US-12623801-B2 - Apparatus and method for producing tubular packages

US12623801B2US 12623801 B2US12623801 B2US 12623801B2US-12623801-B2

Abstract

Apparatus ( 10 ) for producing tubular packages includes a packaging material dispenser ( 12 ) and a forming section ( 20 ). The forming section ( 20 ) comprises a progressive folding region ( 26 a, FIG. 8 ) having a plurality of discrete, elongate external guide surfaces ( 50, 52, 54, 56 ) extending generally in the machine direction (A). The elongate external guide surfaces are spaced apart from one another and configured for contact with an outer surface of the packaging material so as to progressively guide and fold the packaging material about a longitudinal axis from a planar configuration into a tubular structure. The elongate guide surfaces may be arcuate and may be provided by means of guide rods. The apparatus may be a horizontal or vertical form, fill seal type apparatus. The packaging material ( 14 ) may be a semi-rigid packaging material such as paperboard, cartonboard, or semi-rigid plastics.

Inventors

Kevin Ferris
Daniel Bortos
Leesha Muman
Ben Thistleton
Phillip Loxley
Colin Bosworth

Assignees

INTERCONTINENTAL GREAT BRANDS LLC

Dates

Publication Date: 20260512
Application Date: 20200204
Priority Date: 20190227

Claims (20)

1 . An apparatus for producing tubular packages sequentially from an initially generally flat, substantially continuous length of packaging material, each package enclosing one of a series of items conveyed through the apparatus in a machine direction in use, the apparatus comprising: a packaging material dispenser arranged to dispense a substantially continuous length of packaging material and convey the material in the machine direction; a forming section through which the packaging material is conveyed in the machine direction, the forming section being configured to fold the packaging material from an initially flat configuration into a tubular package structure, the forming section being a progressive folding region defined by a plurality of discrete, elongate external guide surfaces extending spaced apart from one another and configured to come in contact with an outer surface of the packaging material so as to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the packaging material passes through the progressive folding region; and guide members which define the elongate external guide surfaces, wherein at least some of the guide members are supported by a plurality of plates provided along the progressive folding region, each of the plurality of plates having an aperture through which the packaging material and items to be packaged pass, wherein the plurality of plates comprises a first plate having a first aperture and a second plate having a second aperture, wherein the first plate and the second plate are parallel to each other and spaced apart along the progressive folding region, wherein the first aperture and the second aperture are different in shape, and wherein at least some of the guide members are positioned within the aperture of each of the plurality of plates and are spaced apart along a perimeter of the aperture of each of the plurality of plates.
2 . The apparatus as claimed in claim 1 , wherein, when considered from an upstream end to a downstream end, at least some of the external elongate guide surfaces may be angled laterally inwardly and in a direction perpendicular to the machine direction.
3 . The apparatus as claimed in claim 1 , wherein at least one of the guide members comprises a cylindrical rod.
4 . The apparatus as claimed in claim 1 , wherein the elongate external guide surfaces are configured to define a cage or funnel through which the packaging material is passed in use.
5 . The apparatus as claimed in claim 1 , the apparatus further comprising an item conveyancing arrangement for conveying a series of items to be packaged in the machine direction and sequentially positioning each item proximal to the packaging material at a location such that, in use, inserted items are conveyed through at least part of the progressive folding region between the elongate external guide surfaces, with the packaging material positioned between the items and the elongate external guide surfaces.
6 . The apparatus as claimed in claim 1 , wherein the forming section comprises at least one package former, the, or each, package former defining a packaging material folding channel through which the packaging material is conveyed, the folding channel of the, or each, of the package formers being shaped to fold the packaging material about said longitudinal axis as it passes towards and through the folding channel in use.
7 . The apparatus as claimed in claim 6 , wherein at least one package former is located upstream of the progressive folding region in the machine direction and is configured to fold side regions of the packaging material out of the plane of the initially flat packaging material.
8 . The apparatus as claimed in claim 1 , wherein the apparatus is configured to package generally block shaped items having opposed first and second major faces and opposed sides, the progressive folding region comprising at least one first elongate external guide surface configured for holding the packaging material proximal the first major face of items conveyed through the progressive folding region and a pair of second elongate external guide surfaces, each second elongate external guide surface configured to hold a portion of the packaging material proximal one of the opposed sides of the items.
9 . The apparatus as claimed in claim 8 , wherein the progressive folding region further comprises a pair of third elongate external guide surfaces, each third elongate external guide surface being configured to progressively fold a respective side region of the packaging material into close proximity with the second major face of the items as the packaging material and items traverse from an upstream end of the progressive folding region to a downstream end.
10 . The apparatus as claimed in claim 8 , wherein the apparatus is configured to produce packages in which outer lateral edge regions of the packaging material are sealed together to form a longitudinal fin seal, the apparatus comprising a guide arrangement at a downstream end of the progressive folding region for holding the outer lateral edge portions of the packaging material in close proximity.
11 . The apparatus as claimed in claim 1 , wherein the progressive folding region extends over a length in the machine direction of 1 m or more.
12 . The apparatus as claimed in claim 1 , wherein the apparatus is configured such that at least part of the packaging material travels through the entire forming section in a substantially constant plane substantially parallel with said longitudinal axis.
13 . The apparatus as claimed in claim 1 , wherein the packaging material is a semi-rigid packaging material.
14 . The apparatus as claimed in claim 1 , wherein the guide members are configured to support the packaging material and items to be packaged without a conveyor.
15 . A method of producing tubular packages sequentially from an initially generally flat, substantially continuous length of packaging material, each package enclosing one of a series of items which are conveyed in a machine direction, the method comprising: dispensing a substantially continuous length of packaging material and conveying the packaging material in the machine direction; and, folding the packaging material into a tube-like structure by passing the packaging material through a forming section in a machine direction, the forming section being configured to fold the packaging material from initially flat configuration into a tubular package structure, wherein the forming section being a progressive folding region defined by a plurality of discrete, elongate external guide surfaces extending spaced apart from one another and configured to come in contact with an outer surface of the packaging material so as to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the packaging material passes between the guide surfaces, wherein guide members define the elongate external guide surfaces, and wherein at least some of the guide members are supported by a plurality of plates along the progressive folding region, each of the plurality of plates having an aperture through which the packaging material and items to be packaged pass, wherein the plurality of plates comprises a first plate having a first aperture and a second plate having a second aperture, wherein the first plate and the second plate are parallel to each other and spaced apart along the progressive folding region, wherein the first aperture and the second aperture are different in shape, and wherein at least some of the guide members are positioned within the aperture of each of the plurality of plates and are spaced apart along a perimeter of the aperture of each of the plurality of plates.
16 . The method as claimed in claim 15 , wherein the packaging material is a semi-rigid packaging material.
17 . The method as claimed in claim 15 , wherein the packaging material comprises any one or more selected from the group comprising: paperboard, cartonboard, cardboard, or a semi-rigid plastics.
18 . The method as claimed in claim 15 , wherein the method comprises conveying items to be packaged through the progressive folding region with the packaging material located between the items and the elongate external guide surfaces.
19 . The method as claimed in claim 15 , wherein the method comprises maintaining at least part of the packaging material in a substantially constant plane as it passes through the forming section.
20 . The method as claimed in claim 15 , wherein the guide members are configured to support the packaging material and items to be packaged without a conveyor.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a National Stage application of PCT/IB2020/000033, filed Feb. 4, 2020, which claims the benefit of GB Application No. 1902605.3, filed Feb. 27, 2019, both of which are incorporated by reference in their entirety herein. TECHNICAL FIELD OF THE INVENTION The present invention relates to apparatus and methods for packaging. The apparatus and methods are especially, but not exclusively, suitable for packaging items in tubular packaging made from a semi-rigid packaging material, such as paperboard, cartonboard, and semi-rigid plastic, in a substantially continuous process. BACKGROUND TO THE INVENTION It is known to provide so-called flow-wrap packaging which consists of a flexible tubular container closed at either end, normally with crimping or embossing to provide patterned transverse sealing portions. In general, this type of flow-wrap packaging is manufactured by horizontal or vertical form, fill and seal processes (HFFS or VFFS). In HFFS processes, a flexible packaging film is run through machinery which folds the material around an item and then clamps and seals the ends of the folded material followed by cutting, to provide a sealed packaging. Such packaging can be run through appropriate machinery relatively rapidly, in order to produce many filled packages per minute. Examples of such machinery include the Pack 401 Horizontal Flow Wrapper supplied by Bosch GmbH, Germany and the Horizontal Form Fill Seal Packaging Machine 8000 MH supplied by Ossid, USA. The flexible films conventionally used for flow-wrap packaging generally comprise polymeric materials and are relatively strong, resistant to tearing, highly flexible, and with low dead-fold properties. The known HFFS or VFFS processes and apparatus have been developed to take advantage of these characteristics in wrapping the film about the item being packed and sealing the package. In a typical arrangement, a continuous length of film is drawn from a roll on to a former. The film engages the former on one side and is drawn along the former conforming to its shape. The shape of the former gradually changes along its length and is configured so that the film is directed to move in the machine direction and folded into a tube-like structure as it passes over the former. The item being packaged is introduced into the partially folded packaging film so that the film is wrapped about the item and overlapping longitudinally extending lateral edge regions are sealed together to form a longitudinal seal. Opposed regions of the film are sealed together at either end of the item to form transverse end seals and each package is cut to separate it from the length of film. In some arrangements, it is the inner surface of the film (that is to say the surface which is directed toward the item once the packaging is formed) that engages with the shaped former whilst in others it is the outer surface of the film which engages the former. The known HFFS flow-wrap arrangements are particularly suitable for packaging items that are substantially rigid. Products such as candy and chocolate bars and other food products which are rigid at the temperatures encountered during packaging are often packaged in this manner. Flowable products can also be flow-wrapped using HFFS arrangements if they are first placed in a generally rigid inner container and the flow-wrapped package formed about the filled container. The term “rigid” in this context should be understood as meaning that the item maintains its shape during packaging rather than being flowable. Looked at another way, it can be said that “rigid” items are generally dimensionally stable during packaging. In a typical HFFS arrangement, the packaging film is drawn down on to the former from above at an oblique angle to the horizontal and the former turns the material on to a horizontal flow path whilst also folding or wrapping it longitudinally to form a tube about the item being packaged. This requires the material to be folded in multiple directions or planes at the same time. Whilst this is achievable with the highly flexible polymeric films typically used in flow-wrap packaging, it presents difficulties with semi-rigid materials having greater dead-fold properties as the material will tend to bulge and crease undesirably if folded by a significant amount in more than one direction or plane at the same time. It would therefore be advantageous to provide apparatus for packaging a series of items in packages produced sequentially from a substantially continuous length of packaging material suitable for use with a broader range of packaging materials. It would be particularly advantageous to provide apparatus for packaging a series of items in packages produced sequentially from a substantially continuous length of packaging material suitable for use with packaging materials comprising paperboard, cartonboard, semi-rigid plastics or other semi-rigid packaging materials