Flexible packaging
Methods and apparatus for forming and filling a flexible package are provided in which an evacuation device (26) and a fitment (20) are attached to a sheet of flexible material (16). The sheet of flexible material (16) is formed into a package that is filled and sealed.
This application is a continuation of co-pending U.S. patent application Ser. No. 10/842,980, filed May 11, 2004, and entitled Flexible Packaging, which in turn is a continuation of U.S. patent application Ser. No. 10/126,702, filed Apr. 19, 2002, now abandoned.
TECHNICAL FIELD OF THE INVENTIONThis invention relates generally to packaging, and more particularly to flexible packaging.
BACKGROUND OF THE INVENTIONThe many advantages of flexible packaging have made it the package of choice in many applications. Two prominent fields for flexible packaging are the beverage industry, for example for wines or for beverage syrups, and the pharmaceutical field. Of course, many other applications exist as well.
In general, products are filled into flexible packages and then distributed for use by customers for their particular application. The products are either filled into pre-made bags through fitments, or filled into bags as the bags are being made on form, fill, and seal machines. Often the flexible packaging is distributed in boxes, and such systems are commonly referred to as bag-in-box (“BIB”) systems. “Bag,” as used in this disclosure, is meant to include any flexible package, including, without limitation, bags, pouches, and stand-up packages.
Significant efforts have been made at increasing the efficiency of form, fill, and seal machines, and of operations that make pre-made bags. Furthermore, there have been various developments directed at improving the evacuation efficiency of pre-made bags.
However, attempts at improving evacuation efficiency have often reduced efficiencies during the bag filling operation. For example, one approach for improving evacuation efficiency involves the use of an evacuation device known as a dip strip, which includes a base and raised ribs that create evacuation channels. For this device to work well, it must be coupled closely to the fitment through which product is evacuated from the bag. However, on pre-made bags, the proximity of the evacuation device to the fitment (which is also the filling spout) reduces the maximum flow rate that can be used to fill the bag, thus slowing down the speed of the filling operation. Also, form, fill, and seal systems have not accommodated the manufacture of bags that include evacuation devices to improve evacuation efficiencies. Therefore, a need has arisen for a system that allows for the efficiencies that result from form, fill, and seal machines, along with the evacuation efficiencies that have been allowed with pre-made bag systems.
SUMMARY OF THE INVENTIONIn accordance with the teachings of the present invention, methods and apparatus for forming and filling flexible packages are provided which substantially eliminate or reduce problems associated with prior art systems.
In particular, a method of forming and filling a flexible package is provided that includes partially forming the package, attaching an evacuation device, filling the package, and sealing the package. The evacuation device may be attached before the package is partially formed or after it is partially formed. The package may be sealed by making a top seal.
In other embodiments, the following are provided, alone or together: partially forming the package by folding a sheet of flexible material; partially forming the package by forming side seals; and forming the side seals on a horizontal form, fill, and seal machine.
In still other embodiments, the following are provided, alone or together: partially forming the package by forming a tube from a sheet of flexible material; partially forming the package by forming a bottom seal; and forming the bottom seal on a vertical form, fill, and seal machine.
In another embodiment, a fitment is attached to the flexible package. One method of attaching the fitment includes coupling the evacuation device and the fitment, and attaching the evacuation device comprises attaching the coupled evacuation device and fitment. In one embodiment, the fitment is attached to an inside surface of the flexible package, and does not penetrate the flexible package. In another, the fitment penetrates the flexible package. In one method, a hole is formed for receiving the fitment. The fitment may comprise any suitable access device, and in a particular embodiment, without limitation, is a port that includes a valve.
In another embodiment, the fitment is attached before attaching the evacuation device, and the evacuation device is attached proximate the fitment. In a particular embodiment, the evacuation device is attached to the fitment.
The evacuation device may be attached in many different ways and places, and, for example, may be attached to an inside surface of the flexible package, or seamed into a seal of the flexible package. Without limitation, the evacuation device may be a dip strip.
Another method of the present invention includes attaching a fitment to a sheet of flexible material, attaching an evacuation device proximate the fitment, partially forming the package from the sheet of flexible material, filling the package, and sealing the package. The fitment may be attached before the package is partially formed, or after it is partially formed. Sealing the package may comprise making a top seal.
In a particular embodiment of this method, partially forming the package comprises folding the sheet of flexible material. Also, partially forming the package may comprise forming side seals. The side seals may be formed on a horizontal form, fill, and seal machine.
In another embodiment of this method, partially forming the package comprises forming a tube from the sheet of flexible material. Also, partially forming the package may comprise forming a bottom seal. The bottom seal may be formed on a vertical form, fill, and seal machine.
In another embodiment, the evacuation device and the fitment are coupled, and attaching the fitment and attaching the evacuation device comprise attaching the coupled evacuation device and fitment. In one embodiment, the fitment may be attached to an inside surface of the flexible package, and does not penetrate the flexible package. In another, the fitment penetrates the sheet of flexible material. A hole may be made in the flexible material for receiving the fitment. The fitment may comprise any suitable access device, and in a particular embodiment, without limitation, is a port that includes a valve.
In another embodiment, the fitment is attached before attaching the evacuation device, and the evacuation device is attached proximate the fitment. In a particular embodiment, the evacuation device is attached to the fitment.
The evacuation device may be attached in many different ways and places, and, for example, may be attached to an inside surface of the flexible package, or seamed into a seal of the flexible package. Without limitation, the evacuation device may be a dip strip.
Also provided is apparatus for carrying out the methods described herein.
An important technical advantage of the present invention is that an evacuation device is included as part of a flexible package on form, fill, and seal machines of any kind, including horizontal and vertical machines. Another important technical advantage of the present invention is that a fitment and an evacuation device may be attached to a flexible package during a form, fill, and seal operation, and may be attached as separate units or as a combined or integrally formed unit.
Reference is made in description to the following briefly described drawings, wherein like reference numerals refer to corresponding elements:
The horizontal form, fill, and seal machine 10 shown in
The form, fill, and seal machine 10 of
The plastic material 16 is rolled across a roller 18 and then folded (for example with a collar) to prepare for seaming and filling. Before roller 18, however, a supply of fitments 20 are advanced along a guide 22. Also, a roll 24 of evacuation devices 26 is provided for supplying an evacuation device for each bag. Preferably the roll 24 of evacuation devices 26 is a continuous roll, thus allowing the evacuation devices 26 to be efficiently manufactured as one extrusion (and cut into individual devices for each bag). However, no such roll is needed, and other approaches may be used, such as, without limitation, supplying separated evacuation devices, or using rolls of evacuation devices that include periodic features (such as thin areas for facilitating seaming in to seams).
In the particular embodiment shown in
A combined evacuation device 26 and fitment 20 are advanced to the next station where they are attached to the bag material 16. This station includes heat sealer 34 and press 36. The bag material 16 and a combined internal fitment 20 and evacuation device 26 are passed between the heat sealer 34 and the press 36, and the heat sealer 34 presses the bag material 16 and fitment 20 together against press 36 and heat seals them together. A cutter 38 is provided for cutting the evacuation device 26 so as to separate the appropriate length for each bag. The cutter 38 cuts the material against a stop, which may be part of the guide 22, or any other suitable stop.
As can be seen in
The bag is filled through filler 46 (which may move up and down as each bag is advanced) with the appropriate product. The bag may be widened, to facilitate filling, with vacuum separators 47. After filling, the bag material 16 is advanced to the next station where top sealer 48 seals the top seam, such as with a heat-sealing press, to complete formation of the bag. The bag is then cut at support and cut station 44 and then handled for commercial distribution. For example, without limitation, a conveyer may be positioned to take the bag, after it is cut, to a station for inserting bags into boxes, for BIB-type systems.
Although the particular evacuation device 26 shown in
Heat seal station 68 operates to form the side seals of the bag formed with the embodiment shown in
Next, the web of bag material 16 is advanced to evacuation device attachment station 100. Here, the evacuation devices 26 are advanced along guide 112 between the folds of bag material 16 and heat-sealed in place. In a particular embodiment, each evacuation device 26 is heat sealed to a fitment 86, as is shown in
It should be understood that attaching the evacuation device 26 to the fitment 86 is exemplary only, and the evacuation device 26 may also be attached, without limitation, to the bag material 16 itself, in one or more places, such as by tacking with heat sealing, and may be attached to the bag wall 16 alone or in combination with attaching it to the fitment 86, or may be seamed into the top seam (with or without other attachments). Furthermore, the cutting mechanism shown in
It should also be understood that the particular approach shown for attaching the fitment 86 is exemplary only, and other approaches may be used without departing from the intended scope of the present invention. In particular, the following US patents provide examples of particular ways of attaching a fitment to a web of film (although other approaches may also be used), and are herein incorporated by reference in their entirety; U.S. Pat. No. 5,203,819 entitled Apparatus For Attaching A Fitment To A Web of Film; U.S. Pat. No. 4,779,397, entitled Apparatus and Method for Attaching A Fitment to a Web of Film; U.S. Pat. No. 4,512,136, entitled Fitment Attachment Methods in Horizontal Form/Fill/Seal Machines; U.S. Pat. No. 4,718,215, entitled Apparatus and Method for Attaching Fitments to Flexible Containers; U.S. Pat. No. 4,246,062, entitled Apparatus for Attaching a Fitment to a Pouch; and U.S. Pat. No. 4,695,337, entitled Apparatus and Method for Attaching a Fitment to a Web of Film. These examples apply both to the horizontal form, fill, and seal apparatus discussed herein, and to the vertical form, fill, and seal apparatus to be discussed below.
Furthermore, the particular fitment 86 shown in
Also, with the horizontal apparatus discussed above, it is preferred that the bag walls be formed by folding one sheet of bag material. However, two sheets may be brought together and sealed without departing from the intended scope of the present invention.
As discussed above in connection with fitment 20, the evacuation device 26 significantly increases evacuation efficiency with fitment 86 (or any fitment) by providing evacuation channels for the product to flow through, and preventing the bag walls from closing flow through the fitment during evacuation.
It should also be understood that pass-through fitments, such as though discussed in connection with
Although the present invention encompasses attaching the evacuation device anywhere within the bag, it is preferred that the evacuation device be positioned in such a way that it is in relatively close proximity to the fitment through which product will be accessed. This close proximity helps insure that the web of bag material will not seal off the fitment through which product is accessed during evacuation of the bag.
As discussed above in connection with the horizontal form, fill, and seal machines, the fitments 214 and evacuation devices 220 may be combined and attached to the bag material 202, or separately attached, and may be attached before or after the bag material is formed into a “tube” and before or after any seals are made. Also, any kind of fitment may be used, including, without limitation, internal fitments such as fitments 20, or pass-through fitments such as fitments 86 discussed above. The particular devices for accomplishing this attachment are similar to those discussed above in connection with the other embodiments (such as the devices discussed above in connection with
Throughout the description of the methods of the present invention, it should be understood that, where appropriate, the order of the process may be changed without departing form the intended scope of the present invention. For example, in the vertical embodiments, the fitments and evacuation devices may be attached to the bag material before or after the “tube” structure is formed, and before or after any seals (such as bottom seals) are made. Similarly, for the horizontal embodiments, such attaching may occur before or after folding (or the like), and before or after any seals (such as side seals) are made. Also, it should be understood that any fitment type can be used with each embodiment, including, without limitation, internal type fitments or pass-through type fitments.
The particular descriptions provided are illustrative examples, and features and advantages of each example may be interchanged with, or added to the features and advantages in the other embodiments and examples herein. And, in general, although the present invention has been described in detail, it should be understood that various changes, alterations, substitutions, additions and modifications can be made without departing from the intended scope of the invention, as defined in the following claims.
Claims
1. A method of forming and filling a flexible package, the package to be filled with a liquid product, comprising:
- partially forming the package from a sheet of flexible material;
- attaching an evacuation device to the sheet of flexible material, the evacuation device adapted to facilitate flow of at least some of the liquid product by effectively preventing the sheet of flexible material from closing off flow during evacuation of the package, the evacuation device comprising a first evacuation device end and a terminal end, with a length between the first evacuation device end and the terminal end, wherein the evacuation device comprises a channel directly open to the liquid product at intermediate locations substantially the entire length between the first evacuation device end and the terminal end, such that liquid product may enter the channel at the intermediate locations;
- filling the partially formed package with the liquid product after attaching the evacuation device; and
- after filling, sealing the package by making a top seal.
2. The method of claim 1, wherein the evacuation device is attached before the package is partially formed.
3. The method of claim 1, wherein the evacuation device is attached after the package is partially formed.
4. The method of claim 1, wherein the flexible package is formed and filled on a horizontal form, fill, and seal machine.
5. The method of claim 1, wherein the flexible package is formed and filled on a vertical form, fill, and seal machine.
6. The method of claim 1, and further comprising attaching a fitment to the sheet of flexible material, the fitment comprising a passageway through which a liquid product flows during evacuation of the package, the fitment adapted to be coupled to a pump for evacuation of the package, and wherein filling the partially formed package comprises filling other than through the fitment.
7. The method of claim 6, and further comprising coupling the evacuation device and the fitment before attaching the fitment to the sheet of flexible material.
8. The method of claim 6, and further comprising attaching the evacuation device to the fitment.
9. The method of claim 1, wherein the evacuation device is a dip strip.
10. The method of claim 1, wherein the flexible package comprises two sheets of flexible material, and the top seal is made by sealing the two sheets together.
11. A method of forming and filling a flexible package, comprising:
- attaching a fitment to a sheet of flexible material, the fitment comprising a passageway through which a liquid product flows during evacuation of the package, the fitment adapted to be coupled to a pump for evacuation of the package;
- attaching an evacuation device to the sheet of flexible material proximate the passageway, the evacuation device adapted to facilitate flow of at least some of the liquid product to the passageway by effectively preventing the sheet of flexible material from closing off flow to the passageway during evacuation of the package, the evacuation device comprising a first evacuation device end and a terminal end, with a length between the first evacuation device end and the terminal end, wherein the evacuation device comprises a channel directly open to the liquid product at intermediate locations substantially the entire length between the first evacuation device end and the terminal end, such that liquid product may enter the channel at the intermediate locations;
- partially forming the package from the sheet of flexible material;
- filling the partially formed package with the liquid product after attaching the fitment; and
- after filling and after attaching the evacuation device, sealing the package by making a top seal.
12. The method of claim 11, wherein the evacuation device is attached before the package is partially formed.
13. The method of claim 11, wherein the evacuation device is attached after the package is partially formed.
14. The method of claim 11, wherein the flexible package is formed and filled on a horizontal form, fill, and seal machine.
15. The method of claim 11, wherein the flexible package is formed and filled on a vertical form, fill, and seal machine.
16. The method of claim 11, and further comprising coupling the evacuation device and the fitment before attaching the fitment to the flexible sheet of material.
17. The method of claim 11, wherein the fitment is attached to an inside surface of the flexible package, and is located within the flexible package.
18. The method of claim 11, wherein the fitment penetrates the sheet of flexible material.
19. The method of claim 11, and further comprising attaching the evacuation device to the fitment.
20. The method of claim 11, wherein the flexible package comprises two sheets of flexible material, and the top seal is made by sealing the two sheets together.
Type: Application
Filed: Apr 27, 2009
Publication Date: Aug 27, 2009
Inventors: Alfred A. Schroeder (San Antonio, TX), Michael T. Romanyszyn (San Antonio, TX)
Application Number: 12/386,996
International Classification: B65B 43/08 (20060101);