Methods of manufacturing reclosable packages using transverse application of zipper closure

Abstract

A method of making packages having a reclosable zipper closure on a vertical form, fill and seal process. The method includes providing a length of the zipper closure having a length same as the width of the resulting package. The ends of the length of zipper closure are sealed together prior to applying the zipper closure to the film web. The zipper construction is first applied and adhered to one half of the film web and then to the other half. A tamper-evident structure encasing the zipper closure may be included.

Description

[0001] Priority under 35 U.S.C. §119(e) is claimed to provisional application serial No. 60/178,584, filed Jan. 28, 2000, and entitled “Methods of Manufacturing Reclosable Packages Using Transverse Application of Zipper Closure”. The complete disclosure of application No. 60/178,584 is incorporated by reference herein.

FIELD OF THE DISCLOSURE

[0002] This disclosure concerns reclosable packages. In particular, this disclosure describes methods of manufacturing reclosable packages having a zipper closure mechanism using vertical form, fill, and seal techniques, and the packages made thereby.

BACKGROUND

[0003] Multitudes of consumable goods are available packaged in flexible packages such as plastic bags. Many goods that are not used completely when the package is initially opened rely on a zipper closure to reclose the package and keep the remaining contents fresh. Examples of consumable goods that are often packaged in resealable and reclosable packages, such as bags, with a zipper closure include potting soil, fertilizer, pet food, dog biscuits, vegetables, cereal and many other foods edible by humans.

[0004] Form, fill, and seal technology is known in the packaging industry as a method to manufacture the resealable packages and to package the consumable goods within those resealable packages. Improvements in this type of manufacturing process, and the packages produced, are desirable.

SUMMARY OF THE DISCLOSURE

[0005] The present disclosure relates to a method of manufacturing a package, such as a flexible bag, having a resealable, reclosable zipper closure mechanism by a vertical form, fill and seal process. A tamper-evident seal can be provided on and around the exterior of the zipper closure to provide evidence whether access has been gained to the zipper closure and the interior of the package.

[0006] In particular, the present disclosure relates to a vertical form, fill and seal process that manufactures the flexible package, fills the package with items, and seals the filled package. The zipper mechanism and seals are applied to the package preferably in the same process as filling of the package.

[0007] The methods of this disclosure involve, in general, providing a length of a zipper closure construction having first and second interlocking closure members, pre-sealing together the ends of the first and second closure members, and attaching the zipper closure to side panels as appropriate to provide a package. The zipper closure is cut to the desired length, i.e., essentially the width of the package, prior to incorporation of the zipper closure with the film web that provides the side panels.

[0008] In particular, the present disclosure is directed to a method of manufacturing a reclosable package having a zipper closure construction. The method includes providing a zipper closure construction having a first closure profile and a second closure profile, the closure construction having a length approximately equal to the width of the resulting package. The closure construction is attached to a first half of a film web having a width approximately twice the width of the resulting package. The film web is folded and the edges of the film web are joined to form a seam; the closure construction is sealed to a second half of the film web. After forming a bottom edge, the package is filled and a top edge is made. A tamper-evident structure may be provided at either the bottom edge or the top edge. In another embodiment, an internal tamper-evident structure, such as a web or a peel seal, may be provided.

[0009] The present disclosure also is directed to packages made by the methods disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a perspective view of a flexible, reclosable package shown with access available to the interior of the package;

[0011] FIG. 2 is a cross-sectional view of the flexible, reclosable package taken along line 2-2 of FIG. 1;

[0012] FIG. 3 is a side view of a flexible, reclosable package having a tamper-evident structure;

[0013] FIG. 4 is a cross-sectional view of the flexible, reclosable package taken along line 4-4 of FIG. 3; and

[0014] FIG. 5 is a schematic, perspective view of a process of the present disclosure for producing flexible, reclosable packages similar to those depicted in FIGS. 1 through 4.

DETAILED DESCRIPTION

[0015] The process described herein produces and fills a reclosable package. In some embodiments, a tamper-evident structure, such as an external structure or an internal web or a peel seal is also provided by the process described herein. The process of manufacturing the packages is accomplished on a machine commonly referred to as a vertical form fill, and seal machine.

[0016] A flexible, reclosable package 10 is shown in FIGS. 1 and 2. Package 10 has polymeric film side panels 12 and 14 surrounding an interior 11, as best seen in FIG. 2. A zipper closure arrangement 20 having mating profiles to open and close (unseal and reseal) the mouth 21 of package 10 extends across the width of package 10. Access is obtainable to interior 11 through mouth 21. The zipper closure 20 can include a variety of configurations and structures. Zipper closure 20 can be configured in any known manner, for example, such as disclosed in U.S. Pat. Nos. 4,240,241; 4,246,288; and 4,437,293; each of which is incorporated by reference herein.

[0017] In FIGS. 1 and 2, zipper closure 20 has a first interlocking mating profile 22 and a second interlocking mating profile 24 which disengage and engage, as appropriate, to open and close package 10. Zipper closure 20 extends from first side edge 32 to second side edge 34 at mouth 21. First and second mating profiles 22, 24 of zipper closure 20 are attached to side panels 12, 14, respectively, by sealing flanges 26, 28, as depicted in FIG. 2. Side panels 12, 14 extend along side first and second mating profiles 22, 24 and in particular extend along, and past, upper flanges 27, 29 of first and second mating profiles 22, 24, respectively; this is best seen in FIG. 2.

[0018] Package 10 includes three edges, side edges 32, 34 and bottom edge 36, that together with side panels 12, 14, form interior 11 of package 10. In the particular arrangement shown, bottom edge 36 is a bottom seal 31, formed by the application of heat and pressure to side panels 12, 14 to seal side panels 12, 14 together and create bottom seal 31. Package 10 also has a top edge 30, which is the edge of package 10 closest to mouth 21 and most distant from bottom edge 36. In FIG. 2, top edge 30 is the edge where side panels 12, 14 terminate. In some embodiments, top edge 30 may be where upper flanges 27, 29 terminate. The terms “top” and “bottom” are relative terms used in respect to package 10 as shown in FIGS. 1 and 2. It is understood that package can be oriented in different directions, so that, for example, top edge 30 would not be at the top most portion of the figure but would be positioned else where. However, no matter what orientation package 10 is in, top edge 30 is the edge of package 10 closest to mouth 21 and most distant from bottom edge 36.

[0019] In the embodiment depicted, the distance between first side edge 32 and second side edge 34 is the width of package 10. Preferably, each of first side edge 32 and second side edge 34 is a fold line between side panels 12, 14, which is formed when a single sheet of film material is folded to form the two side panels 12, 14. Preferably, the single sheet of film is sealed at seam 13, shown in phantom in FIG. 1; such a seam 13 is commonly referred to as a “fin seal”.

[0020] In FIGS. 3 and 4, a second embodiment of a package 10′ is shown. Package 10′ is similar to package 10 of FIGS. 1 and 2 except that package 10′ includes a tamper-evident structure 40 encasing zipper closure 20. Package 10′ has a zipper closure 20 extending from a first side edge 32 to a second side edge 34; the distance between side edges 32, 34 is the width of package 10′. Similar to package 10 in FIGS. 1 and 2, package 10′ includes three edges, side edges 32, 34 and bottom edge 36, which together with side panels 12, 14, form the interior 11 of package 10′. In the embodiment depicted, top edge 30′ of package 10′ is the edge of package 10′ most distant from bottom edge 36; for package 10′, top edge 30′ is the tip of tamper-evident structure 40. Preferably, each of first side edge 32 and second side edge 34 is a fold line between the side panels, which are formed when a single sheet of film is folded. The single sheet of film is sealed at seam 13, shown in phantom, and at bottom seal 31.

[0021] In FIGS. 3 and 4, package 10′ includes tamper-evident structure 40 positioned over and encasing zipper closure 20. By “tamper-evident”, it is meant that it provides an indication to the consumer as to whether the package 10 has been previously opened. In order to access zipper closure 20 and interior 11 of package 10, the tamper-evident structure 40 needs to be penetrated. In the embodiment depicted in FIGS. 3 and 4, tamper-evident structure 40 covers and forms a complete enclosure around the zipper closure 20; tamper-evident structure 40 encases and otherwise surrounds zipper closure 20.

[0022] Tamper-evident structure 40 is formed by sealing the tops of side panels 12, 14 over zipper closure 20. Preferably, the seal 43 (FIG. 4) which forms tamper-evident structure 40 is continuous; that is, with no unsealed portions between side panels 12, 14 along top edge 30′. However, in some embodiments spot sealing may be acceptable. Each end of tamper-evident structure 40, that is, at first side edge 32 and at second side edge 34, is preferably continuously sealed.

[0023] In order to gain access to zipper closure 20 and package interior 11, the tamper-evident structure 40 needs to be penetrated. Tamper-evident structure 40 can include a feature such as a perforation line 42, a tear-bead, a zip-strip, a score-line, a die line, a region of highly oriented material, or other type of weakened area that allows for easy removal of tamper-evident structure 40 to expose zipper closure 20. Once tamper-evident structure 40 of package 10′ has been removed, the resulting package is that shown in FIGS. 1 and 2 as package 10.

[0024] Various modifications of tamper-evident structures are known throughout the art of resealable packaging. For example, a second tamper-evident structure, such as a web, can extend between sealing flanges 26, 28 (FIGS. 2 and 4), thus providing a second barrier to broken in order to gain access to interior 11 of package 10, 10′. Examples of web tamper-evident structures are disclosed, for example, in U.S. Pat. Nos. 4,925,316 and 5,964,532, each of which is incorporated by reference herein.

[0025] Similarly, a peel seal can be positioned between sealing flanges 26, 28 of zipper closure 20 or between side panels 12, 14 to provide a hermetic barrier for the interior 11. A peel seal can be resealable; that is, it can be opened and resealed multiple times. Alternately, a peel seal can be a single use seal, which, once broken, cannot be resealed. Examples of peel seals are disclosed, for example, in U.S. Pat. Nos. 4,925,316 and 5,893,645, each of which is incorporated by reference herein. These internal tamper-evident structures, i.e., those tamper-evident structures between the zipper closure 20 and package interior 11, can be used with or without an external tamper-evident structure, such as structure 40 (FIGS. 3 and 4).

[0026] The packages described and disclosed in FIGS. 1 through 4 can be manufactured by vertical form, fill and seal techniques in accordance with the present disclosure. The package, whether with or without a tamper-evident structure 40 or an internal structure such as a web or a peel seal, is manufactured, filled, and sealed by a single process that includes multiple sequential steps. The zipper closure 20 and any optional features, such as tamper-evident structure 40, are applied to the package prior to the package being filled with any items.

[0027] Referring to FIG. 5, a vertical form, fill and seal process, in accordance with the present disclosure, is shown at 100. As illustrated in FIG. 5, the process line progresses from right to left; that is, the final filled package is at the left side of FIG. 5. It should be understood that other orientations of process 100 can be used with the teachings of the present disclosure; for example, the process can progress from left to right. The bag or package is manufactured in a vertical orientation so that the filling takes place through the “upper end” of the package, as it is manufactured. The “upper end” of the package, as manufactured, may be bottom edge 36 of package 10 or may be mouth 21.

[0028] Referring to FIG. 5, the process to manufacture and fill packages 10, 10′ of FIGS. 1 through 4 will be described. Polymeric film 110, which will provide the side panels 12, 14 (FIGS. 1 through 4), is provided on roll 101. The width of polymeric film 110 is the distance between film edges 110a, 110b, which is approximately equal to twice the width of package 10; the distance between film edges 110a, 110b is approximately twice the distance between side edge 32 and side edge 34. In another embodiment, film 110 may be extruded, cast or otherwise formed immediately before this vertical form, fill and seal process, thereby eliminating the step of winding the film after forming the film and then unwinding when the packages are made.

[0029] An extended length of zipper closure 20, with first closure profile 22 (FIGS. 2 and 4) and second closure profile 24 (FIGS. 2 and 4) interlocked, is provided via spool 102. Zipper closure 10 may be extruded, cast or otherwise formed immediately before this vertical form, fill and seal process, thereby eliminating the step of winding the zipper closure after forming the film and then unwinding when the packages are made.

[0030] In accordance with the present disclosure, zipper closure 20 is cut to a length approximately equal to the width of the resulting package; the resulting cut zipper segment is depicted at 25 in FIG. 5. That is, zipper closure 20 is cut to the length needed to extend between side edge 32 and side edge 34 of packages 10, 10′ (FIGS. 1 and 3), as described below. Further in accordance with the present disclosure, the two mating profiles 22, 24 (FIGS. 2 and 4) are sealed together at the ends 25a, 25b of the cut zipper segment 25. The ends 25a, 25b of the mating profiles 22, 24 may be sealed together either before, after or as zipper closure 20 is cut to the desired length to form zipper segment 25. Ends 25a, 25b are sealed together prior to zipper segment 25 being sealed to film 110, as will be explained further below.

[0031] As depicted in FIG. 5, zipper closure 20 from spool 102 progresses to sealing station 120, which provides heat and pressure to pre-seal or seal together first and second mating profiles 22, 24 (FIGS. 2 and 4) of zipper closure 20. Ultrasonic energy can alternately or additionally be used to pre-seal or seal the ends 25a, 25b. As used herein, the terms “seal” and “pre-seal” mean that two pieces, such as first and second mating profiles 22, 24, are adhered to each other, at least with a temporary bond, preferably with a permanent bond. In some instances, the thickness of first and second mating profiles 22, 24 may be thinner where pre-sealing is done by sealing station 120 than where no pre-sealing has occurred.

[0032] Sealing station 120 includes a pair of first sealing bars, bottom first sealing bar 121 and top first sealing bar 122, and a pair of second sealing bars, bottom second sealing bar 123 and top second sealing bar 124. These sealing bars 121, 122, 123, 124 apply heat, pressure, ultrasonics, or any combination thereof to zipper closure 20 at the areas where they contact zipper closure 20. The energy applied by sealing bars 121, 122, 123, 124 is sufficient to at least pre-seal first and second mating profiles 22, 24 of zipper closure 20 together. Preferably, this pre-sealing or sealing of first and second mating profiles 22, 24 is done at ends 25a, 25b. First sealing bars 121, 122 are spaced from second sealing bars 123, 124 a distance equal to the length of the cut zipper closure segment 25, which is essentially the same length as the width of the resulting package 10, 10′ between side edges 32, 34. The resulting length of zipper closure 20 is one that has seals disposed along its length; the seals are spaced to correspond to where the zipper closure 20 will eventually meet side edges 32, 34 of package 10, 10′. Thus, each length of zipper closure 20, which is approximately the same as the width of the resulting package, has a seal between the mating profiles 22, 24 at each end 25a, 25b of a zipper segment 25.

[0033] In some embodiments, zipper closure 20 may be cut to a length slightly shorter than the distance between side edges 32, 34; this may be done if zipper closure 20 has a tendency to stretch or otherwise distort during the pre-sealing, cutting, and positioning processes, as will be described below.

[0034] The seals produced on zipper closure 20 by sealing bars 121, 122, 123, 124 may be formed by only one pair of sealing bars or by both sets. That is, a seal may be formed by being contacted by only one pair of first sealing bars 121, 122 and second sealing bars 123, 124; or, a seal may be formed by being contacted by both pairs 121,122,123,124 of sealing bars. The number of contacts by the sealing bars, and the temperature and duration of contact are dependent on the speed at which the process progresses.

[0035] Nip rolls can be used incrementally pull the sealed zipper closure 20 to cutter 112, which cuts zipper closure 20 to its final length at the produced heat seals. Preferably, each seal is cut through the center by cutter 1112. Examples of features that can be present on cutter 112 include a sharp edge, such as a knife blade, a heated edge, and ultrasonic vibration. In some embodiments, second sealing bars 123, 124 may be designed to at least partially cut through zipper closure 20 at the heat seal produced by those bars. This can eliminate the need for a separate cutter 112.

[0036] The cut zipper closure 20 is positioned onto film 110 between film side edges 110a, 110b by profile positioner 114. Profile positioner 114 may include a gripper 116 that actually grabs zipper closure 20 and pulls zipper closure 20 onto film 110. The cut length of zipper closure 20 is positioned on a portion of film 110 so that zipper closure 20 is approximately centered on film 110; this results in seam 13 (FIGS. 1 and 3) positioned approximately equally between first side edge 32 and second side edge 34. Zipper closure 20 will be centered on film 110 if the midpoint of zipper closure is equally positioned between side edges 110a, 110b of film 110. In some embodiments, zipper closure 20 can be positioned more to one edge of the film 110, for example edge 110a, than the other edge; this would result in seam 13 being positioned more to first side edge 32 or second side edge 34 of package 10, 10′ than the other. Yet in further embodiments, zipper closure 20 can be positioned to extend from side edge 110a of film 110 to approximately its centerline; with such an arrangement seam 13 will be positioned essentially at one of first and second side edges 32, 34.

[0037] A profile applicator 118 adheres, at least temporarily and preferably, permanently, zipper closure 20 to film 110 at the point where profile positioner 114 positions zipper closure 20. Profile applicator 118 can use heat, pressure, ultrasonics, or any combination to adhere zipper closure 20 to film 110. Only one half of zipper closure 20, that is, the side positioned on film 110, is attached to film 110 by profile applicator. It is one of sealing flanges 26, 28 (FIGS. 2 and 4) that is sealed to film 110.

[0038] Various rollers, guides, tensioners, and the like can be used throughout process 100 to guide zipper closure 20 and film 110 and to secure the attachment of zipper closure 20 onto film 110.

[0039] Once the zipper closure 20 is attached to film 110, film 110 moves to column 128 that folds film 110 and provides structure to film 110 during the following steps of the vertical form, fill and seal process. Items to be packaged within the resulting package 10, 10′ are deposited into the package through column 128.

[0040] Film 110 is folded around column 128 so that side edges 110a, 110b are brought together. There may be a slight overlap of side edges 110a, 110b. The folded film 110 with the zipper closure 20 progresses to seaming station 130, which provides seam 13 (FIGS. 1 and 3) by the application of heat, pressure, or both to the joined film side edges 110a, 110b. Seaming station 130 includes first seaming bar 131 and second seaming bar 132; either one, or both of which may be heated. Seaming bars 131, 132 extend essentially parallel to column 128 and film side edges 110a, 110b, and essentially perpendicular to zipper closure 20. Once seam 13 is produced, film 110 is in the form of a tube or casement 140. Seam 13 is typically perpendicular to zipper closure 20. The tube or casement 140 results in side panels 12, 14 of package 10, 10′.

[0041] Tube 140, with zipper closure 20 adhered to the inside of half of the tube material, progresses to sealing bars 134, 135. Sealing bars 134, 135 provide heat and pressure transversely across tube 140.

[0042] Process 100 can be adapted to form the packages in an upright or an upside down position. That is, the packages can be made with bottom seal 31 made first, so that the package is filled at the top, close to the mouth 21 of package 10, and then the top at zipper closure 20 is sealed. Alternately, the packages can be made with a top seal at zipper closure first, so that the packages are filled through the bottom edge 36, and then the bottom seal 31 is made. In either orientation, the process providing the package is similar.

[0043] FIG. 5 shows package 10′ being manufactured in an upside down position with zipper closure 20 positioned downward so that the upper end of the package is bottom edge 36. When manufactured in an upside down position, sealing bars 134, 135 first securely seal both sides of zipper closure 20 (i.e., flanges 26, 28 (FIG. 4)) to the film tube 140. Sealing bars 134, 135 may be constructed to simultaneously form tamper-evident structure 40 (FIGS. 3 and 4) over zipper closure 20. This intermediate package is then filled with items deposited through column 128, and bottom seal 31 is made.

[0044] Sealing bars 134, 135 can be adapted for various processing procedures. As mentioned above, sealing bars 134, 135, or other similar sealing bars, can be used to create a tamper-evident structure over zipper closure 20, such as tamper-evident structure 40 of FIG. 3. Sealing bars 134, 135 can be designed to seal the film of tube 140 over zipper closure 20, thereby encasing zipper closure 20 and creating tamper-evident structure 40 (FIG. 3). A perforator system or other system can be incorporated into sealing bars 134, 135 to provide a perforation, score, or other weakness in the film 140 that allows tamper-evident structure 40 to be removed to gain access the zipper closure 20 when the package is opened by the consumer. In some embodiments, it may be desired to provide a perforated or weakened area in the film as an individual step, rather than simultaneously with the creation of the seals. Further, as shown in FIG. 5, sealing bars 134, 135 can simultaneously seal zipper closure 20 to tube 140 and also form bottom seal 31 of the adjacent package. In some embodiments, different sealing bars may be used to form bottom seal 31 than are used to seal zipper closure 20 to the film web 140. Sealing bars 134, 135 can also be adapted to cut apart and separate adjacent packages.

[0045] In some embodiments, the process of the present invention includes production of packages that have no tamper-evident structure 40 external to the zipper closure 20. Rather, only an internal tamper-evident structure, or no tamper-evident structure is present. As one example of an internal tamper-evident structure, a zipper closure 20 can be produced as a single piece, with the sealing flange 26 of the first mating profile connected to the sealing flange 28 of the second profile by an extension of film or web. Once incorporated into a package, the connecting piece between the sealing flanges is an internal tamper-evident structure. Another example of an internal tamper-evident structure is a peel seal, which can be present between the sealing flanges of the mating profiles when the zipper closure 20 is on spool 102.

[0046] The above specification is believed to provide a complete description of the manufacture and use of particular embodiments of the invention. Many embodiments of the invention can be made.

Claims

1. A method of manufacturing a reclosable package comprising a zipper closure construction, the reclosable package having a width and the zipper closure extending the width of the package, the method comprising:

(a) providing a zipper closure having a length approximately equal to the package width, the length defined by a first end and a second end, the zipper closure having a first mating profile and a second mating profile;

(b) sealing the first mating profile to the second mating profile at the first end and at the second end to provide first and second end seals;

(c) after the step of providing the zipper closure having a length approximately equal to the package width and after the step of sealing the first mating profile to the second mating profile, attaching the first mating profile to a first portion of a film web;

(d) attaching the second mating profile to a second portion of the film web;

(e) joining a first side edge and a second side edge of the film web approximately perpendicular to the zipper closure to form a casement;

(f) forming a bottom edge to provide an interior defined by the casement and the bottom edge; and

(g) forming a top edge.

2. The method according to claim 1, further comprising, between the step of forming a bottom edge to provide an interior defined by the casement and the bottom edge and the step of forming a top edge:

(a) filling the package interior.

3. The method according to claim 1, wherein the step of forming a top edge is done before the step of forming a bottom edge to provide an interior defined by the casement and the bottom edge.

4. The method according to claim 3, further comprising, between the step of forming a top edge and the step of forming a bottom edge to provide an interior defined by the casement and the bottom edge:

(a) filling the interior.

5. The method according to claim 1, wherein the step of providing a closure construction having a length approximately equal to the package width comprises:

(a) cutting an extended length of closure construction to a length approximately equal to the package width.

6. The method according to claim 1, wherein the step of sealing the first mating profile to the second mating profile at the first end and at the second end to provide first and second end seals is done before the step of providing a zipper closure having a length approximately equal to the package width, the length defined by a first end and a second end.

7. The method according to claim 6, wherein the step of providing a closure construction having a length approximately equal to the package width comprises:

(a) cutting at least partially through the first and second end seals.

8. The method according to claim 7, wherein the step of cutting at least partially through the first and second end seals comprises:

(a) cutting through the first and second end seals with a blade.

9. The method according to claim 7, wherein the step of cutting at least partially through the first and second end seals is accomplished by a sealing bar used to provide at least one of first and second end seals.

10. The method according to claim 1, wherein the step of attaching the first mating profile to a first portion of a film web comprises:

(a) attaching the first mating profile to a first portion of the film web equally between the first side edge and the second side edge of the film.

11. The method according to claim 1, wherein the step of forming a top edge comprises:

(a) providing a tamper-evident structure over the zipper closure to indicate whether access has been gained to the zipper closure.

12. The method according to claim 11, wherein the step of providing a tamper-evident structure over the zipper closure to indicate whether access has been gained to the zipper closure comprises:

(a) providing a tamper-evident structure comprising a perforation.

13. The method according to claim 1, wherein the step of joining a first side edge and a second side edge of the film web to form a casement is done before the step of attaching the second mating profile to a second portion of the film web.

14. A method of making and filling a reclosable package comprising a zipper closure construction, the reclosable package having a width and the zipper closure extending the width of the package, the method comprising:

(a) providing a zipper closure segment having:

(i) a first mating profile and a second mating profile;

(ii) a length approximately equal to the package width, the length defined by a first end and a second end;

(iii) the first mating profile being sealed to the second mating profile at the first end and at the second end at first and second end seals, respectively;

(b) attaching the first mating profile of the zipper closure segment to a first portion of a film web;

(c) after the step of attaching the first mating profile to a first portion of a film web, joining first and second edges of the film web approximately perpendicular to the zipper closure segment to form a casement;

(d) attaching the second mating profile of the zipper closure segment to a second portion of the film web;

(e) forming a top edge to provide an interior defined by the casement and the bottom edge; the top edge comprising a tamper-evident structure encasing the zipper closure;

(f) filling the package interior; and

(g) forming a bottom edge.

15. The method according to claim 14 wherein the step of providing a zipper closure segment having a length approximately equal to the package width, the length defined by a first end and a second end, comprises:

(a) cutting an extended length of zipper closure to a length approximately equal to the package width to provide a zipper closure segment.

16. A reclosable package made according to claim 14.

17. The reclosable package according to claim 16, the package comprising:

(a) first and second side panel sections, the first and second side panel sections having first and second side edges and a bottom edge, the side edges and bottom edge defining an interior;

(b) a zipper closure sealed to the first and second side panel sections along a top edge of the side panel sections; and

(c) a tamper-evident structure encasing the zipper closure.

18. The reclosable package according to claim 17, further comprising an internal tamper-evident structure extending between the first and second side panel sections and positioned between the zipper closure and the package interior.