HK1039305A1 - Customized prescription product packaging and method and system for producing customized prescription product packaging - Google Patents

Abstract

This invention provides packaging for housing at least one prescription product comprising customized graphics on at least some surface area of said packaging, said customized graphics being selected by the individual doctor prescribing said prescription product or the patient to receive said prescription product. This invention further provides the method and system for producing customized packaging which houses at least one prescription product, wherein said packaging is customized by the individual doctor prescribing and/or said patient receiving said at least one prescription product comprising the steps of: receiving an order for at least one prescription product from said doctor or a refill order from said patient; and printing out customized graphics specified by said doctor or said patient for said package for at least one prescription product.

Description

Packaging for customized products, method and system for producing packaging

Technical Field

The present invention relates to a customized product package and a method of producing a customized product package.

Background

The packaging of contact lenses is well known in the art of contact lens manufacture. For short-term use of contact lenses or wearing contact lenses, such package designs typically consist of blister packages that are employed by practitioners for storage and distribution of hydrophilic contact lenses, or for sale to patients wearing contact lenses. The blister package has a plastic bowl region for holding the contact lens and aqueous solution, and a lid, such as a welded lid holder, which may be composed of one or more layers of polymeric or layered materials. A plurality of blister packs may be removably connected to one another by an array of blister packs made from a lid stock. An example of a blister package is described and disclosed in martize's patent attorney assigned US 4691820, wherein a package for disposable or specialty contact lenses is provided that is suitable for use in a sterile storage environment for storing hydrophilic contact lenses, wherein the lenses are immersed in a sterile aqueous solution.

An array of one or more blister packs for sale to a patient is located in a box or carton. Typically, a plurality of blister packs containing contact lenses are packaged in a sterile aqueous solution and stored in cartons each capable of holding a number of blister packs; such as: 15 or 20 or other suitable number of blister packs. Typically, cartons are constructed of rectangular cardboard or paperboard that has been printed with one or more color identifying indicia, side printing, decorative designs and/or instructions, and manufacturing related information as required by various governmental regulations and or regulations.

The cartons are typically packaged in large storage cases, close to the processing line for the contact lenses, and are handled aseptically. The large storage box containing the carton is oriented toward the center of the drawing and the shelves positioned therein. In the case where the contents of the carton do not require further processing, upon shipping and/or sale of the acceptance procedure, the bulk storage case ultimately withstands removal of the products contained in the carton, such as blister-packaged contact lenses, from the case, separate immersion may involve a sorting procedure for a variety of different products, and subsequent shipment to the intended customer, such as a home or foreign vendor, doctor, optometrist, or potential user of contact lenses.

Both the lidstock and the carton may include information printed thereon before the lidstock is fused to the blisters or before the array of blister packages is positioned within the carton. At this time, the information attached to the cover rack or the carton is limited to the capacity, the axial direction, the cylindrical surface, the end date, and the lot size. All other information and side printing on the cover stock and carton is typically done on the production line prior to packaging the contact lenses.

Disclosure of Invention

The present invention provides a package for at least one customized product comprising a specific design for said package, said design being designed for a specific customization by a certain doctor and/or for a certain patient to receive said at least one customized product.

The present invention also provides a method and system for producing a customized package containing at least one customized product, wherein the package is customized by an individual physician and/or the patient receives the at least one customized product, the method comprising the steps of:

receiving instructions from the physician or supplementing the patient with an instruction for at least one customized product; and

printing a customized specific pattern for at least one customized product by the doctor or the patient.

The invention is particularly beneficial in providing a carton for a doctor with a particular design for a new patient who may be fitted with a trial pair of contact lenses and must return to the doctor who is rising up in position. The invention also provides a vehicle for the doctor to publish the product advertisement.

Drawings

Embodiments of the present invention will be described in detail below with reference to the accompanying drawings; wherein:

FIG. 1 is a schematic view of the top and side of an array of blister packs with a specific pattern;

FIG. 2 is a schematic view of the upper and side of the carton with a particular design;

FIG. 3 is a schematic view of the upper portion of an insert with a specific pattern;

FIG. 4 is a schematic view of an upper portion of a label with a specific design for a carton;

fig. 5 is a schematic view of an upper portion of a system for printing a label with a specific design attached to a carton.

Fig. 6 is a database for recording labels within the printing system shown in fig. 5.

Detailed Description

The invention will be described for a particular product, a contact lens; however, any product may be substituted for contact lenses, and examples of other specific products include pharmaceuticals, eyeglasses, medical devices, or the like.

An "identification device" is a set of numbers, bar codes, two-dimensional matrices, three-dimensional matrices, inductive transmission/reception devices or radio frequency integrated circuits or similar devices. Preferably, each identification means includes some specific information for each component. The identification means may be machine-readable and/or human-readable. The machine-readable identification device preferably has information stored in a database corresponding to the identification device. For packaging, the information stored in the database corresponding to the identification means may not be present on the package to be read by a human. That is, the database is accessed exclusively by entering the identification device, and information relating to the product packages within the database is known by means of a bar code reader or the like.

As shown in fig. 1, 2 and 3, a package containing at least one contact lens with a specific pattern can be used as any portion of the package for a contact lens. The contact lens package includes a primary package and a secondary package. The primary package is the package adjacent the contact lens, and the secondary package surrounds the primary package. There may be a number of layers of packaging for the contact lens; however, in an embodiment, there is a primary package and a secondary package. The specific pattern is attached to the primary package and/or the secondary package, and/or is a package insert located within the secondary package. The specific pattern may be an alphanumeric message, a drawing, a photograph and/or the like or a combination of the above.

The primary package for the contact lens is preferably a blister package with a lid holder, however, it may have any form, such as a glass bottle, a tin box, a tray, a box, such as a filled sealed box, providing sufficient length to protect the contact lens. Figure 1 shows an array 10 of blister packages having a specific pattern. The blister pack array 10 consists of 5 blister packs 11. Each blister pack 11 consists of individual five bases 12 connected to each other by adjacent lid holders 13, the bases 12 being scored so that individual blister packs 11 can be detached from the array 10. Each base 12 preferably includes an injection molded or thermoformed plastic co-molded recess 15, the recess 15 being surrounded by a protrusion 18 around its edge. A flexible flap or cover frame 13 is attached to the surface of the projection 18 to sealingly close the recess 15 in a gas or liquid tight manner. In the recess 15 of the base part, a contact lens (not shown) is immersed in a sterile aqueous solution (not shown). Preferably, the contact lens is a hydrophilic contact lens made of a material known to those of ordinary skill in the art. The particular pattern 14 shown is present on the lid holder 13 and indicates to the patient that the contact lens is contained within each blister pack and that the patient sees the contact lens located therein. The specific pattern 14 for each blister pack located on the lid holder is: "contact lens for the left eye of JOAN". There may be no specific information on the package, such as: power for spherical contact lenses or power, cylinder, axial for toric contact lenses, only indicating who the product is used and its characteristics of use. The package can be identified only by the processor using at least one identification means, also called product identification means, preferably machine-readable identification means on the package, preferably on at least the secondary package, more preferably on both the primary and secondary packages, identification means for the contact lens, information corresponding to the product identification means, such as: SKUs, lots, ages can be stored in one or more databases. When the product identification device is entered into the computer, this information, which is accessible to the database, is entered into the database.

The packages preferably used for contact lenses include primary and secondary packages. The secondary package is preferably a carton, but may have any form, such as: a bag, plastic bag, capsule, box, iron box, case, glass bottle, or tray. The secondary package preferably contains a plurality of primary packages. The secondary package is best shown in fig. 2. Fig. 2 shows a carton containing a plurality of contact lenses each in a primary package. The rectangular carton 20 is preferably made of paperboard. The carton 20 comprises a flat top wall panel 21 and an opposed bottom wall panel, a front panel 25 and an opposed rear panel (not shown), opposed end walls 24 (only one end shown), which are bonded or adhered to form a sealed structure in accordance with known carton forming techniques. The top wall panel 21 includes a downwardly extending front panel 26 with a plug 27 intermediate the lower edge of the front panel 26, the plug 27 for insertion into a socket (not shown) formed intermediate the front panel to facilitate reclosing of the carton 20. The top wall panel 21 swings upwardly about the rear fold line 28 to open the carton 20. The top wall panel 21 of the carton shown has a specific design 22, 23 consisting of an alphanumeric number 22 and a graphic 23. The alphanumeric numbers 22 are: "contact lenses supplied by JOHN doctors for JOAN SMITH". The graphic 23 is a picture of John's doctor who customized the contact lens.

Fig. 3 is a third embodiment of the present invention wherein the specific pattern is an additional package insert. The packaging insert may be paper or any object such as: a toy, a mirror, etc. attached to the package. Fig. 3 shows a piece of paper as the insert 30 and the specific pattern 31 is alphanumeric information: "these contact lenses are provided by JONES, o.d. doctor for JOAN SMITH, and our office will tell you the planned flow within a month. During this time, if you have any problems with these contact lenses, please dial my office phone 555-. Your eyes are important to me. The "package insert paper sheet 30 is removable and suitable for insertion into a secondary package, such as a carton. The specific patterns shown in the drawings serve as examples. Any alphanumeric information, graphics or pictures selected by the physician or patient may be used.

Fig. 4 shows a label 40. The label may be affixed to a blank area of the package, or may be an overlabel that partially or completely covers the area of the label used for illustration. Label 40 is preferably a label with an adhesive attached. The label 40 for the carton shown in the figures has a shape similar to the carton shown in fig. 2. Label 40 is formed from a composition comprising paper, a polymer (e.g., polyvinyl chloride film) or a metal film, preferably paper. Preferably, there is an adhesive layer (not shown) covering the back of the top layer 47. The label may have a skin (not shown) affixed to its top 47 which can be removed from the adhesive layer before the label 40 is affixed to the package. Preferably the adhesive is a durable adhesive such as: the Averdanesen LP-430 durable/latex acrylic adhesive has a working range of temperatures from-54 to +92 ℃; the avdanesen S-4600 durable/avrri adhesive has a working range of temperatures from-40 to +80 ℃. In addition, label 40, which consists of only top layer 47 and an adhesive layer, may be used for packaging before the top layer is used for packaging. The label 40 has various types of specific patterns 41, 42 and 43. The label 40 has a picture 41 of the doctor, a picture of a sailboat 42, and an alphanumeric message indicating the contact lens as "555-. The photographs, pictures and alphanumeric information may be selected by the physician. The doctor can specify a picture with which he/she is familiar, such as a picture of a horse fan.

As shown in fig. 4, the tag may include additional information such as a product identification device 45 and a tag identification device 46, both of which are preferably machine-readable identification devices. The product identification device 45 is used to identify the type of contact lens and the characteristics of the contact lens in the carton to which the label 40 is applied. The optional label identification means 46 can be used to identify the designated label 40 so that it can mark and unmark the carton so that the label can be glued to the correct carton and so that the product is delivered to the correct recipient, whether a patient or a doctor. In addition, in this embodiment, the label identification device records the quality of the label through a specific pattern printing system. Alternatively, the label identification means 46 may be part of the top layer 47 of the label, and when the top layer 47 is removed from the skin layer, it is preferred that the label identification means 46 does not extend beyond the skin layer until the label is attached to the correct carton.

Alternatively, the product identification means 45 may be absent from the label and, when the label 40 is applied to the label, there is no covered area on the package. If the tag identification means is not on the tag, the instructional information may correspond to the product identification means in the database, and after the package is applied and affixed, the product identification means can be used to record the package status. Alternatively, if the tag identification device is on the package, the tag identification device may be a product identification device.

The label 40 is shown with some standard graphics 44 that are not physician and/or patient specific, the standard graphics 44 may be present on the label before the specific pattern label, or a non-specific pattern may be printed on the label 40 while the specific pattern is affixed thereto. In short, the specific and non-specific patterns may be attached to the package in any order. Non-specific information includes, for example, identification symbols and edge prints related to products manufactured and/or marked by the company, introductions related to the use of the products packaged in the carton, contents of decorative markings, instructions for use, warnings about products not specified for the dispensing of customized products, or the like.

If the specific design is attached to the main package, the main package comprises a blister pack comprising a bowl and a lid holder, preferably the specific design is attached to the lid holder. The cover frame can be directly printed with an additional specific pattern, and the specific pattern can also be attached to the cover frame by indirectly printing a label with the specific pattern and adhering the label to the cover frame. Alternatively, the label may have a blank area which can be adhered to the frame and printed after being adhered to the frame, a preferred method for printing a specific design on the label will be described in more detail below. (the preferred method, described in more detail below, is for printing out labels for cartons, but it could instead be for printing out labels for pallets). In the embodiment shown in fig. 1, the specific pattern 10 is directly attached to the cover frame by printing on the cover frame. An area may be reserved on the cover frame for a specific pattern, or the specific pattern may cover the entire cover frame.

Preferably, the specific pattern is attached to the secondary package. The secondary package is preferably a carton. The specific pattern may be attached to the inside or outside of the surface area of the secondary package. The specific pattern is preferably not less than 5%, preferably up to 25%, more preferably not less than 50% of the outer surface area of the secondary packaging. Preferably, the specific pattern comprises a background image of at least 30%, preferably up to 60% or 80% of the outer surface area of the secondary package. Preferably at least one panel or wall for the carton has some specific design, preferably at least two panels have some specific design, more preferably at least three panels have some specific design. Another approach is to attach a specific pattern to the outer surface of the secondary packaging, which specific pattern is able to cover a portion of the inner surface of the secondary packaging. It is preferable that the outer surface of the subsidiary package has a specific pattern.

The specific pattern may be directly or indirectly attached to the secondary package. The label may be printed directly on the secondary packaging or may be applied to the secondary packaging and then printed on the label. For direct printing, the specific pattern may be printed on a label on one of the labels shown in fig. 4, and may then be affixed to an adhesive label on the secondary package. The label may be small or large, and may be part of the means for sealing the secondary package, or it may cover a portion of the outer surface of the secondary package that is not adjacent to any sealing means, i.e. a flap, tear strip, tab, seam, etc. of the secondary package. Although printing on the label first has the disadvantage of requiring a second step of affixing the label to the package, this method is also preferred since not all contact lenses for which an order is to be made, i.e. for a doctor or patient, require a specific design to be affixed to the package. The preferred method of printing the label will be described in more detail.

Alternatively, the specific pattern may be printed directly on the secondary packaging. The secondary package may be assembled or disassembled at the time of printing or without the primary package inside. For example, if the secondary package is a carton, the specific pattern may be printed on a flat carton blank or an erected empty carton. The "support and method for cartons" that may be in Duis et al due to the support of the assembled empty cartons during printing, U.S. serial No.: no.09/217879, filing date: patent documents on 12/21/1998 are hereby incorporated by reference. Alternatively, the carton may be directly printed by laser or ink jet printing after the contact lens primary package is inserted into the carton. Alternatively, a label with a blank area may be attached to the carton and then a specific design may be attached to the label. If the secondary package is not a carton, it is preferred that the printing technique used on the secondary package be adapted to the secondary packaging material used.

Alternatively, the specific pattern may be printed on an insert that is insertable into the secondary package, such as on a production line prior to sealing of the secondary package.

Printing on, e.g., the primary package, the secondary package, and/or the package insert may be by any printing method, such as by thermal, laser, electrophotographic, ink jet, and pad printing. These methods are applicable to a certain type of printed material and are known to those skilled in the art. The method for printing on the label will be explained below.

For each embodiment, the method of printing a particular pattern begins with a doctor ordering a particular contact lens. The order is received according to methods known to those skilled in the art, such as: e-mail, telephone, internet, fax, etc., unless the method of ordering is changed, so that the doctor/patient has the ability to describe what particular patterns they like for use on the package, and which one can choose for use on the package. Preferably, there are a large number of pictures, photographs and messages to choose from, and each message selected will be translated into a code and stored in the memory of the computer that will be entered into the printing device. In addition, the doctor can specify pictures, photographs, and information in addition to the selected information. For example: when the Jones doctor takes back his order, he can specify which carton, if any, to print his own photograph, previously provided to the manufacturer, and stored in computer memory into the printing device. Depending on what package is in a particular pattern, that is, the primary package, the secondary package or insert, and if a particular pattern is to be appended to the package, either inline or offline how the intended order information for the package is processed. If the specific pattern is to be attached to the main package, the order information is then transmitted to a production line having a label printer for the cover frame or the cover frame, so that the specific pattern is attached to the main package before the main package is placed in the auxiliary package. If a particular pattern is to be attached to the secondary package, this information can be communicated to the contact lens production line either before or after the primary package of contact lenses is loaded into the secondary package, printed directly on the secondary package, or printed on a label for the secondary package. The improved package is preferably marked with an identification means, preferably a machine-readable identification means, whose order is to be transmitted so that it can be recorded and transmitted to the correct doctor or patient. Alternatively, conventional packages have on their exterior a specialized machine-readable code (e.g., product identification device) for identifying the product and other information, such as lot number, stock-keeping unit (SKU-stock keeping unit), and expiration date. The machine-readable code can have attached information identifying the predetermined package that has received the particular pattern and whose product is to be routed. In addition, the exterior of the package may be marked with a human-visible indicator that the package has received a particular design that may be recorded by an operator or that will assist in quality verification prior to shipment or ordering.

The preferred method of manufacturing a contact lens is to place the contact lens in a primary package, place a plurality of primary packages of contact lenses in a secondary package and sterilize the contact lens by prior art methods, and then attach a specific design to the secondary package using an off-line printed label. The order information for the specific pattern is transmitted to a specific pattern printing system separate from the contact lens production line. The specific pattern printing system will print a label that covers at least a portion of the exterior surface of the secondary package, such as a carton. Preferably, the order by the doctor will be removed from the frame in the usual manner of assembling the ordered contact lens in its usual secondary package. The label produced at the specific pattern printing system will be matched to the order assist package for each doctor, and then the label is affixed to the assist package in an automated or manual manner. After the label according to the doctor's order is affixed to the secondary packaging, the order is sent directly to the doctor or patient.

In an alternative method, the specific pattern may be added in-line, i.e. in the production line for the contact lenses, on the primary package and preferably also on the secondary package. In the in-line packaging mode, order information is provided to the contact lens production line that produces the order, and the right to create a particular pattern is placed in the production line and attached to the packaging line. If the specific pattern is attached to the primary package, such as the lid frame, approximately when the ordered contact lens is placed in each primary package, and the lid frame is then heat sealed to the bowl. If a particular pattern is to be added to the secondary package, the carton is preferably printed on its production line before the primary package is placed in the carton and heat sealed to the carton. Printing may be by any of the methods listed above. The outer appearance of the package, e.g. the outer appearance of the secondary package, preferably has identification means, preferably a machine-readable code, associated with the specific pattern to be stored for shipment to the correct contact lens consignee.

In the preferred method, the patterns will be appended off-line and there will be one or more databases that will record the doctor's name and the particular pattern selected. As described above, when an order for a custom product is large and order information for a particular pattern or the need for a doctor's name package that requires a particular pattern on his/her package will be combined and searched within the database. (optionally, order information for the name of the patient requiring a particular pattern will be searched). When one or more orders with specific pattern requirements are found, the specific pattern information is transmitted to the specific pattern printing system. In a preferred mode, and with a specific pattern printed by a specific pattern printing system. The label will then match the correct package, preferably with the carton containing the contact lens ordered. Preferred methods of assembling or removing ordered products follow the method described in Duncan et al, "apparatus and method for automated warehousing and filling of multiple product orders," U.S. patent Ser. No.: (VTN-453) is incorporated herein by reference. The retrieved (combined) order will be deferred to an out-of-line, pattern-specific printing system for printing labels with specific patterns on cartons and receiving labels as ordered.

Preferably the off-line method for producing labels with specific patterns comprises a printing step, one or more quality inspection steps. More preferably, the method further comprises a painting step. The most preferred method further comprises one or more shearing steps. These and other steps will be illustrated in connection with a system for printing a label having a specific design as shown in fig. 5.

Fig. 5 shows a specific pattern printing system 500 comprising a printing press 502, an inspection station 505, a paint application device 508, a cutting device 509, a label applicator 513 and a production floor controller 512. The production floor controller 512 is a computer or the like that records the labels within the printing system 500. The production floor controller includes memory, programs, processors, databases, and the ability to receive information from components of the printing system 500 and output information and instructions to operate the components of the printing system. The operation of the production site controller 512 will be described below.

The order for the contact lens and specific pattern is preferably received from a central customer order processing server (not shown) through a separate order processing system that is connected to the production floor controller 512. The customer order may be received by telephone, mail, internet, fax, or any other method. Some order processing flows are disclosed in US patent 4598280, incorporated herein by reference, others known in the art. Preferably, only orders for specific patterns are received in connection with the production floor controller 512. Other information includes the quantity ordered, the date ordered, the person ordered, the product ordered, the specific design printed on the carton, and the shipping address. In the system 500, the production floor controller 512 orders the information for the labels within the order, which is printed on a web page and stored in a database. Fig. 6 shows a database 60 that can be used to store the ordered order information. Fig. 6 is merely an example, and more or newer fields may be used for labels recorded within printing system 500, as will be apparent to those skilled in the art. Database 60 includes fields for order information such as order quantity 61 (each order having an order quantity), product inventory 62, identification of the type of product ordered, and specific patterns 63, 64, etc. that are specified by the physician and/or patient for the product. The pattern field 63 specifies the background art. The pattern field 64 specifies a message. The more or more updated fields may be provided. Other fields, such as the SKU field, may indicate that an additional non-specific pattern is printed on the label. One or more fields in the database 60 may be locked to additional databases that may provide additional information when desired, such as when the order quantity may be locked to a database having the doctor's name and address and/or the identification number in the pattern field is locked to indicate which pattern is to be printed by the printer 502.

Preferably labels from the same order are printed on printers adjacent to each other and labels with similar patterns (like a background image) are reproduced on another web and a label identification means is predetermined on each label. The sorted label information is connected to a control unit 501 for the printing press 502. The roll 550 of label material, preferably having a width of 32 centimeters, is fed to the digital printer 502. The label material is preferably comprised of a top layer of polyvinyl chloride coated paper having an adhesive back coating and a removable skin layer as shown in fig. 4. An example of a commercially available paper web is PVC which is a white pigmented web having an indeterminate metallic gloss top layer on which is an adhesive layer such as Datacal PLV-400-FW opaque MT/C-354V-29S 50K-8 available from Flexicon corporation. In a preferred mode, the web is blank and not previously cut or scored; however, in alternative embodiments, the web may be cut, scored and/or pre-printed with a non-specific pattern on the web. For example, the labels may be printed separately instead of the web and/or the labels may also have marking information printed thereon. Currently, at least 5000 labels are printed on each roll of web. After all of the labels printed on the first web have been printed, the first spool 550 is removed from the printer 502 and replaced with a second spool 550 having a second web.

The digital printer preferably has 100% variation of text and graphics for the label, the printer preferably being purchased from Xeikon or Indigo. A control unit 501 for the printer 502 controls the printing of the label and controls the printer 502 to print information on the label, if any, of a specific pattern, contact lens, as controlled by the production floor controller 512. Preferably each label also has label identification means printed immediately behind the label or web so that the label can be recorded. Specific information corresponding to the label identification device 65 is stored in the database 60 of the production site controller 512, preferably with information on the location of each label on the web (preferably in the fields 67, 68, 66 for row, column or reel number), the specific pattern 63, 64 specified by the doctor or patient, and the SKU 62 of the product containing the label. After the web moves through the printing press 502, the web is accumulated in accumulator 504 before passing through quality check station 505, which quality check station 505 preferably employs visual inspection instruments 520 such as: a spectrophotometer or densitometer examines the density of the color and the reading of the toner, pigment, or dye. A densitometer and spectrophotometer available from Gretag Macbeth corporation may be used in this application, as follows: spectroeye spectrophotometer D200-11 three color plate densitometer, D19C densitometer, and SP99 multi-angle spectrophotometer and 408 color reflection densitometer available from X-Rite corporation. Currently, photoelectric densitometers are hand-held; however, a fixed densitometer may be used in the method of the invention. In addition, the operator can make subjective estimates of the tags.

The visual inspection instrument 520 may continuously verify the quality of the pattern and provide a feedback signal to the control unit 501 to allow the printer to automatically correct or alert the operator if the printer is unable to correct the printing problem. If the print quality is below a certain level, the labels in the web area will be rejected and will be prompted in the control system 503 (a computer including processing instructions and memory) and will be scheduled for printing with the rejected labels in the production floor controller 512 including a computer including processing instructions and memory). The reject indicia is in field 69 of database 60 and production floor controller 512 will indicate that the rejected label is reprinted. This will be entered into the following record in the database by moving the fields 61, 62, 63, 64 for any rejected label along with other new order information, at which point the rejected label is retained on the other fields for recording purposes.

The operator at inspection station 505 will visually inspect the labels on the web at set intervals, such as every 15 minutes. At this point, the operator will scan the label recognition device on the web with the hand-held scanner 519, and the hand-held scanner 519 inputs at least one label recognition device at a certain area on the web, and the label recognition device under test enters the label control system 503. The handheld scanner 519 is preferably a bar code scanner. If the label has such a problem, the operator will contact the label control system 503 through the scanner 519, keyboard or the like, the label will have a false detection, and all printed labels will be rejected due to the last operator detection. The rejected labels are determined by the label control system 503 and communicated to the production floor controller 512 for final detection. The rejection of the labels will be marked in the database 60 on the field 69 and finally the labels will be reprinted.

After the print quality check, the web is rewound on the reel-up. The mandrel of each spool 550 has an identification device and ultimately a machine-readable code, such as a bar code or the like, so that the production site controller 512 and label control system 503 can record each spool 550 and the label identification device with the spool 550 is in the database 60 connected thereto where the labels are printed. (tag control system 503 ultimately has a database similar to database 60). If an individual label on the roll is not detected, or if the entire roll is not detected, the control system 512 will instruct the printer to reprint the label and update the database and notify the label control system 503 of the new location (row, column, and roll) of the reprinted label. Preferably, if any label for an order fails the test, all labels for that order will be reprinted on a new reel, and all labels for the same order will be retained together.

Next, the web, preferably on a reel, is unwound at an unwinder 507 and fed to a glossing station 508 where the web, and particularly the labels on the web, will receive uv radiation to treat the surface gloss to improve its appearance and increase the friction of the labels. An example of a suitable surface treatment is INXCURE uk kflexo P/I COATING that can be applied to the system, for example: belamrk surface treatment coatings, including anilox rollers. It is preferable to check the web for any defects and errors after the surface coating process, confirming that the surface process is the correct coating process. The detection may be done by an operator or by a visual detection instrument similar to the apparatus and methods described above. The detector will enter the label recognition device using the second handheld scanner 519 to verify that individual labels or the entire web can be rejected again if the surface coating and labels do not pass the detection. If the web is rejected, the label control system 503 will mark the spool identification means and will inform the production floor controller 512 of this information, and the controller 512 will update the database 60, and in particular the field 69, and instruct the printer 502 to reprint all the labels on the spool. If only a label is rejected, the label control system 503 will mark the label recognition device of the label and will notify the production floor controller 512 of this information, and the controller 512 will update the database 60 and instruct the printer 502 to reprint the rejected label. Preferably all labels on an order are reprinted on the same reel.

After inspection, the web is fed to the embossing cutter 509 and the embossing cutter 509 cuts the labels through the top layer of the web, and in the next step the labels wrapped around the top layer of the web are removed from the web, revealing the labels on the skin. In this embodiment, two separate machines are processed according to the steps described. In this embodiment, multiple columns, such as three columns, of labels are printed on the web. After the labels are cut, the web is cut transversely into small rolls 551, such as three rolls in a slitting machine. The roll may be recorded by a machine-readable code on each roll mandrel. Prior to slitting the web, the label control system 503 updates its database by dispensing each column of labels on the reel as one of three rolls, marked on field 70 when the rolls and reels are mounted on the slitting machine. The labels are preferably printed on the web so that product labels for the same order are adjacent to each other in the same column. As shown in fig. 6, three products for order number 10175 are printed on 1 column of reel 2.

The printed labels are only for products on the list; thus, any spool 551 is selected by the operator and loaded onto the label applicator 513. When the machine-readable code for the selected roll is entered into the label control system 503, the labels of the products affixed to the list are removed from the list and sent to the specific pattern printing system 500, preferably by a reader (not shown) on the label applicator 513. In an alternative embodiment, each roll 551 may be set on one side until all cartons have received the particular label on the roll that has been removed from the list. In another embodiment, the label for the order already positioned on the product is connected to the production site controller 512 to instruct the pick and/or assembly equipment (not shown) to pick the carton from the list. The cartons, preferably receiving labels, are transported on a conveyor to a label coater 514 (shown in cross-section), preferably in the same order as the labels on the reels they are used with. Alternatively, the cartons may be conveyed in the order of assembly on conveyor sections (not shown) or within the cartons. Each conveyor section may have a machine-readable code within the conveyor section associated with the order. The conveyor section machine-readable code and associated order information can be coupled to the production floor controller 512 via the instrument that assembles the order. In either embodiment, the order is preferably delivered to the system 500 in the same order as the particular label on the roll for the order, and/or the cartons of products within the order are preferably delivered to the system 500 in the same order as the label on the roll for the order. Preferably, the cartons are fed to the coating machine on a carton width conveyor belt 514 in exactly the same sequence as the labels on the reels being used.

The cartons are conveyed to an applicator 513. A product handle such as a robot hand may be used to remove products from the conveyor and place them on the applicator 513. Labeling machines are typically purchased. Since each product has a label, the product is typically placed on a second conveyor belt 517 that transports the product to a finished product inspection, packaging, and shipping area (not shown). The products are preferably placed on the conveyor 517 at regular intervals in the same order as the individual orders.

Preferably, the label applicator 513 is used for only one type of label on the carton and, after inspection, the identification means on the conveyor section (if employed) is read by a reader (not shown) and/or the identification means on the carton is read by a reader (not shown) and/or the label identification means is read by a reader (not shown). The label applicator 513 will automatically pass the rejected labels on the roll. (the production floor controller 512 provides the record information on the label as a record in the database 60 to the label applicator 513). The label applicator 513 may also include a detection mechanism (not shown) that confirms that each label is in the correct position and not defective before allowing delivery to shipment. If the inspection mechanism, such as a vision system or an operator, does not inspect the labeled products, the non-inspected products are rejected and the inspection for the cartons is repeated from the beginning and the remainder of the cartons within an order will be placed aside. If an error occurs that requires operator attention, the operator may use the manual scanner 519 to notify the label control system 503 that a label has been removed and marked by the database 60 and the production floor controller 512. This step may be performed at any point in the printing or other process of producing the labeled product.

The label applicator 513 preferably continues the labeling and detection steps until all of the labels on the roll are applied to the carton. When no more labels are available on the roll, a signal is indicated to the operator that the roll 551 should be replaced, and no matter which roll the operator is at, he/she must reach the label applicator 513, or the production floor controller 512 will notify the operator to load the next roll 551 on the label applicator 513 so that the label application process will continue.

The package may not require manual identification of the customized product before and/or after use of the particular pattern, and may include only one machine-readable identification device for recording the processed and shipped product. The specific pattern will preferably be used to identify whose product it is, and may not represent any specific information. This is particularly beneficial to prevent the product from being provided to others who do not have the product in their possession.

While the embodiments of the present invention have been illustrated by reference to the accompanying drawings and described in the text, it will be apparent that various changes and modifications in form and detail can be made therein without departing from the spirit and substance of the invention. The invention is not to be limited to the details and arrangements shown and described, except as indicated by the appended claims.

Claims (24)

1. A package for containing at least one contact lens, having an identification means and a specific pattern on at least some surface areas of the package, the specific pattern being selected by a doctor who customizes the contact lens or a patient who receives the contact lens; wherein the specific pattern is specified when the contact lens is ordered by a manufacturer; the package is shipped from the contact lens manufacturer who has the specific pattern and the identification device on the package.

2. The package of claim 1, wherein: the particular pattern is used to identify the person receiving the contact lens.

3. A package as defined in claim 2, wherein: the package does not recognize the customization.

4. The package of claim 1, wherein: the specific pattern is used to identify the doctor who customized the contact lens.

5. The package of claim 1, wherein: the package comprises a primary package, a secondary package, the specific pattern and the identification means being on at least some surface areas of the secondary package.

6. The package of claim 5, wherein: the specific pattern and the identification means are on at least some surface area of the primary package.

7. The package of claim 1, wherein: also included is a non-specific pattern that identifies the manufacturer of the contact lens.

8. The package of claim 7, wherein: the package comprises a primary package, a secondary package, the identification means and the specific pattern being on at least some surface area of the primary package.

9. A package according to claim 8, wherein said primary package is a blister package comprising a bowl and a lid holder, wherein said specific pattern and said identification means are on said lid holder.

10. The package of claim 9, wherein: the specific pattern and the identification means are printed onto the cover frame.

11. The package of claim 9, wherein: the pattern is printed onto a label to be adhered to the cover frame.

12. The package of claim 7, wherein: the package comprises a primary package, a secondary package, the specific pattern being on at least some surface area of the secondary package, the secondary package being a carton.

13. The package of claim 12, wherein: the specific pattern is printed on the carton.

14. The package of claim 14, wherein: the pattern is printed onto a label to be adhered to the carton.

15. The package of claim 1, wherein: the pattern includes alphanumeric symbols.

16. The package of claim 1, wherein: the pattern comprises a picture.

17. A method of producing a specific package containing at least one contact lens, characterized by: the package designated by a single doctor who customizes the contact lens or a patient who receives the at least one contact lens, comprising the steps of:

receiving an order for at least one of said customized products from said physician or a replenishment order from said patient; and

printing a specific pattern and identification means specified by the doctor or the patient for the packaging of at least one of the contact lenses during the manufacturing of the at least one contact lens.

18. The method of claim 17, wherein: the printing step entails printing the specific pattern and identification means on the primary package for the contact lens.

19. The method of claim 17, wherein: the printing step entails printing the specific pattern and identification means on the secondary packaging for the contact lens.

20. The method of claim 17, wherein: the printing step entails printing the specific pattern and the identification means on a label.

21. The method of claim 20 further comprising the step of label surface treating.

22. The method of claim 20, wherein: after the printing step, the method further comprises the step of affixing the label to the package.

23. The method of claim 20, wherein: the package has a machine-readable code and the method further comprises the step of verifying the label identification device and the machine-readable code prior to the affixing step.

24. The method of claim 17, wherein: the printing step is performed by a pattern-specific printing system.