging machine is configured to mold a closure directly onto a carton. The machine includes a carton erection station to receive and erect a carton and a direct injection molding station. The molding station has an internal mold tool for receipt of the carton, and an external mold tool set. The internal tool and external tool set are configured to receive and secure a portion of the carton therebetween and define a mold cavity with the portion of the carton disposed therein. The external mold tool set defines an opening for receiving a polymer injection system to inject polymer into the mold cavity. A closure is directly molded in place on the carton, with the polymer encapsulating the inner peripheral edge of the carton opening that is disposed within the mold cavity. The packaging machine also includes a filling station for filling the carton and a sealing station for forming a seal on the carton.