Abstract: A carton blank is used in a form, fill and seal machine on which a closure is directly molded onto the carton. The molding portion of the machine includes a tool set having first and second tool elements in which the first tool element has an aligning member extending therefrom in a direction transverse to a direction of loading the carton between the first and second tool elements. The aligning element has a predetermined shape having diverging surfaces. The carton blank includes a rear wall panel, a first side wall panel, a front wall panel and a second side wall panel. Each panel is separated from its adjacent panels by a vertical score line. A closure panel is adjacent the front wall panel, has an opening therein and is configured for having a closure molded thereon. The closure panel is partitioned from the front wall panel by a first horizontal score line. The closure panel has a closure panel fin panel extending from a side opposite the front wall panel.

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.

Abstract: A transfer unit is configured for use with a form, fill and seal packaging machine. The transfer unit receives a partially erected carton from a first station in a tubular form, conveys the carton to a second station, and conveys the carton from the second station to a third station. The transfer unit includes a hub defining a longitudinal hub axis and configured for rotational movement about the hub axis. A plurality of car pairs are mounted to the hub for longitudinal movement along the hub. Each of the car pairs includes first and second cars, each of which has first and second mandrels mounted thereto. The mandrels are configured to receive a partially erected carton. Each mandrel has a mandrel axis and is rotational about its respective axis. The mandrel axes are perpendicular and tangential to the hub axis.

Abstract: A transfer unit is configured for use with a form, fill and seal packaging machine. The transfer unit receives a partially erected carton from a first station in a tubular form, conveys the carton to a second station, and conveys the carton from the second station to a third station. The transfer unit includes a hub defining a longitudinal hub axis and configured for rotational movement about the hub axis. A plurality of car pairs are mounted to the hub for longitudinal movement along the hub. Each of the car pairs includes first and second cars, each of which has first and second mandrels mounted thereto. The mandrels are configured to receive a partially erected carton. Each mandrel has a mandrel axis and is rotational about its respective axis. The mandrel axes are perpendicular and tangential to the hub axis.