WO2025027442A1

WO2025027442A1 - A shaping station for making a container starting from a semi-finished product and related apparatus

Info

Publication number: WO2025027442A1
Application number: PCT/IB2024/057042
Authority: WO
Inventors: Andrea Bartoli
Original assignee: Sarong Societa' Per Azioni
Priority date: 2023-08-01
Filing date: 2024-07-19
Publication date: 2025-02-06

Abstract

Described is a shaping station (4) for making a container (C) starting from a semi-finished product made of cellulose-based material which defines a containment space, and an apparatus (100) comprising the shaping station (4). The shaping station (4) comprises at least one shaping device (4a), configured for receiving the semi-finished product and for executing a shaping of it. The shaping device (4a) comprises a first shaping element (40) and a second shaping element (41), one between the first and the second shaping elements (40, 41) is configured to receive the semi-finished product. At least one, between the first and the second shaping elements (40, 41) is movable relative to the other, in such a way as to intercept and form the semi-finished product at respective processing surfaces, in order to stabilise on the latter a predetermined thickness and/or a predetermined shape to obtain the container (C).

Description

DESCRIPTION

A Shaping station for making a container starting from a semifinished product and related apparatus

This invention relates to a shaping station for making a container starting from a semi-finished product and to a relative apparatus for making a container comprising the shaping station.

In particular, the invention can be applied in the field of making containers for products, in particular for food, cosmetic, pharmaceutical or other types of products.

There are currently various machines for making these containers, configured for forming a film made of polycoupled material of a plastic type, fed for example from a reel, by multi-impression moulding.

Generally speaking, these machines comprise a plurality of operating stations positioned in sequence, such as, for example, a feeding station, a cutting station and a forming station.

The forming station generally involves the use of a punch which is able to form the polycoupled film of a plastic type in such a way as to obtain the desired container by means of forming techniques of known type which comprise specific mould dies and the blowing of air, for example by the punch itself.

In recent times, with the transition to a more sustainable industry aimed at reducing the use of plastic materials, it has been decided to use a film made of a cellulose-based material, for example paper. The film may be a material made entirely of thermoformable paper, or it may be a polycoupled material with a prevalence of cellulose-based material.

The prior art making machines when fed with cellulose-based material have proved to be disadvantageously ineffective in achieving the desired quality level which, on the contrary, can be obtained with the previously used plastic materials. In detail, it was noted that after forming a cellulose-based material to obtain a container, the formed container is subjected to deformations associated with an elastic return of the cellulose-based material.

In other words, a container made by forming a cellulose-based material has residual stresses and consequently tends to lose its original shape over time, making a storage of empty containers made of cellulose-based material disadvantageous, as well as their use after a period of time. Indeed, since the containers obtained in this way may be defective and cause a large number of rejects, they are unsuitable for being filled with a product and sealed for placing on the market.

Since plastic-based materials tend to maintain over time a shape imparted by forming, both before and after filling them, a use of containers made of cellulose-based material instead of containers made of plastic-based material is disadvantageous and therefore detrimental to transition to a more sustainable industry.

It has also been noted that, after forming of a cellulose-based material to obtain a container, the formed container has a non-uniform thickness.

In other words, a container which is formed from cellulose-based material comprises creases, that is to say, a plurality of humps and dips, on its surface.

Disadvantageously, a non-uniform thickness of a formed container makes it impossible to perform an effective and resistant sealing by applying a closing film on the container, after its filling.

In other words, due to the creases on the surface of a cellulose-based container, a stability in the adherence between a closing film and the container is compromised.

Even more disadvantageously, prior art making machines have proven to be unsuitable for forming a cellulose-based material in such a way as to form on the cellulose-based material the same shape which can be formed on a plastic material. Generally speaking, a container made of plastic material comprises predetermined shapes on its surface such as, for example, corners, connecting radiuses less than 3 mm, text, logos and similar features.

It was noted that forming a container comprising these shapes on a cellulose-based film or sheet results in the breakage of the product and/or in failure to achieve the necessary quality level.

In other words, making a container made of cellulose-based material faithfully replicating the characteristics of a container made of plastic material is complex and difficult, both when it comes to obtaining a shape that lasts over the duration of storage of the empty container as a semifinished product for subsequent processing, and when it comes to obtaining a shape of predetermined quality in terms of the thickness characteristics of the walls and/or their shape.

The technical purpose of the invention is therefore to provide a shaping station for making a container made of cellulose-based material, which is able to overcome the drawbacks of the prior art.

An aim of the invention is to provide a shaping station for making a container made of a cellulose-based material, which allows to obtain containers of the desired quality, that is to say, which have a shape lasting over time and which are able not to interfere with a sealing of the container using films.

A further aim of the invention is to provide a shaping station for making a container by shaping a cellulose-based material which avoids unwanted breakages of the container during its production or during its subsequent use by a consumer.

Another aim of the invention is to provide a shaping station for making a container by shaping a cellulose-based material, which allows shaped parts such as corners, text and the like to be imprinted on the container.

The technical purpose indicated and the aims specified are substantially achieved by a shaping station for making a container comprising the technical features described in one or more of the appended claims. The dependent claims correspond to possible embodiments of the invention. In particular, the technical purpose indicated and the aims specified are substantially achieved by a shaping station for making a container defining a containment space for a product, preferably a food product.

According to the invention, a shaping station is proposed for making a container starting from a semi-finished product made of a cellulose-based material, wherein said semi-finished product comprises a base wall, a lateral wall, and a flanged edge extending from the lateral wall, the base wall and the lateral wall defining a containment space, the shaping station comprising: a feeding device, configured for feeding at least one semifinished product; at least one shaping device, positioned downstream of said feeding device and configured to receive said semi-finished product and to execute a shaping of said semi-finished product, wherein the shaping device comprises a first shaping element and a second shaping element; wherein one between the first shaping element and the second shaping element is configured to receive said semi-finished product, and wherein at least one, between the first shaping element and the second shaping element, is movable relative to the other, in such a way as to intercept the semi-finished product for forming the semi-finished product at respective processing surfaces, in order to stabilise on said processing surfaces a predetermined thickness and/or a predetermined shape for obtaining said container.

For this reason, thanks to the first shaping element and the second shaping element it is possible to form a shaping of a semi-finished product obtained by forming a sheet, or a film, made of cellulose-based material allowing both a removal of any, and often present, residual stresses of the semi-finished product formed, and a definition on the semi-finished product of shapes such as connecting radiuses, corners, texts, logos or others.

The shaping allows not only to produce a container of the desired quality and having a long-lasting shape, but also to prevent unwanted breakages of the container during its production and during its use, and, at the same time, allows shapes to be imprinted on the container such as corners, text and the like.

According to one version, the apparatus comprises a feeding station for feeding a film, a station for cutting the film positioned downstream of the feeding station, a forming station, which is positioned downstream of the cutting station and which is configured for receiving and for forming the sheets in such a way as to obtain a semi-finished product comprising a casing defining a containment space, and a shaping station, which is positioned downstream of the forming station and which is configured for receiving the semi-finished products and for performing a shaping, that is to say, a further deformation or forming, of each semi-finished product to obtain the container.

It should be noted that the shaping station can be integrated in the apparatus, that is to say, in a production line, or it can be used as such since it comprises a feeding device configured for feeding at least one semifinished product inside the station.

Further features and advantages of the invention will be more apparent in the following non-limiting description of a shaping station and an apparatus for making a container.

The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without restricting the scope of the invention and in which:

- Figure 1 and Figure 2 are schematic representations of an apparatus for making a container according to this invention, according, respectively, to a first and second embodiment;

- Figures 3A-3F are schematic views of a succession of processing operations performed by a forming station of the apparatus of Figures 1 and 2;

- Figure 3G is an enlargement of Figure 3D; - Figure 4 is a schematic view of a shaping station of the apparatus of Figures 1 and 2 comprising a first shaping element and a second shaping element positioned in a closed configuration;

- Figure 5 is a schematic view of the shaping station of Figure 4 comprising the first shaping element and the second shaping element positioned in an open configuration;

- Figure 6 and Figure 7 are schematic views, respectively, of the first and second shaping elements;

- Figure 8 and Figure 9 are schematic views of the first shaping element, respectively, in a first and second embodiment;

- Figures 10 to 12 are schematic views of containers obtained or which can be obtained by means of the apparatus of Figures 1 and 2, and by means of the shaping station of Figures 3 to 9.

With reference to the accompanying drawings, the numeral 4 denotes a shaping station for making a container “C” starting from a semi-finished element “S” in its entirety, and the numeral 100 denotes an apparatus for making a container “C” starting from a film made of cellulose-based material in its entirety which, for simplicity of description, will hereafter be referred to as the apparatus 100.

With reference to Figures 5 and 10-12, the container “C” defines a containment space “Vc” for a product, for example a food product, or a cosmetic or pharmaceutical product, or of other types.

More in detail, the container "C" comprises a base wall "C1" and a lateral wall "C2" defining the containment space "Vc", and a flanged edge "C3" extending from the lateral wall "C2".

With reference to Figures 3F and 4, the semi-finished product “S” comprises a base wall “S1 ”, a lateral wall “S2”, and a flanged edge “S3” extending from the lateral wall “S2”.

More in detail, the base wall "S1" and the lateral wall "S2" define a containment space "V" of the semi-finished product "S". Preferably, the containment space “V” of the semi-finished product “S” is different from the containment space “Vc” of the container “C”.

The semi-finished product “S” may also comprise a film “F”, in turn comprising at least one concavity defined by a lateral wall “S2” and a base wall “S1 ”.

Preferably, the semi-finished product “S”, as well as the container “C” made from the semi-finished product “S”, is made of a cellulose-based material. The cellulose-based material may be either thermoformable paper, or it may be a polycoupled material with a prevalence of cellulose-based material.

In the latter case, the polycoupled material (not illustrated) may comprise a first layer of paper and/or paperboard, a second layer of thermoplastic polymer and a third layer of paper and/or paperboard. Still more preferably, the polycoupled material may comprise a fourth layer, optionally peelable, made of thermoplastic polymer configured to come into contact with the food product.

Preferably, the first layer of paper is thermoformable, optionally recyclable or compostable.

Preferably, the first layer of paper and/or paperboard is made of paper having a grammage of 50-500 gr/m2 coupled by means of the second layer (for example polyethylene, or a compostable plastic material) to the third layer consisting of paper having a grammage of 50-500 gr/m2 with features similar to the first layer and optionally with a different thickness. The fourth layer, which can be optionally peelable, may be made of polyethylene (abbreviated PE) or Mater-bi, polyhydroxyalkanoates (PHA) and in particular in polyhydroxybutyrate (PHB) or other recycled, recyclable or compostable plastic materials.

The material, according to a simplified version, may also comprise a single layer of thermoformable paper which can be optionally recycled or compostable, with a basic weight of 50-500 gr/m2. The material in its simplified version can be used, for example, when used for packaging products which do not require an impermeable layer. Optionally, a first layer of paper and/or paperboard with a grammage of 50- 500 gr/m2 may be coupled to a second layer having a function of an oxygen barrier, for example made of EVOH or PVOH, and to a sealable and optionally peelable third layer which may be made of polyethylene (abbreviated PE) or Mater-bi, polyhydroxyalkanoates (PHA) and in particular the polyhydroxybutyrate (PHB) or other recycled, recyclable or compostable plastic materials.

The term “grammage" means a density value of paper and/or paperboard, which is expressed as a value in grams per square metre.

In use, the shaping station 4 can be used as such, for performing processing operations on a semi-finished product “S”, or it can be integrated into the apparatus 100.

The shaping station 4 comprises a feeding device (not illustrated in the accompanying drawings) configured for feeding a semi-finished product “S”. For this reason, the feeding device is configured for picking up a semifinished product “S” from a storage station, not illustrated, if the shaping station 4 is used as such, or for feeding the semi-finished product “S” from a station of the apparatus 100 if the shaping station 4 is integrated into the apparatus 100.

With reference to Figures 4 and 5, the shaping station 4 comprises at least one shaping device 4a, positioned downstream of the feeding device and configured to receive the semi-finished product “S” and to execute a shaping of the semi-finished product “S”.

The term “shaping” means a processing of the semi-finished product “S” aimed at giving the semi-finished product “S” a predetermined profile, that is to say, a shape.

The term “shape” means any profile, line, thickness or shape of the container “C”, such as, for example, connecting radiuses, edges, text, logos and others.

In detail, the shaping device 4a comprises a first shaping element 40 and a second shaping element 41 . One between the first shaping element 40 and the second shaping element 41 , and preferably the first shaping element 40, is configured to receive the semi-finished product “S” fed by means of the feeding device.

At least one between the first shaping element 40 and the second shaping element 41 , and preferably the second shaping element 41 , is movable relative to the other, in such a way as to intercept the semi-finished product “S” for forming the semi-finished product “S” at respective processing surfaces “A”, illustrated in Figures 4, 8 and 9 by way of a non-limiting example.

The first shaping element 40 and the second shaping element 41 are therefore designed to intercept the semi-finished product "S" for performing a forming of the semi-finished product "S", that is to say, for transferring on the semi-finished product "S" at least part of a shape of the first shaping element 40 and/or of the second shaping element 41 .

Preferably, the shaping station 4 comprises at least one pushing element 5 connected or connectable to:

- the first shaping element 40, to move the first shaping element 40 towards the second shaping element 41 , according to a predetermined shaping contact force between the first shaping element 40, the processing surfaces “A” of the semi-finished product “S” and the second shaping element 41 , and/or

- the second shaping element 41 , to move the second shaping element 41 towards the first shaping element 40, according to a predetermined shaping contact force between the first shaping element 40, the processing surfaces “A” of the semi-finished product “S” and the second shaping element 41 . Preferably, according to a version of the shaping station 4 illustrated in the accompanying drawings, the pushing element 5 is connected to the second shaping element 41 , whilst the first shaping element 40 is fixed.

According to an embodiment, the pushing element 5 is made in the form of a pneumatic cylinder.

Preferably, the shaping station 4 comprises a control unit (not illustrated in the accompanying drawings) operatively connected to the pushing element 5 for controlling an actuation of the pushing element and configured to allow a user to set the above-mentioned shaping contact force.

Thanks to the pushing element 5 it is possible to set up and monitor parameters that influence the forming of the semi-finished product “S” (making it more or less effective and longer lasting) such as the above- mentioned shaping contact force.

The forming of the semi-finished product “S”, performed by the first shaping element 40 and by the second shaping element 41 , is designed to stabilise on the processing surfaces “A” of the semi-finished product “S” a predetermined thickness and/or a predetermined shape to obtain said container “C”.

The term “stabilise" means making the predetermined thickness and/or the predetermined shape defined on the semi-finished product "S" by means of the shaping device 4a durable and constant over time, in such a way that the container "C" obtained does not undergo subsequent deformations, associated with, for example, residual stresses.

Generally speaking, the semi-finished product “S” is produced by forming a film or a sheet of cellulose-based material and such forming is aimed at defining an original shape on the semi-finished product “S” but may introduce residual stresses in the formed semi-finished product “S” which cause an elastic return of the cellulose-based material after the latter has been formed.

Consequently, there is a non-durability and a non-constant nature over time of the original shape of the semi-finished product “S”, which, on the contrary, tends to deform spontaneously losing its original shape.

Thanks to the shaping station 4, in detail thanks to the first shaping element 40 and the second shaping element 41 designed to form the semi-finished product “S” to obtain the container “C”, it is possible to reduce the residual stresses in the semi-finished product “S”, stabilising a shape of the container “C” over time. In this way, for example, it is possible to store a semi-finished product “S” admitting a relative deformation (linked to the residual stresses contained therein) and then perform at a later time a shaping of the semi-finished product “S” by means of the shaping station 4, in such a way as to stabilise, and therefore make durable over time, a predetermined thickness and/or a predetermined shape on the semi-finished product “S” to obtain a container “C” to be filled, to be sold, or to be used in another way.

In addition to the above, generally, a semi-finished product “S” produced by forming a film or a sheet of cellulose-based material comprises creases, that is to say, humps and dips, on its surface, making its sealing, for example by means of films which are sealed at the flanged edge “S3”, complex.

Thanks to the first shaping element 40 and the second shaping element 41 , designed to form the semi-finished product “S”, it is possible to stabilise a uniform thickness on the semi-finished product “S” to guarantee a facilitated sealing of the container “C” obtained.

According to an embodiment, the first shaping element 40 and the second shaping element 41 generate a predetermined contact force acting on the flanged edge "S3", in such a way as to stabilise a thickness on it and, at the same time eliminating any creases.

This contact force is preferably between 80 kg/cm² and 130 kg/cm², more preferably between 90 kg/cm² and 120 kg/cm². For example, the contact force can be 95 kg/cm² or 1 17 kg/cm²

In other words, the pushing element 5 which can be connected to the first shaping element 40 and/or to the second shaping element 41 is able to generate the contact force indicated above.

It should be noted that the sealing of a container “C” by applying a closing film on the flanged edge “C3” of the container “C” contributes to a stabilisation of a shape of the container “C” over time.

In more detail, a closing film sealed on the flanged edge “C3” of a container “C”, as it is not very extendible, is able to considerably limit a widening of a profile of the flanged edge “C3”. More in detail, with reference to Figures 4, 5, 8 and 9, the first shaping element 40 is preferably configured to receive, even more preferably supporting, the flanged edge “S3” of the semi-finished product “S”.

The first shaping element 40 and the second shaping element 41 are movable along an operating direction “X” between:

- an open configuration, illustrated in Figure 5, wherein they are spaced apart, for example to allow a feeding of the semi-finished product “S” or (in the case of Figure 5) to allow an extraction of the container “C” formed using the first shaping element 40 and the second shaping element 41 , and

- a closed configuration, illustrated in Figure 4, wherein they are close together in such a way as to intercept at least the flanged edge “S3” of the semi-finished product “S” in order to stabilise a uniform thickness on the flanged edge “S3”.

In other words, the processing surfaces "A" are at least partly located on the flanged edge "S3".

According to an embodiment not illustrated, the second shaping element 41 is made in the form of a pressing device having a shape, for example annular, designed to intercept the flanged edge “S3”.

When made in the form of a pressing device, the second shaping element 41 preferably has a shape such that it adapts to the semi-finished product “S”, thus ensuring a facilitated shaping of the semi-finished product “S” and allowing a greater uniformity of the thickness stabilised on the flanged edge “S3”.

For this reason, the second shaping element 41 , when made in the form of a pressing device, may be made in different sizes (for semi-finished products “S” having different shapes), even more preferably the second shaping element 41 is interchangeable in the shaping station 4 when necessary.

Thanks to the first shaping element 40 and the second shaping element 41 , which are designed to form the semi-finished product “S”, it is therefore possible to “level” and “flatten” the humps, the dips and the creases on the semi-finished product “S”, stabilising a uniform thickness on the flanged edge “S3” and thus allowing to obtain a container “C” having a respective flanged edge “C3” able to guarantee a correct and durable sealing.

Figure 8 shows an embodiment of the first shaping element 40 wherein the first shaping element 40 comprises a respective surface intended to receive, preferably to support, the flanged edge “S3” of the semi-finished product “S”.

For this reason, according to this embodiment, in the closed configuration the first shaping element 40 and the second shaping element 41 are positioned at a predetermined distance, measured along the operating direction “X”, corresponding to a predetermined and uniform thickness stabilised on the flanged edge “S3” by means of the first shaping element 40 and the second shaping element 41 (when in the closed configuration). Preferably, the shaping station 4 comprises a control unit (not illustrated in the accompanying drawings) configured to allow a user to set the above- mentioned predetermined distance and operatively connected to the first shaping element 40 and/or to the second shaping element 41 for controlling a movement of them.

It is therefore possible, in the same shaping station 4, to stabilise on the flanged edge “S3” of different semi-finished products “S” respectively different thicknesses, since the predetermined distance and, therefore, the predetermined thickness on the flanged edge “S3” can be modified over time.

Figure 9 shows a further embodiment of the first shaping element 40 wherein the first shaping element 40 comprises a groove “G”, configured to receive the flanged edge “S3” of the semi-finished product “S”.

According to this further embodiment, in the closed configuration the second shaping element 41 is positioned in abutment with a portion of the first shaping element 40 adjacent to the groove "G", in such a way as to intercept the flanged edge "S3" in order to stabilise on the flanged edge "S3" a thickness which is uniform and equal to a depth of the groove "G". Thanks to the first 40 and the second 41 shaping element, it is possible to reduce a thickness of the base wall “S1 ” of the semi-finished product “S”, or of part of the base wall “S1 ” (on the basis of the requirements), in such a way as to obtain a container “C” having a base wall “C1 ” with reduced thickness, or comprising zones with reduced thickness.

Thanks to the first 40 and the second 41 shaping element, it is possible to reduce a thickness of the lateral wall “S2” of the semi-finished product “S”, or part of the lateral wall “S2” (on the basis of the requirements), in such a way as to obtain a container “C” having a lateral wall “C2” with reduced thickness, or comprising areas with reduced thickness.

In order to reduce a thickness of the lateral wall “S2” (or of a part thereof) and/or of the base wall “S1 ” (or of a part thereof) of the semi-finished product “S”, it is possible to actuate the pushing element 5 to move one between the first 40 and the second 41 shaping element towards the other in such a way as to concentrate the thrust produced by the pushing element 5 in a predetermined zone of the first 40 or of the second 41 shaping element.

More in detail, if the pushing element 5 is connected to the first shaping element 40, the pushing element 5 is connected to a portion of the first shaping element 40 for moving it towards the second shaping element 41 according to a shaping contact force (between the first shaping element 40, the processing surfaces “A” of the semi-finished product “S” and the second shaping element 41 ) which is predetermined and concentrated in the zone in which the pushing element 5 is connected to the first shaping element 40. In other words, if the pushing element 5 is connected to a portion of the first shaping element 40 intended to come into contact with the base wall "S1" of the semi-finished product "S" (or on part of it), the shaping contact force will be concentrated on the base wall "S1" and a container "C" will be obtained whose base wall "C1 " has reduced thickness, or comprises zones with reduced thickness.

In the same way, if the pushing element 5 is connected to the second shaping element 41 , the pushing element 5 is connected to a portion of the second shaping element 41 for moving it towards the first shaping element

40 according to a shaping contact force (between the first shaping element 40, the processing surfaces “A” of the semi-finished product “S” and the second shaping element 41 ) which is predetermined and concentrated in the zone in which the pushing element 5 is connected to the second shaping element 41 .

In other words, if the pushing element 5 is connected to a portion of the second shaping element 41 intended to come into contact with the lateral wall “S2” of the semi-finished product “S”, the shaping contact force will be concentrated on the lateral wall “S2” (or on part of it) and a container “C” will be obtained whose lateral wall “C2” has reduced thickness, or comprises areas with reduced thickness.

Preferably, the first shaping element 40 and/or the second shaping element

41 comprises a heating element (not illustrated in the accompanying drawings), configured for heating the respective first shaping element 40 and second shaping element 41 .

Thanks to the heating element it is possible to heat one or more portions of the semi-finished product “S” after stabilising a predetermined thickness on the base wall “S1 ” or lateral wall “S2” of the semi-finished product “S”, in such a way as to facilitate and make longer lasting the stabilised thickness. These features are particularly advantageous when the container “C” is intended for use on dispensing machines, that is to say, when the container “C” is single-use and single-dose and is a capsule for beverages. In this case:

- the containment space “Vc” of the container “C” is intended to contain the initial product, for example ground coffee or tea, from which the final product, for example the beverage, is obtained;

- a covering element suitable for hermetically closing the containment space “Vc” of the container “C” is applied on the flanged edge “C3”, in order to seal the initial product inside the container “C”.

In use, that is to say, when it is inserted in a dispensing machine, the container "C" can be perforated to allow the introduction of pressurised liquid, typically water, and the dispensing of the beverage obtained.

Generally, the base wall "C1 " and/or the lateral wall "C2" is perforated by an injection device, or extraction device, of the dispensing machine.

The container “C” may, for example, be used in a dispensing machine of a first type in which the base wall “C1 ” is perforated by an injection device for injecting liquid under pressure, for example water, into the capsule and the covering element is perforated by an extraction device to allow the final product to be dispensed.

The injection device may comprise a plurality of blades and/or nozzles provided with respective pointed ends, configured for perforating the base wall “C1 ”.

The extraction device may comprise a plurality of sharp elements which, engaging with the covering element during extraction, perforate it in a plurality of different zones.

In this case, it is advantageous that the zones with reduced thickness of the base wall “01 ” are those intended to be perforated by the corresponding blades and/or nozzles of the injection device.

On the other hand, if the container “C” is used in a dispensing machine of a second type, the base wall “C1 ” may be perforated by an extraction device to allow the extraction of the beverage whilst the covering element may be perforated by an injection device. Typically, in this case, the fluid injection device and the extraction device of the dispensing machine are made as nozzles provided with a pointed end.

In this case, it is advantageous that the zones with reduced thickness of the base wall “C1 ” are those intended to be perforated by the corresponding nozzle of the extraction device.

It is therefore necessary that the container “C” guarantees a high quality of dispensing: for this purpose, it is necessary for the base wall “01 ” to be easily perforated, to guarantee the correct injection of water into the capsule or the extraction from it of the final product. Thanks to the possibility of reducing a thickness of the base wall S1 ” or of the lateral wall “S2” of the semi-finished product “S” (or parts of them), it is possible to obtain a container “C” having a base wall “C1 ”, or zones of it, or a lateral wall “C2”, or areas of it, with a reduced thickness and which can be easily perforated.

As illustrated in Figure 7, it should be noted that the second shaping element 41 comprises at least a first portion 400 and at least a second portion 401 defining at least one recess 402 having a predetermined shape.

Moreover, with reference to Figures 6 and 7, the first shaping element 40 has a shape shaped to match the first portion 400 and/or the second portion 401 , in order to stabilise a shape of the recess 402 on the processing surfaces “A” of the semi-finished product “S”.

The recess 402 may also be made, according to a variant embodiment not illustrated, in the first shaping element 40.

It should be noted that the processing surfaces "A" may be positioned, at least partially, on the base wall "S1 " and on the lateral wall "S2" of the semifinished product "S".

Hence, at least one between the first shaping element 40 and the second shaping element 41 may have the recess 402 and the first shaping element 40 is at least partly shaped to match the second shaping element 41 (and vice versa) in such a way as to stabilise on the semi-finished element “S” the recess 402.

Thanks to the first portion 400 and the second portion 401 , and therefore thanks to the recess 402 defined by the portions themselves, it is possible to stabilise a shape of various types on the semi-finished product “S” in such a way as to obtain a container “C” which faithfully replicates a container made of plastic, favouring a transition towards a more sustainable industry. Generally speaking, in fact, containers made of plastic material comprise shapes, that is to say, profiles, such as, for example, those illustrated in Figures 10 to 12.

Purely by way of a non-limiting example, containers made of plastic material generally comprise shapes such as:

- with reference to Figure 10, a recess "I", preferably annular or frame-like, in the base wall "S1", which is useful, for example, for defining a compatibility of the container "C" with machines in which the container "C" can be inserted, for example coffee machines, or for realizing a facilitated nesting of the container "C" in other containers "C" defining a spacing between the flanged edges "C3" of nested containers "C"; and/or

- with reference to Figures 1 1 and 12, an edge “Z”, preferably in the lateral wall “S2”, having, for example, a utility which is identical to those discussed with reference to the recess “I”; and/or

- any other shape not illustrated in the accompanying drawings, texts and logos included.

The forming the above-mentioned shapes (recess "I", edge "Z" or other) is easily obtained starting from plastic materials whilst it is difficult starting from cellulose-based film or sheets since it breaks the film, or the sheet, during its forming to obtain the container "C".

Since the shaping station 4 is configured to perform a forming of a semifinished product “S” already having, unlike a film or a sheet, a respective containment space “V”, it is possible to stabilise on the semi-finished product “S” the above-mentioned shapes (recess “I”, edge “Z” or others) without the need to define at the same time a containment space “V”.

Thanks to the shaping station 4 it is possible to perform a stabilisation of shapes such as the recess “I” or the edge “Z” on the semi-finished product “S” in a facilitated manner, preventing any breakage of the semi-finished product “S” during its shaping.

With reference to the accompanying drawings, the first shaping element 40 is shaped to match the second shaping element 41 in such a way as to stabilise between the base wall "S1" and the lateral wall "S2", and/or between the lateral wall "S2" and the flanged edge "S3" of the semi-finished product "S" a final connecting radius less than an initial connecting radius, respectively between the base wall "S1" and the lateral wall "S2" and/or between the lateral wall "S2" and the flanged edge "S3" of the semi-finished product "S" fed by the feeding device (not illustrated in the accompanying drawings).

The fact that the first shaping element 40 has a shape which is shaped to match the second shaping element 41 makes it possible to effectively stabilise the container “C”. By using the first shaping element 40 and the second shaping element 41 it is possible to modify a shape of the semifinished product "S" by executing and stabilising on it a reduction of the connecting radius between the base wall "S1" and the lateral wall "S2", and/or between the lateral wall "S2" and the flanged edge "S3" of the semifinished product "S".

Preferably, the final connecting radius is less than 2 mm, even more preferably the final connecting radius is less than 1 mm.

For example, it is possible, by means of the first shaping element 40 and the second shaping element 41 , to stabilise on the semi-finished product "S" a right angle (an angle of 90 degrees) between the base wall "S1 " and the lateral wall "S2", and/or between the lateral wall "S2" and the flanged edge "S3".

In other words, thanks to the shaping station 4 it is possible to stabilise a final connecting radius equal to 0 mm.

Thanks to the first shaping element 40 and the second shaping element 41 it is therefore possible to "adjust", that is to say, "finish" and "shape", a profile of the container "C" obtained from the semi-finished product "S", making a profile of the container "C" more or less "bevelled".

According to an embodiment illustrated in Figures 4 to 9, the shaping station 4 comprises the first shaping element 40, in turn comprising a male mould element 40a, and the second shaping element 41 , in turn comprising a mould die 41 a.

In detail, the male mould element 40a is configured to be inserted in the containment space “V” of the semi-finished product “S”, and the mould die 41 a is opposite to the male mould element 40a and movable towards the male mould element 40a to form the semi-finished product “S”.

Preferably, the mould die 41 a is at least partly shaped to match the male mould element 40a.

Thanks to the male mould element 40a, designed to be inserted in the containment space “V”, and to the mould die 41 a it is therefore possible to stabilise a predetermined thickness and/or a predetermined shape simultaneously on the base wall “S1 ”, on the lateral wall “S2” and preferably on the flanged edge “S3” of the semi-finished product “S”, reducing a time for processing the semi-finished product “S” to obtain the container “C”.

Preferably, the male mould element 40a is configured for receiving and supporting the base wall “S1 ” of the semi-finished product “S” and the mould die 41 a is positioned above the male mould element 40a.

Thanks to this positioning of the male mould element 40a and of the mould die 41 a it is possible to define a self-centring by gravity of the semi-finished product “S” on the male mould element 40a.

According to an embodiment, not illustrated, the male mould element 40a and the mould die 41 a define a mould having a variable geometry.

More in detail, the male mould element 40a has a fixed portion, intended to receive the flanged edge “S3” of the semi-finished product “S”, and a movable portion, intended to be inserted in the containment space “V” of the semi-finished product “S” receiving and supporting the base wall “S1 ” of the semi-finished product “S”.

In particular, the movable portion is concentric with respect to the fixed portion and axially movable and/or adjustable.

The term “axially movable and/or adjustable” means a movement and/or an adjustment of the position of the movable portion with respect to the fixed portion along the axis about which the fixed and movable portions of the male mould element 40a extend. With reference to Figure 5, the movable portion can be moved, and/or adjusted in height, along the operating direction "X".

Optionally, the mould die 41 a may comprise a fixed portion, intended to intercept the flanged edge “S3” of the semi-finished product “S”, and a movable portion, intended to intercept the base wall “S1 ” of the semifinished product “S”.

According to an embodiment, the movable portion of the mould die 40a is axially adjustable as a function of the adjustment of the movable portion of the male mould element 40a, allowing the mould die 41 a to be adapted to the axial adjustment of the movable portion of the male mould element 40a. The movable portion of the mould die 40a may alternatively be mounted on springs to make contact with the movable portion of the male mould element 40a and adapt to its axial adjustment.

Alternatively, the mould die 40a has a through cavity, intended to receive the movable portion of the male element 40a and the semi-finished product “S” carried by the latter.

The mould die 41 a is configured for making contact against the fixed portion of the male mould element 40a (that is to say, around the movable portion) intercepting the flanged edge “S3” of the semi-finished product “S”.

It is therefore possible to adjust a positioning of the movable portion of the male mould element 40a so that it is positioned to support the semi-finished product “S” while keeping the flanged edge “S3” suspended with respect to the fixed portion.

By moving the mould die 41 a towards the fixed portion of the male mould element 40a, it is possible to shape the semi-finished product “S” smoothing a first part of the suspended flanged edge “S3” in such a way that it becomes part of the lateral surface “S2”, and pressing a second part of the suspended flanged edge “S3” against the fixed portion of the male mould element 40a when the mould die 41 a comes into contact with the fixed portion of the male mould element 40a.

Alternatively, it is possible to position a semi-finished product “S” resting on the male mould element 40a and lock the flanged edge “S3” of the semifinished product “S” positioning the mould die 41 a in contact with the fixed portion of the male mould element 40a. By moving the movable portion of the male mould element 40a in such a way as to intercept the base wall “S1 ” of the semi-finished product “S” it is possible to smooth the semi-finished product “S” in such a way as to increase an extension of its lateral wall “S2”.

For this reason, thanks to this embodiment it is possible to obtain a container "C" having a respective containment space "Vc" greater than the containment space "V" of the semi-finished product "S".

According to a further embodiment, the semi-finished product “S” may be housed in the mould die 41 a for receiving the movable portion of the male mould element 40a.

According to an embodiment not illustrated in the accompanying drawings, the first shaping element 40 comprises a plurality of male mould elements 40a and the second shaping element 41 comprises a corresponding plurality of mould dies 41 a, wherein the pluralities of male mould elements 40a and mould dies 41 a are designed to receive in series and stabilise in series on a semi-finished product “S” a respective plurality of predetermined thicknesses and/or predetermined shapes.

Thanks to the plurality of male mould elements 40a and the plurality of mould dies 41 a it is possible to set, for each male mould element 40a and for each mould die 41 a, a shaping contact force applied by the respective pushing element 5 suitable with respect to the corresponding shapes and/or thickness.

Preferably, the first shaping element 40 and/or the second shaping element 41 comprises a heating element (not illustrated in the accompanying drawings), configured for heating the respective first shaping element 40 and second shaping element 41 .

Thanks to the heating element it is possible to heat one or more portions of the semi-finished product “S” after stabilising a predetermined thickness and/or a predetermined shape on the semi-finished product “S”, facilitating and making longer lasting the stabilised thickness and/or shape.

Moreover, thanks to the heating element it is possible to heat one or more portions of the semi-finished product “S” before stabilising a predetermined thickness and/or a predetermined shape on the semi-finished product “S”, in such a way as to reduce the force necessary to perform the shaping, that is to say, to give the semi-finished product “S” predetermined shapes and/or thicknesses . In fact, a heating of the semi-finished product “S” makes the material from which it is made more malleable.

According to an embodiment, both the first shaping element 40 and the second shaping element 41 comprise a respective heating element. In other words, the first and the second shaping elements 40, 41 may be heated, by means of the heating element, up to respective temperatures which are different between each other.

For example, if the semi-finished product “S” comprises a layer of plastic material, such as polyethylene, and a layer of paper material, the shaping element, between the first and the second shaping elements 40, 41 in contact with the layer of plastic material is heated to a temperature lower than, or equal to, the temperature to which the other shaping element between the second and the first shaping element 41 , 40 in contact with the layer of paper material is heated, ,.

Preferably, the shaping element 40, 41 in contact with the layer of plastic material is heated up to a first temperature of between 25°C and 100°C, whilst the shaping element 40, 41 , in contact with the layer of paper material is heated up to a second temperature of between 25°C and 160°C.

For example, according to an embodiment, the first temperature is equal to 60°C whilst the second temperature is equal to 1 15°C.

According to an alternative embodiment, the first and the second shaping elements 40, 41 are both at ambient temperature.

According to a further embodiment, one between the first and the second shaping element 40, 41 comprises a compressed air injector.

Preferably, the injector is configured for injecting compressed air at a pressure greater than 6 bar, preferably between 10 bar and 35 bar.

Preferably, the male mould element 40a comprises the injector, whilst the mould die 41 a comprises logos and/or text to be imprinted on the semifinished product “S”. Therefore, prior to a distancing between the male mould element 40a and the mould die 41 a, that is, during shaping of the semi-finished product "S", the injector is configured for injecting compressed air in the direction of the semi-finished product "S" in such a way as to cause a distancing of the semi-finished product "S" from the male mould element 40a towards the mould die 41 a. This distancing is sufficient to allow a flow of compressed air inside the semi-finished product "S" whilst maintaining a hydraulic seal which is able to prevent leaks of compressed air exiting from the semi-finished product "S".

Consequently, thanks to the compressed air injected by means of the injector it is possible to imprint in an improved manner the texts and/or the logos of the mould die as well as improve the definition of all the geometries which characterise the mould die 41 a.

According to a further embodiment, not illustrated in the accompanying drawings, the mould die 41 a is replaced by a body with an imprinted logo and/or text, suitable for being pushed against the male mould element 40a to intercept a portion of the base wall “S1 ” and/or of the lateral wall “S2” of the semi-finished product “S” in such a way as to stabilise the text or the logo on it.

According to a further embodiment, not illustrated in the accompanying drawings, the mould die 41 a is replaced by a body having a substantially annular shape, suitable for contacting the flanged edge “S3” to stabilise on the edge a predetermined thickness, or predetermined shapes or logos.

As described above, in use, the shaping station 4 can be used as such, for performing processing operations on a semi-finished product “S”, or it can be integrated in the apparatus 100.

In more detail, the apparatus 100 is configured for making a container “C”. With reference to Figures 1 and 2, the apparatus 100 defines a respective processing path “L” and comprises a feeding station 1 configured for introducing in the processing path “L” at least one film “F” made of a cellulose-based material, for example, unrolling a reel “B”.

Downstream of the feeding station 1 , the apparatus 100 comprises a cutting station 2 configured for intercepting the film "F" fed along the processing path "L" and for cutting the film "F", in such a way as to obtain at least one sheet "F1 ", for example circular in shape.

The apparatus 100 further comprises a forming station 3 positioned downstream of the cutting station 2.

The apparatus 100, as described below, may not comprise the cutting station 2; in that case, the film “F” is transferred from the feeding station 1 directly to the forming station 3.

The forming station 3 comprises at least one forming device 3a, configured to receive the sheet “F1 ” cut in the cutting station 2 and to form the sheet “F1 ” in such a way as to define the semi-finished product “S”.

With reference to Figure 1 , the forming station 3, and in particular the forming device 3a, comprises at least a respective male mould element 30 and a respective mould die 31 opposite the male mould element 30.

At least one between the male mould element 30 and the mould die 31 is movable relative to the other along an operating direction "Y", in such a way as to intercept and form the sheet "F1" to obtain the semi-finished product "S".

Preferably, the forming station 3 also comprises a pressing device 32 which can be moved along the operating direction "Y" and configured to protect a peripheral portion of the sheet "F1 " and to block or rub the peripheral portion of the sheet "F1 ", in such a way as to define, during the forming of the semifinished product "S" by means of the forming device 3a, the flanged edge "S3" of the semi-finished product "S".

In use, the mould die 31 is configured for receiving and supporting a peripheral portion of the sheet “F1 ”, cut by the cutting station 2, and, the forming station 3 is configured for performing on the sheet “F1 ” a forming step to obtain the semi-finished product “S”. Preferably, the forming station 3 is configured to perform a deep-drawing step on the sheet “F1 ”, before the forming step.

The deep-drawing step comprises:

- with reference to Figures 3A and 3B, a movement of the pressing device 32 towards the sheet “F1 ” resting on the mould die 31 , in such a way that the pressing device 32 comes into contact with the peripheral portion of the sheet “F1 ” allowing, however, a sliding; it follows that the peripheral portion of the sheet “F1 ” is interposed and slidable between the mould die 31 and the pressing device 32;

- with reference to Figures 3C and 3D, a movement of the male mould element 30 towards the mould die 31 , and thus towards the sheet “F1 ”, in such a way as to intercept the sheet “F1 ” to define a sliding of the sheet “F1 ” in the mould die 31 and between the mould die 31 and the pressing device 32.

In more detail, the forming step comprises a movement of the male mould element 30 towards the mould die 31 in such a way that the male mould element 30 is positioned at a distance from the mould die 31 , measured along the operating direction “Y”, predetermined as a function of the material with which the sheet “F1 ” is made.

The forming step comprises a plastic elongation deformation of the sheet “F1 ”, with reference to Figures 3E and 3F:

- a movement of the pressing device 32 towards the sheet “F1 ” resting on the mould die 31 , in such a way that the pressing device 32 comes into contact with the peripheral portion of the sheet “F1 ” blocking it; it follows that the peripheral portion of the sheet “F1 ” is interposed and constrained between the mould die 31 and the pressing device 32;

- a movement of the male mould element 30 towards the mould die 31 , and thus towards the sheet “F1 ”, until pressing the sheet “F1 ” against the mould die 31 , in such a way as to form the sheet “F1 ” and make the semi-finished product “S”;

- a movement of the male mould element 30 away from the mould die 31 and from the semi-finished product “S” obtained to allow its extraction from the mould die 31 .

At least during the forming step, the pressing device 32 performs the function of reducing the formation of creases, that is to say, humps and dips, present on the sheet ‘F1 For this purpose, the pressing device 32 optionally comprises a tooth 32a illustrated in Figure 3G intended to come into contact with the sheet “F1 ”.

Thanks to the tooth 32a it is therefore possible to limit the formation of the creases on the sheet “F1 ” to be formed.

Preferably, the pressing device 32 may be made in different sizes, to obtain respective semi-finished products “S” having different shapes, even more preferably the sizes are interchangeable according to requirements in the forming station 3. Advantageously, thanks to the above-mentioned sizes it is possible to use a specific pressing device 32 configured for making a semi-finished product “S” of desired shape, thus guaranteeing an effective limitation in the formation of creases on the sheet “F1 ”.

The use of the tooth 32a, or the formats, described above is not, however, sufficient to prevent a poor adherence between the flanged edge "S3" of the semi-finished product "S" and a closing film.

According to an aspect of the apparatus 100, the forming station 3 is configured to perform only the forming step.

It should be noted that the deep-drawing and forming steps comprise a sliding of the sheet “F1 ” along a profile of the mould die 31 ; it is therefore difficult to form on the sheet “F1 ” shapes of various types simultaneously with the containment space “V” to obtain the semi-finished product “S”.

In other words, a recess 402 of the type contained in the shaping device 4a would cause a tearing, or at least a damage, of the sheet “F1 ” during its deep-drawing and/or forming, that is, during its sliding on the recess 402. The same observations also apply to a connecting radius, between portions of the mould die 31 intended to form on the sheet “F1 ” the lateral wall “S2” and the flanged edge “S3” of the semi-finished product “S”, less than 3 mm and preferably less than 2 mm, as well as with shapes of another type such as, for example, text or logos.

The shaping station 4, unlike the forming station 3, is configured to perform a forming of a semi-finished product “S” already having, unlike a film or a sheet, a respective containment space “V”, so that a sliding of the semifinished product “S” on the first shaping element 40 and on the second shaping element 41 is small with respect to a sliding of the sheet “F1 ” during the deep-drawing and/or during the forming performed by the forming station.

Thanks to the shaping station 4 it is therefore possible to stabilise on the semi-finished product “S” the shapes without the need to define at the same time a containment space “V” and therefore without damaging the semifinished product “S” being processed.

The semi-finished product “S” formed in this way is extracted from the forming station 3 and transferred to the shaping station 4 described above and having the same advantages described above.

In detail, in the forming station 3 at least one between the male mould element 30 and the mould die 31 is movable relative to the other according to a forming contact force between the male mould element 30, the sheet “F1 ” and the mould die 31 , whilst in the shaping station 4 at least one between the first shaping element 40 and the second shaping element 41 is movable relative to the other according to a shaping contact force between the first shaping element 40, the processing surfaces “A” of the semi-finished product “S” and the second shaping element 41 , greater than the forming contact force.

It should be noted that, as shown in the accompanying drawings, the mould die 41 a of the shaping station 4 is movable towards the male mould element 40a according to the above-mentioned shaping contact force.

Thanks to the shaping station 4, located downstream of the forming station 3 for forming the semi-finished product “S” formed in the latter, it is possible to apply on the semi-finished product “S” (in such a way as to not cause a breakage of the semi-finished product “S”) a shaping contact force which is greater than a forming contact force applicable to the sheet “F1 ” (in such a way as to not cause a breakage of the sheet “F1 ”). In this way, it is possible to form on the semi-finished product ‘S’ shapes and/or thicknesses which require a contact force which is incompatible with the sheet ‘F1

It should be noted that the shaping contact force, applied to the semifinished product “S” by the shaping station 4 is not only a very high force but may also be applied without an initial transient, that is to say, without an initial progression, and is configured to be maintained over time.

According to an embodiment, the contact force is maintained for a predetermined period of time, which is between 0.2 seconds and 4 seconds. According to another embodiment, the contact force is maintained for a period of time equal to 1 .2 seconds.

According to a further embodiment, the contact force is maintained for a period of 3 seconds.

The fact that both the first shaping element 40 and the second shaping element 41 are heated and may comprise a respective heating element as described above, together with the fact that the contact force is maintained for the predetermined period of time as described above, makes it possible to effectively stabilise the container “C” guaranteeing, for example, an elimination of any creases of the flanged edge “S3” by means of a reduction in the thickness of the flanged edge “S3”.

Considering a semi-finished product “S” comprising a layer of polyethylene and a layer of paper material and applying, for example, a predetermined contact force equal to 1 17 kg/cm² at ambient temperature, for a period of time equal to 1 .2 seconds, it is possible to obtain a reduction in the thickness of the flanged edge “S3” equal to 0.082 mm.

For the same period of time and for the same contact force, heating a shaping element, between the first and the second shaping element 40, 41 , in contact with the polyethylene to a temperature of 60°C and heating the shaping element, between the first and the second shaping elements 40, 41 , in contact with the paper material to a temperature of 1 15°C, it is possible to obtain a reduction in the thickness of the upper flanged edge “S3”, equal to 0.169 mm.

Vice versa, keeping the temperature of the shaping elements 40, 41 in contact with the polyethylene at a temperature of 60°C and the temperature of the shaping element 40, 41 in contact with the paper material at a temperature of 1 15°C, but increasing the period of time to 3 seconds, it is possible to reduce the contact force to 95 kg/cm² whilst obtaining a reduction in thickness of 0.144 mm.

For this reason, the shaping contact force is a decisive parameter for obtaining the desired shaping of the semi-finished product “S”, however, with a suitable choice of the period of time during which the shaping contact force is maintained and of the temperature of the first and the second shaping element 40, 41 , it is possible to obtain the reduction in the desired thickness of the flanged edge “S3”, in relation to the material used and any creases contained therein.

According to a further aspect of the apparatus 100, and with reference to Figure 2, the apparatus 100 comprises a deforming station 10, located downstream of the feeding station 1 and upstream of the cutting station 2, comprising at least one deforming device 10a having at least one engaging surface 10b provided with an undulating geometry and configured for engaging the film “F” along the processing path “L” in such a way as to impress, on a processing surface “A1 ” of the film “F”, the undulating geometry.

Thanks to the deforming device 10a, that is to say, thanks to the undulating geometry formed on the engaging surface 10b, it is possible to redistribute the material of the film “F” in such a way as to fully use the coefficient of elongation of the cellulose-based material during the forming of the semifinished product “S” by the forming device 3a and of the container “C” by the shaping device 4a. As mentioned above and according to a further embodiment of the apparatus 100 not illustrated in the accompanying drawings, the feeding station 1 may be configured for feeding the film “F” directly into the forming station 3, positioned downstream of the feeding station 1. The forming station 3 is in this case configured for forming the film “F” in such a way as to obtain the semi-finished product “S” defining on the film “F” at least one concavity defined by a lateral wall “S2” and a base wall “S1 ”.

According to a further embodiment, downstream the forming station 3 there is the shaping station 4, configured for performing a semi-finished shaping “S”, that is to say, of the film “F” formed, in such a way as to make at least one container “C”.

Moreover, according to the further embodiment, downstream the shaping station 4 there is a cutting device, configured for cutting the film “F” in such a way as to define a plurality of containers “C” separate from each other.

According to an aspect of the invention, the shaping station 4 is integrated or can be integrated in a packaging unit (not illustrated in the accompanying drawings).

The packaging unit comprises the shaping station 4, a filling station and a sealing station.

The filling station is positioned downstream of the shaping station 4 and is configured for placing a product, preferably a food product, in the containment space Vc of the container “C”.

In more detail, in the packaging unit the second shaping element 41 of the shaping station 4 may be movable for transferring the shaped container “C” from the shaping station 4 to the filling station.

Thanks to the second shaping element 41 , designed to transfer the shaped container “C” to the filling station, it is possible to prevent a deformation of the shaped container “C” before it is filled. The deformation of the shaped container “C” is in fact contrasted by the second shaping element 41 , inside of which the container “C” is positioned. Thanks to this variant, it is therefore possible to prevent a possible release of residual stresses from the shaped container “C”.

The sealing station is positioned downstream of the filling station and is configured for applying a closing film on the container “C” in such a way as to seal containment space “Vc” of the container “C”.

For this reason, the container “C” is, once filled, transferred to the sealing station, so as to seal it, at its flanged edge “C3”, by means of a closing film, which contributes to a stabilisation of a shape of the container “C” over time. Thanks to the packaging unit it is therefore possible to maximise a stabilisation of a shape stabilised on the container “C” by shaping it.

According to an aspect of the invention, the filling and sealing stations may be integrated in the apparatus 100 downstream of the shaping station 4.

The advantages discussed above for the shaping station 4 also apply to the apparatus 100 and the packaging unit just described.

For this reason, the invention is able to overcome the drawbacks of the prior art.

Advantageously, by means of the shaping station 4 it is possible to form a semi-finished product “S” having a respective containment space “V” in such a way as to obtain a container “C” comprising shapes and/or thicknesses which are incompatible with a forming of a sheet “F1”, or of a film, and in particular incompatible with a possibility of preventing breakages or tearing of the sheet “F1 ” during their forming on it.

In this way, the invention makes it possible to not damage the cellulose- based container “C” during its production process during the above- mentioned operations, allowing, however, a container made of plastic material to be replicated, favouring a transition to a more sustainable industry by replacing the plastic materials with the cellulose-based materials.

Claims

1 . A shaping station (4) for making a container (C) starting from a semifinished product (S) made of a cellulose-based material, wherein said semifinished product (S) comprises a base wall (S1 ), a lateral wall (S2), and a flanged edge (S3) extending from the lateral wall (S2), the base wall (S1 ) and the lateral wall (S2) defining a containment space (V), the shaping station (4) comprising:

- a feeding device, configured for feeding at least one semi-finished product (S);

- at least one shaping device (4a), positioned downstream of said feeding device and configured for receiving said semi-finished product (S) and for executing a shaping of said semi-finished product (S), wherein the shaping device (4a) comprises a first shaping element (40) and a second shaping element (41 ); wherein one between the first shaping element (40) and the second shaping element (41 ) is configured for receiving said semi-finished product (S), and wherein at least one, between the first shaping element (40) and the second shaping element (41 ), is movable relative to the other, in such a way as to intercept the semi-finished product (S) for forming the semi-finished product (S) at respective processing surfaces (A), in order to stabilise on said processing surfaces (A) a predetermined thickness and/or a predetermined shape to obtain said container (C).

2. The shaping station (4) according to claim 1 , wherein the first shaping element (40) is configured to receive said flanged edge (S3) and wherein the first shaping element (40) and the second shaping element (41 ) are movable along an operating direction (X) between an open configuration, where they are spaced apart, and a closed configuration, where they are moved towards each other in such a way as to intercept the flanged edge (S3) of said semi-finished product (S) for stabilising a uniform thickness on said flanged edge (S3), said processing surfaces (A) being at least partly positioned at said flanged edge (S3).

3. The shaping station (4) according to claim 2, wherein in said closed configuration said first shaping element (40) and said second shaping element (41 ) are positioned at a predetermined distance, measured along said operating direction (X).

4. The shaping station (4) according to claim 2, wherein the first shaping element (40) comprises a groove (G) configured to receive said flanged edge (S3) and wherein in said closed configuration said second shaping element (41 ) is positioned in abutment relative to a portion of said first shaping element (40) adjacent to said groove (G), in such a way as to intercept the flanged edge (S3) of said semi-finished product (S) for stabilising on said flanged edge (S3) a thickness which is uniform and equal to a depth of said groove (G).

5. The shaping station (4) according to any preceding claim, wherein said first shaping element (40), or said second shaping element (41 ) comprises at least a first portion (400) and at least a second portion (401 ) defining at least one recess (402) having a predetermined shape, said first shaping element (40), or said second shaping element (41 ) is shaped to match said first portion (400) and/or said second portion (401 ) in order to stabilise a shape of said recess (402) on said processing surfaces (A).

6. The shaping station (4) according to any preceding claim, wherein said first shaping element (40) is shaped to match said second shaping element (41 ) in such a way as to stabilise between said base wall (S1 ) and said lateral wall (S2) and/or between said lateral wall (S2) and said flanged edge (S3) of the semi-finished product (S) a final connecting radius less than an initial connecting radius, respectively, between said base wall (S1 ) and said lateral wall (S2) and/or between said lateral wall (S2) and said flanged edge (S3) of the semi-finished product (S) fed by said feeding device.

7. The shaping station (4) according to any preceding claim, comprising:

- a pushing element (5) connected to said first shaping element (40) for moving said first shaping element (40) towards said second shaping element (41 ), according to a predetermined contact force between the first shaping element (40), said processing surfaces (A) and the second shaping element (41 ), and/or

- a pushing element (5) connected to said second shaping element (41 ) for moving said second shaping element (41 ) towards said first shaping element (40), according to a predetermined shaping contact force between the first shaping element (40), said processing surfaces (A) and the second shaping element (41 ).

8. The shaping station (4) according to any preceding claim, wherein said first shaping element (40) comprises a male mould element (40a), configured for inserting in said containment space (V), and wherein said second shaping element (41 ) comprises a mould die (41 a), opposite the male mould element (40a) and movable towards the male mould element (40a) for forming said semi-finished product (S).

9. The shaping station (4) according to claim 8, wherein said male mould element (40a) is configured for receiving and supporting said base wall (S1 ), and wherein said mould die (41 a) is positioned above said male mould element (40a).

10. The shaping station (4) according to any preceding claim, wherein said first shaping element (40) comprises a heating element configured for heating said first shaping element (40), and/or wherein said second shaping element (41 ) comprises a heating element configured for heating said second shaping element (41 ).

11 . The shaping station (4) according to any one of claims 8 to 10, wherein the male mould element (40a) comprises a fixed portion, intended to receive the flanged edge (S3) of the semi-finished product (S), and a movable portion, intended to be inserted in the containment space (V) of the semifinished product (S), said movable portion being movable and/or adjustable along the operating direction (X).

12. An apparatus (100) for making a container (C) defining a containment space (Vc) for a product, preferably a food product, said apparatus (100) defining at least one processing path (L) and comprising: - a feeding station (1 ) configured for introducing in said processing path (L) at least one film (F) made of a cellulose-based material;

- a cutting station (2), positioned downstream of said feeding station (1 ), configured for intercepting said film (F) along said processing path (L) and for cutting said film (F) in such a way as to obtain at least one sheet (F1 )

- a forming station (3), positioned downstream of said cutting station (2), comprising at least one forming device (3a), configured to receive said sheet (F1 ) and to form said sheet (F1 ) in such a way as to define a semi-finished product (S) comprising a base wall (S1 ), a lateral wall (S2), and a flanged edge (S3) extending from the lateral wall (S2), the base wall (S1 ) and the lateral wall (S2) defining a containment space (V) of the semi-finished product (S);

- a shaping station (4), according to any one of claims 1 to 11 , positioned downstream of said forming station (3).

13. The apparatus (100) according to claim 12, wherein:

- said forming device (3a) comprises at least one respective male mould element (30) and a respective mould die (31 ) opposite the male mould element (30), wherein at least one between the male mould element (30) and the mould die (31 ) is movable relative to the other in such a way as to intercept said sheet (F1 ) according to a respective forming contact force exerted between said male mould element (30), said sheet (F1 ) and said mould die (31 ); and wherein

- at least one between said first shaping element (40) and said second shaping element (41 ) is movable relative to the other according to a respective shaping contact force exerted between the first shaping element (40), said processing surfaces (A) and the second shaping element (41 ), said shaping contact force being greater than said forming contact force.

14. The apparatus (100) according to claim 12, wherein:

- said forming device (3a) comprises at least one respective male mould element (30) and a respective mould die (31 ) opposite the male mould element (30), wherein the male mould element (30) is movable towards the mould die (31 ) in such a way as to intercept said sheet (F1 ) according to a forming contact force between said male mould element (30), said sheet (F1 ) and said mould die (31 ); and wherein

- said first shaping element (40) comprises a male mould element (40a), configured to be inserted in said containment space (V) of said semifinished product (S), and wherein said second shaping element (41 ) comprises a mould die (41 a), opposite the male mould element (40a) and movable towards the male mould element (40a) according to a respective shaping contact force between the male mould element (40a), said processing surfaces (A) and said mould die (41 a), said shaping contact force being greater than said forming contact force.

15. The apparatus (100) according to any one of claims 12 to 14, comprising a deforming station (10), located downstream of said feeding station (1 ) and upstream of said cutting station (2), comprising at least one deforming device (10a) having at least one engaging surface (10b) provided with an undulating geometry and configured for engaging said film (F) along said processing path (L) in such a way as to impress, on a processing surface (A1 ) of the film (F), said undulating geometry.

16. A packaging unit for a container (C) defining a containment space (Vc) for a product, preferably a food product, said packaging unit defining at least one filling path and comprising:

- a shaping station (4), according to any one of claims 1 to 1 1 ;

- a filling station, positioned downstream of said shaping station (4), configured for positioning a product, preferably a food product, in said containment space (Vc) of said container (C);

- a sealing station, positioned downstream of said filling station, configured for applying a closing film on the container “C” in such a way as to seal said containment space (Vc) of said container (C).