ES2999085T3 - Packaging insert - Google Patents

Abstract

An insert for a fluid wrap packaging assembly has a bottom wall (18) and a peripheral wall (20) extending from said bottom wall to define an interior volume (21) for containing the product (14). The insert has a tab (20) at an upper end of the peripheral wall that is movable between a closed position in which it at least partially closes the interior volume at the upper end of the insert and an open position in which it does not impede access to the interior volume. The insert (12) is top-fillable when in an upright position with the tab open and then movable to a horizontal orientation for fluid wrap using an HFFS process with the tab closed to prevent the contents from spilling out. The insert is particularly suitable for allowing a plurality of disc-shaped products, such as beverage tablets, to be fluid wrapped using HFFS processes. (Automatic translation with Google Translate, no legal value)

Description

DESCRIPTION

Packaging piece

Technical field of the invention

The present invention relates to packaging. The invention relates in particular to a part [insert] for assembling a flow-wrap packaging, to a continuously packaged packaging assembly comprising the part, and to the process for producing a continuously packaged packaging assembly comprising the part.

Background of the invention

It is well known to provide beverage ingredients in a container that can be inserted into a compatible beverage preparation machine to prepare a beverage. Generally, a beverage container contains sufficient ingredients to produce a single serving of the desired beverage, such as filter coffee, espresso, Americano, cappuccino, latte, and the like. These beverage ingredient containers are frequently referred to as "pads" [soft pods] or "discs." For convenience, the term "soft beverage pod" will be used herein. However, the invention is applicable to the packaging of many different types of such beverage containers and, indeed, can be used to package a variety of different products, especially when several products are to be packaged together.

A known type of soft beverage pod consists of a pre-dosed beverage ingredient portion contained between two disc-shaped layers of flexible material, such as filter paper. The layers are usually sealed together around their peripheries, creating a closed ingredient cake or pod. Such soft beverage pods are suitable for use in coffee machines that can operate at pressurized and/or atmospheric pressure. In use, the soft beverage pod is placed in a holder, which is then closed with a lid. Hot water is supplied to the top of the soft beverage pod such that the hot water passes through the soft beverage pod to form the beverage, which exits the container through an outlet. In an alternative known arrangement, a soft beverage pod comprises a rigid concave cover whose upper end is closed by a first sheet of flexible material. A second sheet of flexible material is located at the base of the cover, and the beverage ingredient is located between the first and second flexible sheets. The cover defines a fluid outlet and one or more fluid conduits in its base. The flexible sheets are typically a filter material that allows water to pass through the soft pod and the beverage ingredient. This type of soft pod is used similarly to the first type described above, but is less prone to damage or improper insertion into a machine. The cover can be made of a polymeric material or a cardboard or paperboard-type material, and the soft pod is typically disc-shaped.

While coffee is the most common beverage ingredient used in soft drink pods, other ingredients or a blend of ingredients, such as powdered milk and/or tea, can also be used. For some beverages, two soft drink pods containing different ingredients can be used sequentially. To prepare a latte, for example, it is common to use one soft drink pod containing the coffee ingredients and another containing powdered milk. In this case, each soft drink pod contains only a proportion of the ingredients needed for a single portion.

Because the ingredients contained in soft drink pods are perishable, it is common to package multiple soft drink pods together in a hermetically sealed package made of flexible, gas-impermeable film to keep the ingredients fresher for longer. In one known arrangement, the soft drink pods are packaged in a pouch or bag made using a vertical form-fill-seal (VFFS) process. VFFS is a well-known packaging method in which a packaging film is taken from a roll and folded around a mold to form a vertically aligned tube. Opposite longitudinal edges of the film are sealed together to produce a longitudinal seal, frequently positioned at the rear of the package. Opposite portions of the film tube are sealed together at the base of the package to form a first transverse seal, and the soft drink pods fall by gravity from a hopper into the partially sealed package. The package is then closed by forming a second transverse seal at the top, above the contents, and the film is cut to separate the filled package. This process is repeated in a substantially continuous manner to produce multiple filled packages at a relatively high rate.

With the VFFS process, it is not possible to form the pack tightly around soft beverage pods, as a certain amount of headspace (the unfilled volume of the product, sometimes referred to as "headspace") is required to allow for gas and/or air evacuation from the pack when it is filled and to prevent any of the soft pods from becoming lodged between opposing layers of film material when the filled pack is sealed. Because the pack is larger than strictly necessary to contain the products, it can be argued that this packaging method uses excess film material. This affects the cost of the packaging and has environmental consequences, including a larger than necessary carbon footprint. The fairly loose fill also results in a pack that may have stability issues when the pack is placed upright on a shelf for display purposes.

Because soft drink pods are not tightly packaged in VFFS packaging, they can shift within the packaging and become damaged. Damaged soft drink pods have an inferior appearance, leading to low consumer acceptance and, therefore, low customer satisfaction. There is also a risk that damaged soft drink pods may tear and/or split open in the packaging, releasing the beverage ingredient, which may spill when the package is opened. This negatively impacts the consumer experience. Damage to soft drink pods can also cause brewing issues. For example, damage to a soft drink pod can lead to preferential paths forming through the cake or dose of the beverage ingredient (called "drift"), which could result in partial extraction of the ingredient and, consequently, poor in-cup quality of the extracted beverage.

Another well-known process for producing a package made of flexible film is horizontal form-fill-seal (HFFS), or continuous wrapping. In the HFFS process, the product to be packaged passes through a wrapping area in a generally horizontal path. The packaging film is stretched from a roll to a die, which guides the film into a tubular shape around the product. Opposite longitudinal edges of the film are sealed together to produce a longitudinal seal, often positioned at the rear of the package. Opposite portions of the film tube are sealed together to form transverse seals at each end of the product to close the wrapper. The end seals can be formed sequentially or simultaneously. The HFFS process is typically used to package solid products, such as chocolate bars and blocks of cheese, and the like, and the film is stretched tightly around the product, minimizing headspace.

While HFFS is frequently used to package individual solid products, HFFS can be used to package multiple products by supporting the products in a tray-shaped form and forming a fluidly wrapped wrapper around the tray and the products. For example, it is known to use HFFS processes to package a stack of cookies by placing the stack on its side in a tray made of paperboard or similar and then fluidly wrapping the tray and the stack of cookies. The tray typically has an elongated base with opposing side walls and opposing end walls to define a volume in which the cookies are placed. Once opened, the cookies are removed from the tray and stored elsewhere, for example, in a cookie pan, or dispensed from the tray, which must generally be kept horizontal to prevent the cookies from falling out. While this works well for some products, such as cookies, it is not ideal for use in packaging soft drink pods.

As used herein, the terms “continuously packaged,” “fluid wrap,” “continuously wrapped,” and the like should be understood to refer to HFFS processes.

Another problem with packaging soft drink pods in a hermetically sealed package made of flexible, gas-impermeable film is the tendency of some ingredients to degas. Roasted coffee, in particular, will continue to degas after roasting. If it is packaged in a hermetically sealed package before degassing is complete, this can cause the package to swell or even rupture. To prevent this, roasted coffee is known to be degassed before packaging. However, this means the coffee is less fresh when packaged and requires a considerable investment in degassing silos.

There is therefore a need for an alternative packaging arrangement for products, especially soft drink pods, that overcomes, or at least mitigates, some or all of the drawbacks of known arrangements.

There is also a need for an alternative packaging system for products, especially soft drink pods, in flexible film that would reduce the amount of packaging film material required for a given number of products compared to the known VFFS process.

There is a further need for an alternative way to package products, especially soft drink pods, in a flexible film that reduces the amount of headspace in the resulting package compared to the known VFFS process.

It would also be advantageous to provide an alternative packaging solution that allows ingredients that have a tendency to outgas, such as roasted coffee, to be packaged without having to be completely degassed prior to packaging. TWM268304U describes a container according to the preamble of claim 1. NL2021868A describes a biscuit container comprising a lid hinged to a rear wall and a dispensing opening in a front wall.

Summary of the invention

Aspects of the invention relate to a part for a packaging assembly that is continuously packaged, to a packaging assembly that is continuously packaged, to a process for manufacturing a packaging assembly that is continuously packaged, to a preform of foldable material for forming the part, and to the use of the part in a process for manufacturing a packaging assembly that is continuously packaged.

According to a first aspect of the invention, there is provided a part for a packaging assembly that is continuously packaged comprising a bottom wall and a peripheral wall extending from said bottom wall to define with the bottom wall an interior volume for containing the product, wherein the part comprises at least one tab at an upper end of the distal peripheral wall of the bottom wall, said at least one tab being movable between at least one closed position in which it at least partially closes the interior volume at the upper end of the part and at least one open position in which it does not prevent access to the interior volume through the open upper end.

The part may have a single tab that only partially closes the interior volume at the upper end of the part. In one embodiment, the tab's major surface area is smaller than the cross-sectional area contained by the peripheral wall at its upper end distal from the lower wall.

The bottom wall may be fixed with respect to the peripheral wall.

The peripheral wall may comprise opposite front and rear wall portions and opposite side wall portions extending between said front and rear wall portions. In a

The front and rear wall portions are substantially flat, and said side wall portions are curved. The bottom wall may be inclined relative to the plane of the rear wall portion of said peripheral wall. In one embodiment, the peripheral wall is inclined downwardly toward the rear wall portion when the part is in a vertical, generally upright, orientation. At least one tab may be connected to the upper distal end of the rear wall portion by a hinge or fold line.

The part may have a dispensing opening defined in said front wall portion. In one embodiment, the dispensing opening is open at the distal upper end of the front wall portion and extends over at least 50%, or at least 60%, or at least 70%, or at least 80% of the length of the front wall portion from the distal upper end to the lower end. The dispensing opening may extend across substantially the entire width of the front wall portion. When the front wall portion is planar and the side wall portions are curved, the dispensing opening may extend transversely over the entire planar extent of the front wall portion. The dispensing opening could extend over 60% or more, or over 70% or more, or over 80% or more of the length of the front wall portion. The dispensing opening may occupy a significant proportion of the surface area of the front wall portion and may occupy more than 50%, or more than 60%, or more than 70%, or more than 80% of the surface area of the front wall portion.

The tab may have a shape selected from the group consisting of square, rectangular, semicircular, elongated, triangular, trapezoid, oval, semi-oval, boustrophedon, butterfly-shaped, bone-shaped, half-bone-shaped, and/or any combination thereof.

The tab is mounted on the flat portion of the rear wall and may comprise partially circular lobes on either side, each lobe facing towards a respective one of the curved side wall portions when the tab is in its closed position.

The part may be constructed from a single preform of foldable material, such as cardboard, cardboard, and the like. The part may be manufactured from a corrugated material such as corrugated board or paperboard, or the like. The preform may have interlocking formations configured to hold sections of the preform in their erected configuration such that the preform is positioned in the part without the use of adhesive. The interlocking formations may comprise interlocking lugs.

The peripheral wall may extend below the inferior wall, at least in the lateral wall regions of the peripheral wall.

The part can be configured so that it can be placed vertically on a horizontal surface when filled with product. The part can be placed vertically on the bottom wall or on a lower edge of the peripheral wall that extends below the bottom wall.

According to a second aspect of the invention, there is provided a packaging assembly which is continuously packaged comprising a member according to the first aspect of the invention as set out above containing the product, the tab of the member being in the closed position, the member being encapsulated in a wrapper made of flexible film, the wrapper being closed by a longitudinal seal and a transverse seal at each end of the member.

The wrapper is formed using a HFFS process. The flexible film may be a laminated film having an inner sealing layer and a substantially gas-impermeable outer material. The outer layer may comprise one or more materials selected from the group consisting of polyethylene terephthalate (PET) and oriented polypropylene (OPP).

The product may comprise at least one stack of soft beverage pods. In one embodiment, the product comprises two stacks of soft beverage pods arranged side by side within the part. The soft beverage pods may be disc-shaped. In one embodiment, the part has substantially flat front and rear wall portions and curved side wall portions, and the product comprises two disc-shaped stacks of soft beverage pods arranged side by side within the part, each curved side wall portion extending around an outer peripheral region of one of the respective stacks.

The wrapper may have a degassing valve, which may be an external one-way adhesive valve. At least one of the seals may be a peelable seal and include an unsealed tab region that can be grasped to initiate opening of the seal. At least one seal may be peelable and may have a cut in one of the opposing film regions to assist the user in separating the seal.

According to a third aspect of the invention, there is provided a process for producing a packaging assembly which is continuously packaged according to the second aspect of the invention as set out above, the process comprising the steps of:

a. Fill the part with product while the tab is in an open position;

b. subsequently move the tab to the closed position;

c. forming the wrapper around the filled part with the part in a generally horizontal orientation using a HFFS process.

In one embodiment, step a. is carried out with the workpiece in a vertical, generally upright, orientation, the method comprising carrying out step b. before step c.

The method may comprise moving the tab to the closed position while the part is still vertical after filling, or while the part is moved to a horizontal orientation for step c., or after the part has been placed in a horizontal orientation.

In one embodiment, step c. comprises conveying the filled part in a horizontal orientation through a wrapping area of an HFF apparatus in which a tube-shaped packaging film is formed around the part, which method comprises holding the tab in its closed position while the part is conveyed in a horizontal orientation toward said wrapping area. The method may comprise holding the tab in its closed position by a retaining or pushing tab that is part of the HFF apparatus for conveying the part to the packaging area. The method may further comprise removing the tab before the part is fully encapsulated in the film tube. The method may comprise holding the tab in its closed position through the packaging film after the overhang has been removed. The method may comprise using support elements (fingers) that are part of the HFF apparatus to engage the tab through the film on the sides of the part and keep the tab closed.

When the insert is formed from a single preform of foldable material, the method may comprise erecting the preform to form the insert before step a.

When the preform comprises interlocking formations configured to hold sections of the preform in their assembled condition, the method may comprise engaging the interlocking formations to hold the preform in its erected configuration.

The use of a part according to the first aspect of the invention in a continuously packaged package of HFFS is described.

A preform of foldable material for forming a part according to the first aspect of the invention as set forth above is described, the preform comprising:

a bottom wall panel that forms the bottom wall of the member when erected, the bottom wall panel having curved edge regions on opposite sides and straight edge regions along the front and back portions extending between the curved edge regions;

a first peripheral wall panel connected by a fold line to the bottom wall panel along the front straight edge region, the first peripheral wall panel configured to define the front wall portion and part of each of the side wall portions of the piece when erected, a dispensing opening defined in the first peripheral wall portion;

a second peripheral wall panel connected by a fold line to the bottom wall panel along the rear straight edge region, the second peripheral wall panel configured to define the rear wall portion and part of each of the side wall portions of the member when erected;

The tongue is connected to an edge of the second distal peripheral wall panel of the lower wall panel by a fold line.

The preform may be configured such that the outer side edge regions of the first and second peripheral wall panels that do not connect with the bottom wall panel overlap to define the side wall portions of the member when erected. In one embodiment, the overlapping outer side edge regions of the first and second peripheral wall panels are provided with interlocking formations that are configured to engage and hold the preform upright. The interlocking formations may comprise corresponding pairs of lugs on the first and second peripheral wall panels. There may be two, three, four, or five pairs of interlocking lugs on each side.

Detailed description of the invention

In order that the invention may be more clearly understood, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

Figure 1 is a perspective view of a part for a continuously packaged container according to an aspect of the invention, showing the part filled with two stacks of soft beverage pods and with a movable tab in an open position.

Figure 2 is a front view of a packaging assembly according to an aspect of the invention comprising the filled part of Figure 1 encapsulated in a flexible wrapper formed by an HFFS process.

Figure 3 is a rear view of the packaging assembly of Figure 2.

Figure 4 is a perspective schematic figure illustrating a typical HFFS apparatus for producing the packaging assembly of Figures 2 and 3.

Figure 5 is a plan view of a preform of foldable material for forming the part of Figure 1.

Figures 6 to 9 are a series of perspective views illustrating alternative embodiments of the part of Figure 1, showing the part empty and with the movable tab in a closed position.

Figure 10 is a view of part of the continuously packaged packaging assembly of Figure 2, illustrating a degassing valve applied to the wrapper.

Embodiments of a packaging assembly 10 according to one aspect of the invention have a member 12 configured to contain a plurality of products 14 and, after filling, enclosed in an outer wrapper 16 by a HFFS process. The packaging assembly 10 according to the embodiments described herein is particularly suitable for packaging disc-shaped (e.g., round or circular in plan) soft beverage pods 14 of the type comprising a rigid cover closed at an upper end by a filter material. However, the invention, in its various aspects, may be adapted to package soft beverage pods of a variety of types and shapes, and indeed to package a variety of other products.

The member 12 has a bottom wall 18 and a peripheral wall 20 extending upwardly around the bottom wall. The bottom wall 18 and the peripheral wall 20 together define an internal volume 21 for receiving the soft beverage pods 14. The member 12 has a tab (alternatively referred to as a lug) 22 movably attached to an upper end 24 of the peripheral wall 18 distal of the peripheral wall. The tab 22 engages the distal end of the peripheral wall by means of a hinge or fold line 26 and is movable between a closed position, as illustrated in Figures 6 through 9, and an open position, as illustrated in Figure 1. In the closed position, the tab extends through the member opposite the bottom wall to at least partially close the member at the upper end of the internal volume. The tab 22 may extend substantially parallel to the bottom wall in the closed position, but this is not essential. In the open position, the tab does not extend through the part, so that it does not impede access to the internal volume 21. The tab 22 may extend generally coplanar with the portion of the peripheral wall to which it is coupled in the open position to form an extension of the peripheral wall. However, the tab 22 could be bent outward at least somewhat to ensure clear access to the interior volume. In the present embodiment, the tab is smaller than the cross-sectional area contained by the peripheral wall at its upper end distal from the bottom wall, so that the tab only partially closes the part. That is, a major surface area of the tab is smaller than the cross-sectional area contained by the peripheral wall at its upper end distal from the bottom wall.

The member 12 forms a container for holding a plurality of soft beverage pods 14 in a desired configuration and around which a packaging film may be continuously wrapped. In the present embodiment, the soft beverage pods are arranged in two stacks 28 arranged side by side. The member 12 is configured such that the peripheral wall closely conforms to the outer profile of the adjacent stacks to minimize the free volume within the member when filled. To this end, the peripheral wall 20 has a substantially planar rear wall portion 30 and an opposing substantially planar front wall portion 32. The front and rear wall portions are joined by curved side wall portions 34, 36, each of which closely follows the outer peripheral shape of a respective one of the disc-shaped stacks of soft beverage pods. Each of the stacks 28 rests on the bottom wall when the part is in an upright position, as shown in Figure 1, such that the stacks are generally vertically aligned with a longitudinal axis of each stack extending generally perpendicular to the bottom wall 18. However, in one embodiment, the bottom wall 18 is arranged to slope slightly downwards towards the rear wall portion (as viewed when the part is in an upright position). This causes the stacks of soft drink pods to fall rearwardly over the rear wall portion when transported and reduces the risk of the soft drink pods falling out of the part.

It will be appreciated that the shape of the part may be adapted depending on the shape and arrangement of the products 14, but will generally be configured to minimize the free space within the part when filled. For example, the part could be adapted to have a generally tubular shape to contain a single stack of disc-shaped soft drink pods 14.

The member defines a dispensing opening 38 in the front wall portion 32. This provides easy access to the soft beverage pods in the member so that after opening the packaging assembly 12 and removing the member from the overwrap 16, the user may select and remove the individual soft beverage pods 14 either through the top of the member or through the dispensing opening. The dispensing opening 38 opens at the upper end of the front wall portion 32 such that the dispensing opening is contiguous with the open upper end of the member/internal volume and extends downwardly for 50% or more of the length of the front wall portion. The dispensing opening could extend over 60% or more, or over 70% or more, or over 80% or more of the length of the front wall portion. The dispensing opening 38 extends substantially over the entire width of the planar front wall portion 32. The dispensing opening occupies a significant proportion of the surface area of the front wall portion and could occupy more than 50%, or more than 60%, or more than 70%, or more than 80% of the surface area of the front wall portion. The dispensing opening 38 is made as large as possible while ensuring that the soft beverage pods are retained in the workpiece before being dispensed. To this end, curved sidewall regions of the workpiece extend beyond the widest of the two stacks of soft beverage pods measured in the transverse direction of the workpiece (e.g., perpendicular to a longitudinal axis X of the workpiece/packaging assembly). The sidewall portions 34, 36 extend beyond a midline of the soft beverage pods, at least partially around a front of the soft beverage pods. The provision of a large dispensing opening 38 not only provides easy access to the soft drink pods, but also reduces the amount of material used in the part.

Typically, the part 12 is filled while in a vertical, generally upright, orientation with the tab in its open position, as shown in Figure 1. This is advantageous as it allows top filling of the part 12 by using gravity to draw the soft pods 14 into the part from above. After filling, the tab 22 moves to the closed position, extending over the tallest products in each stack. When the tab is closed, it is operative to prevent the soft pods 14 from spilling out of the part when they are in a horizontal orientation so as to fluidly envelop them. The tab may be moved to the closed position while the part is still in the vertical position, or it may be moved when the part 12 is tilted from a vertical orientation to a horizontal orientation, or even once the part has reached horizontal.

Once the piece 12 has been filled and with the tab 20 moved to the closed position, it is fluidly wrapped using a largely conventional HFFS fluidly wrapping process to completely enclose the piece and the soft beverage pods 14 in the wrapper 16.

HFFS processes for continuous wrapping are well known in the art and will not be described in detail. However, briefly referring to Figure 4, which shows a typical HFFS continuous wrapping arrangement, the filled piece 12 is conveyed in a horizontal orientation toward and through a wrapping area 40. The piece 12 is expected to be positioned so that it rests on the rear wall portion 30 of the peripheral wall with the bottom wall 18 at the leading or trailing end with reference to the machine direction M. A substantially continuous length of flexible packaging film 42 is drawn from a roll 44 down onto a forming stand 45 which guides the film into a tubular form surrounding the filled piece 12. Opposite longitudinal edge regions of the film are joined together to form a longitudinal seal 46. In the present embodiment, the longitudinal seal is a fin seal 46 wherein the longitudinal edge regions of the film are joined together face-to-face inside by a pair of fin seal rollers 48. In the finished packaging assembly, the fin seal 46 is then wound to form a longitudinal seal 46. fin 46 is folded to one side or the other, as is known in the art. However, the longitudinal seal could be an overlap seal. Once the film material has been wrapped around the piece 12, a pair of end seal bars 50 crimp opposite layers of the film tube to form a transverse end seal 52 at each end of the piece 12. In the present embodiment, the end seals are formed sequentially, but could be formed simultaneously using two pairs of end seal bars. The end seals are also fin-shaped seals, but the end seal adjacent to the bottom wall of the piece is folded to one side so that the packaging assembly 10 can be held upright on its base, as shown in Figures 2 and 3. The process is carried out substantially continuously over a period of time, a series of filled pieces 12 being transported through the wrapping zone 40 one after the other at a usually set spacing to be wrapped in the film 42.

At least the top end seal 52a is a peelable seal and, as illustrated in Figure 2, may be formed in a header 53 including an arrangement of lugs to assist a user in opening the wrapper 16. The header 53 has a region 53a of greater depth (measured in the longitudinal direction of the packaging assembly) in its center, where there is an unsealed area 53b outside the transverse end seal 52a. In the unsealed area 53b, the opposing portions of the film material are not joined together so that they form lugs that a user can grasp to separate the top end seal 52a. Typically, the longitudinal seal 46 will also be a peelable seal so that the wrapper can be opened far enough to remove the piece 12. The outer/top edge of the header 53 may be curved in the center to provide a region of greater depth.

In one embodiment that is a modification of the general HFFS process and apparatus, the tab 22 is held in its closed position as the workpiece 12 is conveyed toward and into the wrapping area. This may be effected by a retaining or push-in tab (schematically indicated by 54 in Figure 4) that engages the outer surface of the tab as the workpiece is conveyed and may be part of the infeed conveyor system. The tab moves outward as the workpiece is conveyed onto the film tube so as not to foul the film. The HFFS apparatus may also be provided with finger rests or other support means that (indirectly) engage the tab on the sides of the package from outside the film as the tabs are dropped down to hold the tab in the closed position. This prevents the soft drink pods from falling out until the film has stretched around the end of the pod enough to prevent the tab from opening.

It will be appreciated that the HFFS process for forming the wrapper 16 may vary from that shown in Figure 4.

Because the flexible packaging film 42 is wrapped around the blank 12 and the blank is configured near the outer periphery of the stacked soft beverage pods, free space within the packaging assembly is kept to a minimum. This reduces the amount of packaging film 42 required compared to that required to package an equivalent number of soft beverage pods using the well-known VFFS process. The soft beverage pods 14 are also packaged much more securely and are less likely to move within the packaging assembly.

The packaging film 42 may be any suitable type of film known in the art, and the seals may be formed in any desired manner known in the art that is compatible with the intended application. The packaging film 42 may be a laminate having a gas-impermeable outer layer and an inner sealing layer. The inner sealing layer may comprise a heat-sealable means, but a cold seal or a pressure seal may also be used. The sealing means may provide a permanent seal or a peelable seal. In one embodiment, at least one seal is a peelable seal. In one embodiment, at least one of the seals is peelable and is provided with a cut in the film material on one side to make it easier for the user to simulate peeling the seal.

The outer layer of the film material may be any suitable material, such as polyethylene terephthalate (PET). However, PET is not currently recyclable. In one embodiment, the film material 42 is selected to maximize recyclability, and the outer layer could be oriented polypropylene (OPP) or any other suitable material.

The part 12 may be made of any suitable material. In one embodiment, the part is made of a recyclable material. In one embodiment, the part is made of cardboard, paperboard, or other paper-based material. In one embodiment, the part is made of corrugated (fluted) material in which corrugations are provided on the outer surfaces of the part. The use of a corrugated material helps protect the soft beverage pods 14 during handling and shipping. In one embodiment, the part is made of corrugated cardboard or paperboard. In one embodiment, the part is made of a single preform 60 of foldable material, such as cardboard, paperboard, or other paper-based material, which may be corrugated. In one embodiment, the part is made of a single preform of foldable material that can be erected without the use of adhesives.

Figure 5 is a plan view of a preform 60 of foldable material for forming the part of Figure 1.

The preform 60 has a bottom wall panel 62 which forms the bottom wall 18 of the part 12 when erected. The bottom wall panel has curved edge regions 64, 66 on opposite sides and straight edge regions 68, 70 along the front and back portions extending between the curved edge regions.

A first peripheral wall panel 72 is connected by a fold line 74 to the bottom wall panel 62 along the front straight edge region 68. The first peripheral wall panel defines the front wall portion and part of each of the side wall portions of the member 12 when erected. The dispensing opening 38 is defined in the first peripheral wall portion.

A second peripheral wall panel 76 is connected by a fold line 78 to the bottom wall panel 62 along the rear straight edge region 70. The second peripheral wall panel defines the rear wall portion and part of each of the side wall portions of the member when erected. Tab 22 is connected to an edge of the second peripheral wall panel distal of the bottom wall panel 62 by fold line 26.

To position the preform 60 in the workpiece, the first and second peripheral wall panels 72, 76 are folded relative to the bottom wall panel 62 about their respective fold lines 74, 78 in the same direction until they extend generally perpendicular to the bottom wall panel. The outer side edge regions of the first and second peripheral wall panels that do not connect with the bottom wall panel 62 are folded inwardly about the curved side edge regions of the bottom wall panel. On each side, the respective outer side edge regions of the first and second peripheral wall panels overlap to form the curved side wall regions of the workpiece and are secured together where they overlap to hold the preform in its erected configuration. The overlapping outer side edge regions of the first and second peripheral wall panels may be bonded together using an adhesive or the like to hold them in position. However, in one embodiment, the overlapping outer side edge regions are provided with interlocking lugs that engage to hold the preform upright without the use of adhesive. In the embodiment shown, the interlocking lugs 82 comprise corresponding pairs of lugs 82a, 82b on the first and second peripheral wall panels. In the present embodiment, there are three interlocking pairs of lugs 82a, 82b on each side, but the number may be varied as needed. The number and orientation of the interlocking lugs are selected to ensure that the overlapping outer side regions of the first and second peripheral wall panels remain firmly connected, but without creating surfaces that might trap the packaging film or soft beverage pods. Other arrangements may be made to mechanically lock the overlapping outer side regions of the first and second peripheral wall panels.

Following assembly of the preform to form the blank 12, the blank may be filled as described above and the tab folded about the fold line 26 to extend from the rear wall portion 30 toward the front wall portion 32 through the open end of the interior volume above the tallest soft drink pods in the stacks. The size and shape of the tab 22 may be varied. In one embodiment, the size and shape of the tab 22 are selected to effectively hold the soft drink pods 14 in position while using a minimum of material. As illustrated in Figures 1 and 5, the tab may have a substantially semicircular shape with a straight edge region at its edge distal from the fold line 26. However, as illustrated by dashed lines 22a in Figure 5 and in the embodiments shown in Figures 6 through 9, the tab may have an alternative shape that is configured to better conform to the products and the outer peripheral shape of the member 12. In the present embodiment, where the member is configured to hold two stacks of discs, such as soft beverage pods, the tab may have two partially circular tab regions that are directed toward the curved sidewall portions 34, 36 such that each protrusion is located above a respective one of the stacks. Generally speaking, the tab should be shaped and sized to be effective in holding the product 14 in place when the member is oriented horizontally to fluidly envelop it while keeping the amount of material in the tab to a minimum.

During the continuous wrapping process, the interior of the wrapper may be flushed with nitrogen to remove oxygen from within the packaging assembly and help keep ingredients, particularly coffee, fresh. In the present embodiment, comprising two stacks 28 of soft drink pods 14 side-by-side, there is a possibility that there may be dead space between the two stacks adjacent to the rear wall portion 30 that may not be completely discharged. To alleviate this problem, a small hole or opening 84 may be provided in the tab at its center adjacent to the rear wall and at a corresponding location on the bottom wall 18 to improve discharge and reduce oxygen levels in the package.

As illustrated in Figure 10, the wrapper 16 may be provided with a one-way degassing seal 86 to allow gases emitted by the packaged ingredients to exit the wrapper 16. This may be an external adhesive seal that adheres to the outside of the wrapper over one or more vent openings in the film material.

In addition to protecting the soft beverage pods 14 and providing a suitable closure for fluid wrapping, the member 12 forms a convenient dispenser for holding the beverage pouches after the packaging assembly has been opened and from which the user can remove the soft beverage pods as required. Once the user has opened the wrapper 16, the filled member can be removed from the wrapper and placed upright on a suitable surface so that it rests against the bottom wall or the lower edges of the peripheral side wall. The tab 22 can be moved to the open position to allow the soft beverage pods to be selected and removed from the member through the open top end. In an alternative embodiment, a line of weakness can be provided between the tab and the peripheral wall to allow the tab to be easily removed upon opening the packaging assembly.

While the packaging assembly 10 according to the embodiment described above is particularly suitable for packaging soft drink pods 14, the teachings herein are applicable to the packaging of a wide range of products. In particular, the teachings herein are applicable to the packaging of other perishable products in which a plurality of products are to be packaged together, especially if the products can be arranged in stacks. The invention is particularly, but not exclusively, suitable for packaging a plurality of disc-shaped products. These products included cookies, biscuits, and other confectionery items. However, the invention in its broadest sense is not limited to use in the packaging of perishable or disc-shaped products, which can be more broadly adapted for use in the packaging of any suitable product.

Relative positional terms such as “top,” “upper,” “lower,” and “bottom” used herein (including the claims) in connection with the piece 12, the packaging assembly 10, and portions thereof are to be understood as referring to the piece, the packaging assembly, and a portion thereof when the piece or packaging assembly is in an upright, generally vertical, position with its bottom wall 18 below the tab 22 and with its longitudinal axis X extending generally vertically, as illustrated in Figures 1 through 4 and 6 through 9. However, it will be appreciated that the piece and packaging assembly may be utilized in other orientations. For the avoidance of doubt, reference to the piece being in a horizontal orientation is to be understood to mean that the piece is supported with its longitudinal axis X disposed substantially horizontally. Generally, the piece 12 will be positioned upon its peripheral wall 20 when in a horizontal orientation.

The above embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention, as defined in the appended claims.

Claims (15)

1. Part (12) for assembling (10) a packaging that is continuously packaged comprising a bottom wall (18) and a peripheral wall (20) extending from the bottom wall (18) to define with the bottom wall (18) an interior volume for containing the product (14), the part (12) comprising at least one tab (22, 22a) at an upper end of the peripheral wall (20) distal of the bottom wall (18), said at least one tab (22, 22a) being movable between at least a closed position in which it at least partially closes the interior volume at the upper end of the part (12) and at least one open position in which it does not prevent access to the interior volume through the open upper end, said peripheral wall (20) comprising opposite front and rear wall portions (32, 30) and opposite side wall portions (34, 36) extending between the portions (32, 30) and (34, 36). 30) of front and rear wall, wherein the front and rear wall parts (32, 30) are substantially flat and the side wall parts (34, 36) are curved, said at least one tab (22, 22a) is connected to the distal upper end of the rear wall part (30) by a hinge or fold line (26), characterized in that a dispensing opening (38) is defined in the front wall part (32). 2. Part (12) according to claim 1, wherein the lower wall (18) is inclined with respect to the plane of the rear wall portion (30) of the peripheral wall (20). 3. Part (12) according to claim 1, wherein the dispensing opening (38) is open at the distal upper end of the front wall part (32) and extends over at least 50%, or at least 60%, or at least 70% or at least 80% of the length of the front wall part (32) from the distal upper end to the lower end. 4. Part (12) according to any one of the preceding claims, wherein the dispensing opening (38) extends substantially across the width of the front wall portion (32). 5. Piece (12) according to any one of the preceding claims, wherein the piece (12) is constructed from a single preform (60) of foldable material, such as cardboard, cardboard and the like. 6. The part (12) of claim 5, wherein the preform (60) comprises interlocking flap portions (82a, 82b) configured to hold sections of the preform (60) in its erected configuration such that the preform (60) is erected on the part (12) without the use of adhesive. 7. Part (12) according to any one of the preceding claims, wherein the part (12) is made of a corrugated material. 8. Packaging assembly (10) which is continuously packaged comprising a piece (12) according to any one of the preceding claims containing the product (14), the tab (22, 22a) of the piece (12) is in the closed position, the piece (12) is encapsulated in a wrapper (16) made of flexible film (42), the wrapper (16) is closed by a longitudinal seal (46) and a transverse seal (52) at each end of the piece (12). 9. Packaging assembly (10) according to claim 8, wherein the product (14) comprises at least one stack of soft single-dose beverages (14) within the part (12). 10. Packaging assembly (10) according to claim 9, wherein the product (14) comprises two stacks of soft single-dose beverages (14) arranged side by side within the part (12). 11. Packaging assembly (10) according to claim 10, wherein the soft beverage pods (14) are disc-shaped and the part (12) is a part (12) according to claim 1, each curved side wall portion (34, 36) extending around an outer peripheral region of one of the respective stacks. 12. A process for producing a packaging assembly (10) that is continuously packaged according to any one of claims 8 to 11, the process comprising the steps of: a. filling the blank (12) with product (14) while the tab (22, 22a) is in an open position; b. subsequently moving the tab (22, 22a) to the closed position; c. forming the wrapper (16) around the filled blank (12) with the blank (12) in a generally horizontal orientation using a HFFS process. 13. Process according to claim 12, wherein step a. is carried out with the workpiece (12) in a vertical orientation, generally vertical, the method comprising carrying out step b. before step c. 14. The process of claim 12 or claim 13, wherein step c. comprises conveying the filled part (12) in a horizontal orientation through a wrapping area (40) of a HFFS apparatus wherein a packaging film (42) is formed into a tube around the part (12), the method comprising holding the tab (22, 22a) in its closed position while the part (12) is conveyed in a horizontal orientation toward said wrapping area (40). 15. The process of claim 14, wherein the preform (60) comprises interlocking flap portions (82a, 82b) configured to hold sections of the preform (60) in their assembled condition; the method comprising coupling the interlocking flap portions (82a, 82b) to hold the preform (60) in its erected configuration.