RECYCLABLE SACHET AND METHODS FOR MANUFACTURING SAME

Abstract

A recyclable single-use sachet is provided including an inner envelope, an outer envelope, an organic additive effective to facilitate biodegradation in a biologically active landfill, and a peripheral seal. The outer envelope can be formed from a single, folded, layer of material, or from multiple layers joined together. Likewise, the inner envelope can be formed from one or more layers of material. Systems and methods for manufacturing the single-use recyclable sachet are also provided.

Description

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/610,602 filed on Dec. 27, 2017, the entire disclosure of which is hereby expressly incorporated by reference.

FIELD OF THE INVENTION

The described invention relates to recyclable single-use packaging that is biodegradable, compostable, and shelf-stable for at least 6 months.

BACKGROUND OF THE INVENTION

Single-use sachets are well known and widely utilized to package a variety of products designed to be used once and then disposed of or destroyed. FIGS. 1-2 illustrate a conventional sachet design (hereinafter “sachet 10”). More specifically, FIG. 1 is a front elevational view of sachet 10 and FIG. 2 is a cross-sectional view of sachet 10 of FIG. 1 taken along line 2-2. As shown in FIG. 2, sachet 10 includes a body 12 that is typically constructed from multi-layer sheets of material (hereinafter “multi-layer stock 14”) comprising a first layer 20, generally formed from a metal material (meaning a solid material that is typically hard, shiny, malleable, fusible, and ductile, with good electrical and thermal conductivity, including mixtures of two or more metals or of one or more metals with certain nonmetallic elements (e.g., alloys)), and a second layer 22, generally formed from a plastic material (meaning a synthetic material made from organic polymers that can be molded into shape while soft and then set into a rigid or slightly elastic form), to provide a barrier to moisture, oxygen, and odors. The first and second layers 20, 22 are laminated, or bonded (adhered), together along the entirety of their respective surfaces. The first and second layers 20, 22 are typically laminated together before the sachet is manufactured and provided as a continuous roll of material. For example, lamination of packaging materials can involve the binding of thin gauges of metallic foil (e.g., aluminum) to paper or plastic film to improve barrier properties. Although lamination to plastic can enable heat sealability, the seal does not completely bar moisture and air. Metallized films contain both a plastic layer and a thin layer of aluminum metal bonded thereto (Fellows P, Axtell B. 2002. Packaging materials. In: Fellows P, Axtell B, editors. Appropriate food packaging: materials and methods for small businesses. Essex, U.K.: ITDG Publishing. p 25-77). These films have improved barrier properties to moisture, oils, air, and odors, and are more flexible than laminated films. Depending on the particular application, conventional sachets 10 can be formed having an inner metal layer and an exterior plastic layer (as discussed hereinabove) or can be formed having an inner plastic layer and an exterior metal layer.

Sachets can be formed from two sheets of the multi-layer stock arranged to face each other, bonded together by a seal 16 along the periphery thereof, as shown in FIGS. 1-2, or from a single sheet of the multi-layer stock folded onto itself and sealed along its periphery, thereby forming a sealed envelope 18 for the contents of the sachet 10. The envelope 18 of the sachet can contain liquid, paste, or dry contents such as medications, supplements, shampoos, toothpastes, lotions, cosmetics, condiments and the like.

FIG. 3 shows a conventional sachet sealing and filling station (hereinafter “filling station 30”) for producing and filling a sachet from a single sheet of the multi-layer stock. As shown, a single roll of the multi-layer stock described above is provided. The multi-layer material is drawn through a series of feed rollers 32 before being folded onto itself and partially sealed along its periphery to create an open envelope. The envelope is then filled, the remaining side of the sachet is sealed, and finally, the sachet is separated from the roll. As shown in FIGS. 1-2 and described above, sachets can be formed from two sheets of the multi-layer stock 14 by following a similar process which adds an additional roll of multi-layer stock 14 and which does not require the step of folding.

Sachets are commonly utilized in emerging and/or poor market segments to distribute quality products to the masses, which was previously not economically viable with traditional multi-use bottle and container product packaging. Currently available sachets are not recyclable without difficulty because the metal layer is not separable from the plastic layer by a user without requiring additional technologies, such as mechanical and/or chemical separation means. Unlike, for example, recyclable plastic bottles and metal cans which can be collected and returned for a deposit or refund, there is no economic incentive to collect used sachets because they are not recyclable, and thus cannot be returned in exchange for a deposit. Because there is no economic incentive to collect and recycle the used sachets, sachet waste has become a major problem in markets where they have gained prevalence. This problem is only expected to grow as adoption of sachet products increases.

Accordingly, what is needed is a sachet and methods for manufacturing the same, which address these, and other, problems associated with the conventional sachets described above.

SUMMARY OF THE INVENTION

It is an object of the described invention to provide a recyclable single-use sachet that is biodegradable and compostable.

According to one aspect, the described invention provides a recyclable single-use sachet, comprising: a first layer of material folded about a fold line, thereby forming an inner envelope; a second layer of material positioned adjacent to the first layer of material, the second layer of material folded about the fold line, thereby forming an outer envelope; a peripheral seal formed between adjacent portions of the inner envelope; an organic additive effective to facilitate biodegradation in a biologically active landfill and the outer envelope being bonded to the inner envelope only along peripheral edges thereof. According to one embodiment of the recyclable single-use sachet, the first material is metal. According to another embodiment, the second material is a polymer selected from polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) polyvinyl chloride (PVC). According to another embodiment, the peripheral seal is a heat seal. According to another embodiment, adjacent portions of the inner envelope are bonded together by an adhesive disposed therebetween. According to another embodiment, the outer envelope being bonded to the inner envelope is only along peripheral edges thereof. According to another embodiment, the outer envelope is bonded to the inner envelope by the heat seal. According to another embodiment, the outer envelope is bonded to the inner envelope by an adhesive disposed therebetween. According to another embodiment, the recyclable sachet further comprises a notch disposed through a peripheral edge of the sachet, the notch configured to allow a portion of the sachet to be torn therefrom.

According to another aspect, a recyclable single-use sachet, comprises: an inner envelope formed from first and second layers of a first material; an outer envelope formed from first and second layers of a second material; a peripheral seal formed between the first and second layers of the inner envelope; an organic additive effective to facilitate biodegradation in a biologically active landfill; and the outer envelope being bonded to the inner envelope only along peripheral edges thereof. According to one embodiment of the recyclable single-use sachet, the first material is a metal. According to another embodiment the second material is a polymer selected from polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) polyvinyl chloride (PVC). According to another embodiment, the first layer of the outer envelope is bonded to the first layer of the inner envelope only along peripheral edges thereof. According to another embodiment the second layer of the outer envelope is bonded to the second layer of the inner envelope only along peripheral edges thereof. According to another embodiment, the inner envelope of the sachet contains liquid, paste, powder, granular, or solid contents. According to another embodiment the solid contents comprise a three-dimensional tablet.

According to another aspect, a method of manufacturing a recyclable single-use sachet, comprising the steps of: providing a first layer of web stock formed from a first material; providing a second layer of web stock formed from a second material; wherein the second material comprises an organic additive effective to facilitate biodegradation in a biologically active landfill; simultaneously feeding the first layer of web stock and the second layer of web stock, the second layer of web stock positioned adjacent to the first layer of web stock; folding the first and second layers of web stock about a fold line so that the first layer of material forms an inner envelope and the second layer of material forms an outer envelope; filling the inner envelope with a product; sealing the inner envelope along the periphery thereof; and bonding the outer envelope to the inner envelope only along peripheral edges thereof. According to one embodiment, the first material is a metal. According to another embodiment, the second material is a polymer selected from polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) polyvinyl chloride (PVC). According to another embodiment, the step of sealing the inner envelope comprises forming a heat seal. According to another embodiment, the step of sealing the inner envelope comprises applying an adhesive between adjacent layers thereof. According to another embodiment, comprising bonding the outer envelope to the inner envelope by the heat seal. According to another embodiment, bonding the outer envelope to the inner envelope only along peripheral edges thereof. According to another embodiment, the step of bonding outer envelope to the inner envelope comprises disposing an adhesive therebetween. According to another embodiment, further comprising the step of separating the sachet from the first and second layers of web stock. According to another embodiment, further comprising the step of cutting a notch through a peripheral edge of the sachet, the notch configured to allow a portion of the sachet to be torn therefrom. According to another embodiment, the step of folding the first and second layers of web stock further comprises feeding the first and second layers of web stock through a guide ring. According to another embodiment, the first and second layers of web stock are provided together on a single continuous roll, the first and second layers of web stock positioned on top of each other and bonded together only along their respective edges.

Other objects and features will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

To assist those of skill in the art in making and using the recyclable sachet of the described invention, reference is made to the accompanying figures, wherein:

FIG. 1 is a front elevational view of a conventional sachet;

FIG. 2 is a cross-sectional view (taken along line 2-2 of FIG. 1) of the conventional sachet of FIG. 1 showing material layers thereof;

FIG. 3 is a perspective view of a conventional sachet sealing and filling station;

FIG. 4 is a front elevational view of a recyclable sachet according to the described invention;

FIG. 5 is a cross-sectional view (taken along line 5-5 of FIG. 4) of the recyclable sachet of FIG. 4 showing material layers thereof;

FIG. 6 is front elevational view of another recyclable sachet according to the described invention;

FIG. 7 is a cross-sectional view (taken along line 7-7 of FIG. 6) of the recyclable sachet of FIG. 6 showing material layers thereof;

FIG. 8 is a front elevational view illustrating another configuration of the recyclable sachet of FIG. 4;

FIG. 9A is a perspective view of a first configuration of a sachet sealing and filling station according to the described invention;

FIG. 9B is a perspective view of a second configuration of the sachet sealing and filling station according to the described invention;

FIG. 10 is a perspective view showing additional aspects of the sachet sealing and filling station according to the described invention;

FIG. 11 is a perspective view of a roll of multi-layer stock for producing the recyclable sachets of the described invention; and

FIG. 12 is a flow diagram showing method steps for manufacturing a recyclable single-use sachet according to the described invention.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

It should be understood that the relative terminology used herein, such as “front”, “rear,” “left,” “top,” “bottom,” “vertical,” and “horizontal” is solely for the purposes of clarity and designation and is not intended to limit the invention to embodiments having a particular position and/or orientation. Accordingly, such relative terminology should not be construed to limit the scope of the present invention.

FIGS. 4 and 5 show a single-use recyclable sachet (hereinafter “sachet 110”) according to some embodiments of the described invention and are referred to jointly herein. More specifically, FIG. 4 is a front elevational view of the sachet 110 and FIG. 5 is a cross-sectional view (taken along line 5-5 of FIG. 4) of the sachet 110. As shown, sachet 110 can be configured to have a generally rectangular shape, however, sachet 110 can be configured in other shapes and sizes without departing from the spirit and scope of the described invention. Sachet 110 includes a body 112 formed from a first layer of material 120 disposed adjacent to a second layer of material 122, the layers 120, 122 folded about a fold line, indicated by dashed line 162, and provided with a peripheral seal 116. The first layer of material 120 is generally formed from a metal material (hereinafter “metal layer 120”) and the second layer of material 122 is generally formed from a thermoplastic material (hereinafter “plastic layer 122”) to provide barriers to moisture, oxygen, and odors. However, as will be understood by those of ordinary skill in the art, depending on the specific requirements of a particular application, sachet 110 can also be formed comprising an inner plastic layer and an exterior metal layer. A notch or slit 128 is disposed through the layers of sachet 110 in the area of the peripheral seal 116. The notch 128 functions as a stress concentrator to assist a user in opening and dispensing the contents of the sachet 110 by tearing away a portion thereof, along a tear line, indicated by dashed line 134.

As shown in FIG. 5, according to some embodiments, metal layer 120 and plastic layer 122 are folded about fold line 162 such that metal layer 120 defines an inner envelope 124, comprising adjacent portions 120a and 120b, and plastic layer 122 defines an outer envelope 126, comprising portions 122a and 122b, the outer envelope 126 being disposed around inner envelope 124. Peripheral seal 116 is formed between adjacent portions 120a and 120b of the inner envelope 124, proximate to the outside limit of each portion (e.g., top, bottom, and right edges of sachet 110, shown in FIG. 4) thereof. According to some aspects of the present disclosure, the seal 116 can be formed by an adhesive (not shown) disposed between adjacent portions 120a and 120b of the inner envelope 124.

According to other aspects of the described invention, peripheral seal 116 can additionally bond outer envelope 126 to inner envelope 124 (e.g., utilizing a single operation/process) along the same area as between adjacent portions 120a and 120b of the inner envelope 124. For example, according to some embodiments, peripheral seal 116 can be a heat seal formed by a “hot jaw” process commonly known to the art. As will be apparent to those of ordinary skill in the art, the “hot jaw” process is advantageous, and provides additional utility, when the inner envelope 124 is formed from a thermoplastic material or comprises an innermost thermoplastic layer disposed such that adjacent portions 120a, 120b will be self-adhering upon application of sufficient heat and pressure. According to the “hot jaw” process, adjacent portions 120a, 120b of inner envelope 124 and portions 122a, 122b of outer envelope 126 are compressed between heated jaws along the outside limit/edges of the sachet 110, melting the thermoplastic material of the inner envelope 124, thereby sealing or welding the adjacent portions 120a, 120b together, and bonding the outer envelope thereto.

According to other aspects of the described invention, peripheral seal 116 can be formed between adjacent portions 120a, 120b using a first process or operation (e.g., heat sealing, induction sealing, ultrasonic welding, etc.) and outer envelope 126 can be bonded to inner envelope 124 using a second process or operation (e.g., providing an adhesive between inner envelope 124 and outer envelope 126).

While the first and second layers of material 120 and 122 are shown in FIG. 5 as comprising single layers, it is contemplated by the described invention that any of the layers of material disclosed herein can comprise one or more sub-layers selected to enhance performance characteristics, such as printability, puncture resistance, burst strength, stiffness, chemical resistance, and moisture and oxygen barrier properties. For example, according to embodiments wherein exterior layer 122 is formed from, or comprises, metal, layer 122 can further include a low-density polyethylene and a polyester layer disposed on an outwardly-facing side of layer 122 of the sachet 110 for enhancing the printability of layer 122.

According to some embodiments, the inner envelope 124 of the sachet 110 can contain liquid, paste, powder, granular, and/or solid contents, such as medications, supplements, shampoos, toothpastes, lotions, cosmetics, condiments and the like. For example, in some embodiments, the contents can be a three-dimensional product, such as a tablet. According to some embodiments, the tablet comprises a contoured surface. According to some embodiments, the tablet can be sized from about 0.25 inches to about 0.75 inches in diameter. According to some embodiments, the thickness of the tablet is sized from about 0.1 inches to about 0.5 inches thick. According to some embodiments, the tablet is sized at about 0.5 inches in diameter and 0.25″ thick.

According to some embodiments, the tablet can be packaged in a sterile unit dose package, meaning a sterile individual sachet containing one tablet per sachet. According to some embodiments, the sterile unit dose package can be presented in a strip containing more than one unit dose package (see, e.g., FIG. 8). According to some embodiments, the strip is perforated so as to enable simple separation of each unit dose package from the other unit dose packages in the strip, described herein in connection with FIG. 8. According to some embodiments, the sterile unit dose package can be presented in a roll of sterile unit dose packages. According to some embodiments, the roll is perforated so as to enable simple separation of each unit dose package from the other unit dose packages in the roll.

FIGS. 6 and 7 show another embodiment of a single-use recyclable sachet (hereinafter “sachet 210”) according to the described invention and are referred to jointly herein. More specifically, FIG. 6 is a front elevational view of the sachet 210 and FIG. 7 is a cross-sectional view (taken along line 7-7 of FIG. 6) of the sachet 210. Sachet 210 differs from sachet 110, shown in FIGS. 4 and 5 and discussed hereinabove, in that sachet 210 is not formed by folding the layers of material upon themselves and thus, includes additional layers of material to create the inner and outer envelopes. As shown, according to some embodiments, sachet 210 can be configured to be of a generally rectangular shape, however, sachet 210 can be configured in other shapes and sizes without departing from the spirit and scope of the described invention. Sachet 210 includes a body 212 formed from a first layer of material 220, a second layer of material 222, a third layer of material 236, and a fourth layer of material 238 provided with a peripheral seal 216. The first and third layers 220, 236 are generally formed from a metal material (hereinafter “metal layer 220” and “metal layer 236”) and the second and fourth layers layer 222, 238 are generally formed from a plastic material (hereinafter “plastic layer 222” and “plastic layer 238”) to provide barriers to moisture, oxygen, and odors. However, as will be understood by those of ordinary skill in the art, depending on the specific requirements of a particular application thereof, sachet 210 can also be formed having inner plastic layers and exterior metal layers. A notch or slit 228 is disposed through the layers of sachet 210 in the area of the peripheral seal 216. The notch 228 functions as a stress concentrator to assist a user in opening and dispensing the contents of the sachet 210 by tearing away a portion thereof, along a tear line, indicated by dashed line 234.

As shown in FIG. 7, metal layers 220 and 236 are disposed adjacent to each other, defining an inner envelope 224, plastic layer 222 is disposed adjacent to metal layer 220, and plastic layer 238 is disposed adjacent to metal layer 236, plastic layers 222 and 238 defining an outer envelope 226. Peripheral seal 216 is formed between plastic layers 222 and 238, proximate to the outside limit of each layer (e.g., top, bottom, right, and left edges of sachet 210, shown in FIG. 6) thereof. According to some aspects of the present disclosure, the seal 216 can be formed by an adhesive (not shown) disposed between adjacent metal layers 220 and 236 of the inner envelope 224.

According to other aspects of the described invention, peripheral seal 216 can additionally bond outer envelope 226 to inner envelope 224 (e.g., utilizing a single operation/process) along the same area as between adjacent layers 220 and 236 of the inner envelope 224. For example, peripheral seal 216 can be a heat seal formed by a “hot jaw” process commonly known to the art. As will be apparent to those of ordinary skill in the art, the “hot jaw” process is advantageous, and provides additional utility, when layers 220 and 236 of the inner envelope 224 are formed from thermoplastic materials or comprise thermoplastic layers, and are arranged such that adjacent layers 220 and 236 will adhere to each other upon application of sufficient heat and pressure. According to the “hot jaw” process, adjacent layers 220 and 236 of inner envelope 224 and layers 222 and 238 of outer envelope 226 are compressed between heated jaws along the outside limits/edges of the sachet 210, melting the thermoplastic material of the inner envelope 224, thereby sealing or welding the adjacent layers 220 and 236 together, and bonding layers 222 and 238 of the outer envelope 226 thereto.

According to other aspects of the described invention, peripheral seal 216 can be formed between adjacent layers 220 and 236 using a first process or operation (e.g., heat sealing, induction sealing, ultrasonic welding, etc.) and the layers 222 and 238 of the outer envelope 226 can be bonded to the inner envelope 124 using a second process or operation (e.g., providing an adhesive between inner envelope 124 and the outer envelope 126).

While the first layer of material 220, second layer of material 222, third layer of material 236, and fourth layer of material 238 are shown in FIG. 7 as comprising single layers, it is contemplated by the described invention that any of the layers of material disclosed herein can be comprised of one or more sub-layers selected to enhance performance characteristics, such as printability, puncture resistance, burst strength, stiffness, chemical resistance, and moisture and oxygen barrier properties. For example, according to embodiments wherein the layers 222 and 238 of exterior envelope 226 are formed from, or comprise, metal, one or more of layers 222 and 238 can further include a low-density polyethylene and a polyester layer disposed on an outwardly-facing side of the sachet 210 for enhancing the printability thereof.

The recyclable sachets of the described invention can be provided in multiple configurations. For example, as shown in FIG. 8, one or more sachets of the described invention can be joined together in a continuous strip, sheet, or roll. More specifically, FIG. 8 shows a multi-envelope recyclable sachet 310 including two sachets 110, shown in FIGS. 4 and 5, joined together along their respective lower and upper edges. Additionally, a perforated tear line, illustrated by dashed line 340, can be provided between sachets 110 to assist a user in separating the sachets from each other. Of course, the multi-envelope sachet 310 can be provided in various other configurations without departing from the spirit and scope of the described invention, and is thereby not limited to the vertically arranged configuration shown in FIG. 8.

As discussed in connection with FIGS. 4-7 above, according to some embodiments, the peripheral seal (and thereby the bond between the inner envelope and outer envelope) is only provided proximate to the edges of the sachet (see, for example, peripheral seals 116 and 216 shown in FIGS. 4 and 6, respectively). Accordingly, as shown in connection with FIGS. 4-7, adjacent surfaces of the inner envelope and outer envelope are not necessarily bonded together. However, as discussed in greater detail below, it is also contemplated that the sachets of the present disclosure can be formed from a single multi-layer laminate (e.g., having inner and outer envelopes bonded together) comprising materials selected to enhance recyclability, biodegradability, and/or compo stability.

According to some embodiments, because adjacent surfaces of the inner envelope and outer envelope are not bonded together, a user can separate the individual layers of the single-use sachets disclosed herein, once the contents thereof are dispensed without requiring additional assistance, such as by mechanical and/or chemical separation means. For example, returning to FIGS. 4 and 5, after tearing away a portion of the sachet 110 along tear line 134, the inner envelope 124 is exposed, as shown in FIG. 5. At this point, the inner envelope 124 and the outer envelope 126 can be grasped and separated by, for example, pulling the envelopes away from each other. A similar separation procedure can be employed to sachet 210, shown in FIGS. 6 and 7. According to some embodiments, the ability to separate the individual layers of the sachets disclosed herein without difficulty, e.g., by mechanical and/or chemical separation means facilitates recycling of the sachets in developing countries and emerging markets where sophisticated recycling facilities are unavailable and human labor is required for the separation of recyclable materials.

According to some embodiments, the foil layer is laminated to the outer, thicker polymer layer. According to some embodiments, the laminate comprises a biodegradable or compostable additive. According to some embodiments, the foil and paper pulp can comprise paperboard, a renewable material made from wood. For example, laminated cartons used to store liquids such as milk and orange juice, composed of Tetra Pak® packaging materials, which are made up of paperboard (73%), plastic (22%) and aluminum foil (5%), have a shelf life of up to a year.

According to some embodiments, sachets can be created utilizing a natural Kraft paper (brown or white) with a foil and LDPE. The packaging can be recycled by separating the paper and foil through a process called “hydro-pulping” wherein machines create a swirling effect within a chamber filled with water and separate out the paper and aluminum. A percentage of juice cartons are currently being recycled in the US through this process. Other examples of paper laminates include those disclosed in WO/2018/178070, which is incorporated by reference herein.

Other examples of materials that can be used for the sachets of the present disclosure include non-toxic, bio-based (meaning derived from plants and other renewable, e.g., agricultural, marine and forestry, materials) sealant web layers, which can make the sachets 100% compostable and environmentally friendly. Additionally, non-toxic bio-based water-based sealant layers can also be used to make the sachets 100% compostable and environmentally friendly.

According to some embodiments, the layers that form each of the inner and outer envelopes can further comprise one or more sub-layers selected to enhance performance characteristics, recyclability and/or compostability.

As described hereinabove, the sachets of the present disclosure can include an outer envelope generally formed from one or more layers of a thermoplastic material (meaning an organic material that melts when heated), and an inner envelope generally formed from one or more layers of a metal material. The layers that form each of the inner and outer envelopes can further comprise one or more sub-layers selected to enhance performance characteristics and/or recyclability.

According to some aspects of the present disclosure, one or more of the layers of the sachet can be biodegradable (meaning a natural chemical process in which materials are transformed into natural substances such as water, carbon and biomass with the help of microorganisms) and/or compostable (a characteristic of a product that enables biodegradation under specific conditions (i.e., a certain temperature, time frame, etc.).

For example, the outer plastic envelope can be generally formed from a polymer (e.g., polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) polyvinyl chloride (PVC), etc.) including organic additives effective to accelerate the biodegradation process of plastic products in a biologically active landfill. According to some embodiments, the additives do not require either UV light or oxygen to enhance biodegradation. According to some embodiments, the additives comprise an organoleptic (meaning a substance perceived by the sense organs) that meets FDA compliance for food contact. According to some embodiments, a “food contact substance” is any substance intended for use as a component of materials used in manufacturing, packing, packing, packaging, transporting, or holding food that is not intended to have any technical effect in such food. Examples of food contact substances include a single substance, such as a polymer or an antioxidant in a polymer, which is reasonably pure. The term “food contact material” as used herein is often, but not necessarily, a mixture, such as an antioxidant in a polymer. According to some embodiments, the organoleptic is a color additive, meaning a dye, pigment or other substance mad by a process of synthesis or similar artifice, or extracted, isolated, or otherwise derived, with or without intermediate or final change of identity, from a vegetable, animal, mineral, or other source that when added is capable, alone or through reaction with other substance, of imparting color thereto. According to some embodiments, the organoleptic is a colorant, meaning a dye, pigment, or other substance that is used to impart color to or to alter the color of a food-contact material, but that does not migrate to food in amounts that will contribute to that food any color apparent to the naked eye. The term ‘colorant’ includes substances such as optical brighteners and fluorescent whiteners, which may not themselves be colored, but whose use is intended to affect the color of a food-contact material. According to some embodiments, the additives work by expanding the molecular structure of polymers, making room for microbes to colonize within the polymer chain and send out chemical signals to attract other microbes. According to some embodiments, the microbes join together to feast on polymer chains, breaking down chemical bonds and accelerating biodegradation. According to some embodiments, the additive breaks down otherwise non-biodegradable plastic into non-toxic inert biomass (humus), methane and carbon dioxide.

According to some embodiments, the additives do not negatively affect the manufacturing process and are available in forms specific for use, for example, in EVA, EVOH, HDPE, LDPE, LLDPE, PET, PETG, HIPS, GPPS, PP, polycarbonate, rubber and nylon. The additives are also compatible with certain grades of TPE, TPU and polystyrene.

According to some embodiments, the additives can comprise approximately 0.5%-4.0% by weight, i.e., about 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, 2.6%. 2.7%, 2.8%, 2.9% 3%, 3.1%, 3.2%, 3.3%, 3.4%, 3.5%, 3.6%, 3.7%, 3.8%, 3.9%, or 4%, of the plastic material. According to some embodiments, 2% additive is effective in achieving 80% aerobic biodegradability in 180 days, and 90% aerobic biodegradability in 255 days on a 1.25 mil thick film.

According to some embodiments, a biodegradable 1.50 mil white HDPE film layer that provides a high barrier with metalizing and EVOH (Ethylene-Vinyl Alcohol Copolymer) can be used. The film can be folded in half and sealed on 3 sides to form a sachet. By not utilizing the traditional foil layer laminated to the outer polymer, the sachet can be entirely recycled. If the sachet does not make it into the waste collection process or make it to the recovery material plants, it will decompose. The material only requires the presence of microbes and time to decompose, meaning that any plastic—films, tubs, bottles, jars, pouches, sachets, etc. won't break down on shelves. While some eco plastics require specific conditions—such as sunlight and high temperatures—to biodegrade in oceans, lakes, soil, home composts, landfills, swamps, forests, etc., the material reverts to its original elements harmlessly, quickly and completely and is beneficial to plant growth. The technology, which provides an ultra high barrier that is moisture resistant, puncture resistant and flex-crack resistant, includes such materials as biaxially-oriented polyethylene terephthalate (BOPET), biaxially-oriented polypropylene (BOPP), bi-axially oriented polyamide (BOPA), (metallized or clear), one way valves, also PE, PA, PS, EPS, bio-foil (meaning a packaging foil made from a biological rather than a plastic material).

According to some embodiments, the additive comprises one or more PETase enzymes isolated from Ideonella sakaiensis, a bacteria that can live on poly(ethylene terephthalate). (See Seo, H., et al, “Biochemical & Biophys. Res. Communic. (available on-line 24 Nov. 2018) 508(1): 250-255). According to some embodiments, a silicon oxide (SiOx) coating can be applied to a PET film (e.g., a polyester film, e.g., polyethylene terephthalate (PET), polyolefin film, polypropylene film, polyethylene film), offering the same barrier properties as a foil layer. By laminating the SiOx coated film to a similar polymer the packaging can be recycled.

According to some aspects of the described invention, one or more of the layers of the sachet can comprise a recyclable molded pulp component, made from a mixture ground scrap paper and water, that is vacuum formed to a mold and then dried. The molded pulp component can be provided with one or more barrier layers, such as those described hereinabove. According to other aspects of the described invention, the molded pulp component can be provided with a bioplastic primarily comprised of polylactic acid and/or starch and mixed with compostable polyesters. The bioplastic, which is biologically degradable and compostable, if burnt, generates less carbon dioxide over its lifecycle than oil-based plastics, and can replace plastic and/or foil barrier layers used, for example, in packaging for food and hygiene products.

Further, while exemplary aspects of the sachet have been described herein, it is expressly noted that specific aspects should not be construed as limiting, but rather that additions and modifications to what is expressly described herein also are included within the scope of the invention. For example, any of the disclosed additives can be utilized in combination with any of the disclosed sachet materials and vice versa.

According to some embodiments, the sachets of the described invention are shelf stable at room temperature (20°−25° C.) at a relative humidity (meaning the amount of water vapor present in air expressed as a percentage of the amount needed for saturation at the same temperature) of from about 30% to about 55%, for at least 3 months, at least 4 months, at least 5 months, at least 6 months, at least 7 months at least 8 months, at least 9 months, at least 10 months, at least 11 months, at least 12 months. According to some embodiments, the sachets of the described invention are shelf stable at room temperature (20°-25° C.) at a relative humidity of from about 30% to about 55% for at least 6 months.

The described invention also relates to systems for manufacturing the recyclable single-use sachet of the described invention. FIGS. 9A-10 show a sachet sealing and filling station (hereinafter “filling station 430”) according to the described invention and are referred to jointly herein. More specifically, FIG. 9A is a perspective view of a first configuration of the filling station 430, FIG. 9B, is a perspective view of a second configuration of the filling station 430, and FIG. 10 shows filling and sealing elements of the filling station 430.

As shown, the filling station 430 includes a support bracket 442 for supporting a roll of plastic web stock 450 and a roll of metal web stock 452. The support bracket 442 can include a bracket extension 448 for supporting the roll of plastic web stock 450. As shown in FIG. 9A, the support bracket 442 can be configured with an upper end comprising angled configuration 444 for supporting the roll of metal web stock 452. Alternatively, as shown in FIG. 9B, the support bracket 442 can be configured with an upper end comprising a straight configuration 446 for supporting the roll of metal web stock 452. A plurality of rollers 432 are provided to draw the web stock 450 and 452 from their respective rolls. A guide ring 454 is configured to fold the web stock 450 and 452 into the shape of a sachet disclosed herein (see, for example, sachet 110 shown in FIGS. 4 and 5). Means for sealing the sachets 456, for example, “hot jaws,” means for filling the sachets (not shown), for example, a nozzle, tube, or the like, and means for cutting or separating the filled and sealed sachets (not shown) from one another, for example, a pneumatic blade, sheers, “hot wire,” or the like, are also provided.

FIG. 11 is a perspective view of a continuous roll of multi-layer web stock, indicated generally at 514, for producing a recyclable single-use sachet using currently available sealing and filling stations, for example, the sealing and filling station 30 described in connection with FIG. 11 above. The roll of multi-layer web stock 514 includes a first layer 520 formed from a thermoplastic material and a second layer 522 formed from a metal material. The first layer 520 and second layer 522 are bonded together along areas, shown by dashed lines 560, proximate to their respective edges and spanning the entirety of the length of the continuous roll of multi-layer web stock 514. Adjacent surfaces of the first layer 520 and the second layer 522 between the bonded areas 560 are not bonded together. Accordingly, the continuous roll of multi-layer web stock 514 can be placed into the filling station 30 without any modification thereto to produce a recyclable single-use sachet according to the described invention, for example, sachet 110 described in connection with FIGS. 4 and 5.

FIG. 12 is a flow diagram, indicated generally at 610, showing method steps for manufacturing a recyclable single-use sachet according to the described invention. In step 612, a first continuous roll of web stock is provided. The first continuous roll of web stock can be, for example, a thermoplastic film similar to the roll of plastic web stock 450, shown in FIGS. 9A and 9B. In step 614, a second continuous roll of web stock is provided. The second continuous roll of web stock can be, for example, similar to the roll of metal web stock 452, shown in FIGS. 9A and 9B. In step 616, the first and second rolls of web stock are simultaneously fed through a guide ring (see, for example, guide ring 454 of FIG. 10) which folds the layers of web stock into the configuration of a sachet having an inner envelope and an outer envelope, such as sachet 110 shown in FIGS. 4 and 5. In step 618, a longitudinal seal is formed along an edge opposite to the fold and in step 620, a lower transverse seal is formed, thereby providing a sachet body that is closed on three sides (e.g., a folded side, an opposite sealed side, and a bottom sealed side). In step 622, the inner envelope is filled through the open, unsealed, top side with product to be dispensed and in step 622, an upper transverse seal is formed, thereby completely enclosing the product within the sachet. The seals formed in the foregoing steps are formed between adjacent portions of the web material, such as seal 116 shown in FIG. 5. As described above, the seal can be formed by a “hot jaw” process commonly known to the art, whereby the plastic layers of the inner envelope and the metal layers of the outer envelope are compressed between heated jaws along edges of the sachet, melting thermoplastic material of the inner envelope, thereby welding the plastic layers together, and bonding the outer envelope thereto. Alternatively, according to other aspects of the described invention, the outer envelope can be bonded to the inner envelope, along the edges thereof, in an additional step. For example, instead of using the residual heat of the “hot jaw” method to bond the outer envelope to the inner envelope, a layer of adhesive can be applied between the layers of web stock, proximate to, and along, the outside limits (e.g., along the lateral edges) of the layers to bond the outer envelope to the inner envelope. The adhesive, or other binding agent suitable for bonding the inner and outer envelopes, can be applied before the sealing operations described in steps 618 and 620 herein, or after. Other means of sealing such as, for example, heat sealing, induction sealing, ultrasonic welding, and the like can also be employed without departing from the spirit and scope of the described invention. Finally, in step 626, the filled and sealed sachet is separated from the rolls of web stock, thereby forming an individual single-use recyclable sachet.

As described above, the sachets of the present disclosure can be configured to be of a generally rectangular shape as well as to comprise other shapes, sizes, and configurations, without departing from the spirit and scope of the described invention. For example, in addition to the generally flat and rectangular single-use sachets described hereinabove in connection with FIGS. 4-8, the sachets of the present disclosure can also be configured as larger multiple-use (e.g., resealable) bags, standup pouches, and the like, suitable for a variety of applications, such as for example, in connection with food, hygiene, and cleaning products (e.g., laundry detergent/pods).

While exemplary embodiments have been described herein, it is expressly noted that these embodiments should not be construed as limiting, but rather that additions and modifications to what is expressly described herein also are included within the scope of the invention. Moreover, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations, even if such combinations or permutations are not made express herein, without departing from the spirit and scope of the invention.

Claims

1. A recyclable single-use sachet, comprising:

a first layer of material folded about a fold line, thereby forming an inner envelope;

a second layer of material positioned adjacent to the first layer of material, the second layer of material folded about the fold line, thereby forming an outer envelope;

a peripheral seal formed between adjacent portions of the inner envelope;

an organic additive effective to facilitate biodegradation in a biologically active landfill; and

the outer envelope being bonded to the inner envelope.

2. The recyclable single-use sachet of claim 1, wherein the first material is a metal.

3. The recyclable single-use sachet of claim 1, wherein the second material is a polymer selected from polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) polyvinyl chloride (PVC).

4. The recyclable single-use sachet of claim 1, wherein the peripheral seal is a heat seal.

5. The recyclable single-use sachet of claim 1, wherein the outer envelope being bonded to the inner envelope is only along peripheral edges thereof.

6. The recyclable single-use sachet of claim 4, wherein the outer envelope is bonded to the inner envelope by the heat seal.

7. The recyclable single-use sachet of claim 1, wherein the outer envelope is bonded to the inner envelope by an adhesive disposed therebetween.

8. The recyclable single-use sachet of claim 1, further comprising a notch disposed through a peripheral edge of the sachet, the notch configured to allow a portion of the sachet to be torn therefrom.

9. A recyclable single-use sachet, comprising:

an inner envelope formed from first and second layers of a first material;

an outer envelope formed from first and second layers of a second material;

a peripheral seal formed between the first and second layers of the inner envelope;

an organic additive effective to facilitate biodegradation in a biologically active landfill; and

the outer envelope being bonded to the inner envelope.

10. The recyclable, single-use sachet of claim 9, wherein the first material is a metal.

11. The recyclable, single-use sachet of claim 9, wherein the second material is a polymer selected from polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) polyvinyl chloride (PVC).

12. The recyclable, single-use sachet of claim 9, wherein the first layer of the outer envelope is bonded to the first layer of the inner envelope only along peripheral edges thereof.

13. The recyclable, single-use sachet of claim 9, wherein the second layer of the outer envelope is bonded to the second layer of the inner envelope only along peripheral edges thereof.

14. The recyclable, single-use sachet of claim 9, wherein the inner envelope of the sachet contains liquid, paste, powder, granular, or solid contents.

15. The recyclable, single-use sachet of claim 14, wherein the solid contents comprise a three-dimensional tablet.

16. A method of manufacturing a recyclable, single-use sachet, comprising the steps of:

providing a first layer of web stock formed from a first material;

providing a second layer of web stock formed from a second material;

wherein the second material comprises an organic additive effective to facilitate biodegradation in a biologically active landfill; simultaneously feeding the first layer of web stock and the second layer of web stock, the second layer of web stock positioned adjacent to the first layer of web stock;

folding the first and second layers of web stock about a fold line so that the first layer of material forms an inner envelope and the second layer of material forms an outer envelope;

filling the inner envelope with a product;

sealing the inner envelope along the periphery thereof; and

bonding the outer envelope to the inner envelope.

17. The method of claim 16, wherein the first material is a metal.

18. The method of claim 16, wherein the second material is a polymer selected from polystyrene (PS), polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) polyvinyl chloride (PVC).

19. The method of claim 16, wherein the step of sealing the inner envelope comprises forming a heat seal.

20. The method of claim 16, comprising bonding the outer envelope to the inner envelope by the heat seal.

21. The method of claim 16, comprising bonding the outer envelope to the inner envelope only along peripheral edges thereof.

22. The method of claim 16, wherein the step of bonding outer envelope to the inner envelope comprises disposing an adhesive therebetween.

23. The method of claim 16, further comprising the step of separating the sachet from the first and second layers of web stock.

24. The method of claim 16, further comprising the step of cutting a notch through a peripheral edge of the sachet, the notch configured to allow a portion of the sachet to be torn therefrom.

25. The method of claim 16, wherein the step of folding the first and second layers of web stock further comprises feeding the first and second layers of web stock through a guide ring.

26. The method of claim 16, wherein the first and second layers of web stock are provided together on a single continuous roll, the first and second layers of web stock positioned on top of each other and bonded together only along their respective edges.