A CONTAINER

This invention relates to a container, and particularly, but not exclusively to a container formed by folding a blank preferably made of cardboard. The container may be used for storing any article, and is particularly useful for storing sandwiches or similar foodstuff. The invention further relates to a blank for forming the container, and to a method for forming the container.

The use of cardboard containers for packaging foodstuffs, has grown rapidly over the last few years, as retailers and consumers alike have become more aware of the environmentally friendly nature of such containers.

As the need for cardboard containers for sandwiches has increased, a need has arisen for more efficient methods of production of the containers. This is because large food manufacturers ma}' often need to produce upwards of 100,000 packed sandwiches a day. Currently, there is no method of production that encompasses a fully automated system that utilises cardboard blanks suitable to be erected within a specialised piece of machinery.

Cardboard sandwich containers fall into two main categories: those with lids attached; and those with separate lids.

It is known to form a cardboard sandwich container having a lid hingeably attached to a body portion of the container. However known sandwich containers are designed to be erected using standard off site gluing and folding machinery, or to be hand assembled.

It is known to form a container without a lid and then to add a lid to a body portion of the container containing a sandwich or other foodstuff after the sandwich has been placed in the container. Again, however, known containers of this type are designed to be erected using standard offsite gluing and folding machinery.

It is known to apply a lid to a bod)' portion of a sandwich container and then to heat seal the lid to the body portion in order to seal the sandwich container once a sandwich has been placed in the pack.

A problem with this known method of applying a lid to a bod)' portion of a sandwich container is that the sandwich container must be raised to a temperature that will allow the lid and the body portion of the sandwich container to melt in order to create a seal therebetween. This process can take around 2 to 3 seconds, and requires a considerable amount of pressure to be applied to the sandwich container.

It is often desirable to have a sandwich container having a bod)' portion that is separate to the lid. This is because production lines, and varieties of sandwiches to be sold in such containers, change constantly. If a food producer uses a container with a lid attached thereto, the whole container tends to be printed with information relating to the variety of the product to be contained within the container. When the retailer changes the variety that it wishes to market, any excess pre-printed containers have to be discarded^ This leads a waste of raw material and involves the food producer in a considerable extra expense.

It is known therefore, to form a body portion of a sandwich container containing no information relating to the product variety to be contained within the container. Information relating to the product is printed onto a separate lid. In this way, when a product variety changes, only the lid is discarded. This reduces waste and expense by approximately 60%.

A problem with this approach is, however, that although the product variety can be featured on the lid, there is generally too much information to allow nutritional information relating to the product to also be contained on the lid due to the limited space available. It is known, therefore, for food producers to adhere a separate label to the body portion of the container providing nutritional

information. These labels are printed separately and are usually attached by hand. This process involves extra expense and is labour intensive.

According to a first aspect of the present invention there is provided a blank for forming a container for packaging foodstuff comprising: first and second side panels ; a back panel having a first side; and a base panel having a first side, the first side of the back panel and the first side of the base panel being spaced apart from, and substantially parallel to one another, the blank further comprises a first flap extending from the first side of the back panel, a first glue line formed on the first flap, and a second glue line formed proximate the first side of the base panel.

A container may be formed by folding the blank and then gluing the folded blank together. The folded blank is glued together by means of the first and second glue lines. Because the first and second glue lines are substantially parallel to one another, the blank lends itself to being assembled using automated machinery.

Conveniently, the blank comprises a second flap extending from the first side of the base panel.

Advantageously, the first and second panels each comprise a first side, and the base panel further comprises a second side opposite to the first side, the first side of the first side panel being coincident with the second side of the base panel, and the first sides of the first and second side panels and the back panel being colinear with one another.

The blank may comprise a third flap extending from the first side of the second side panel, in addition to, or instead of the second flap.

In order to form a container from the blank, the blank may be folded along at least the second side of the base panel.

Advantageously, the first and second side panels each comprise a second side, the back panel further comprises a second side, and a third side opposite to the second side, the second side of the first side panel is coincident with the second side of the hack panel, and the second side of the second side panel is coincident with the third side of the back panel.

In order to form a container from the blank, the blank may be folded along at least the second and third sides of the back panel and also along the second side of the base panel.

Advantageously, the second side of the first side panel is perpendicular to the second side of the back panel.

Preferably, each of the side panels is substantially triangular, and each of the back and base panels is substantially rectangular.

When a container is formed by folding the blank along the second side of the base panel, and the second and third sides of the back panel, a container having a triangular cross-section will be formed. Such a container is useful for containing sandwiches.

Advantageously, the back panel comprises a fourth side, opposite of the first side, the first side being shorter than the fourth side.

A container formed from the blank will have a base defined by the base panel, a back defined by the back panel, and sides defined by each of the side panels.

By forming the first side of the back panel such that it is shorter than the fourth side of the back panel, the base of a container formed from the blank will be tapered towards a back corner of the container. This allows assembled containers to be handled more readily by an automated assembly and packing machine.

Advantageously, the blank farther comprises a lid panel having a first face and second, opposite face.

Advantageously, the first side panel further comprises a third side, and the lid panel comprises a first side coincident with the third side of the first panel.

Alternatively, the base panel further comprises a third side, and the lid panel comprises a first side coincident with the third side of the base panel.

Preferably, the lid panel comprises a hinged flap moveable between a first position in which first information is visible, and a second position, in which second information is visible. By means of a hinged flap it is possible to have different information on each side of the flap. For example, nutritional information relating to the sandwich contained within the container can be printed on an underside of the hinged flap, whilst information relating to the make of the sandwich can be printed on a top side of the flap.

Alternatively, the lid panel may comprise a separate label, removeably attached to the lid portion, or a label extending from the lid portion.

Advantageously, the lid panel comprises an aperture. Conveniently, the lid panel comprises a window patch extending across the aperture. The window patch is conveniently formed from a material which is transparent or translucent, and therefore allows a potential purchaser of the sandwich to view of the contents of the container.

Advantageously, the window patch is formed from a biodegradable material. Preferably the biodegradable material is a biodegradable starch based material such as PLA (polyactic acid).

Advantageously, the window patch extends to cover substantially all of the second face of the lid panel.

Since PLA and most natural starches have a lower melting point than materials such as PVC which are more commonly used to form window patches in containers for sandwiches, it is possible to seal the lid to the body portion of the container without having to raise the container to such a high temperature.

In order to form a heat seal between a lid portion formed of cardboard and PLA, and a body portion formed from cardboard, the container can be heated to 175°C at 3 tons of pressure for 1 to 2 seconds. Of course, the temperature, pressure and time may be varied to suit the prevailing conditions.

According to a second aspect of the present invention there is provided a container formed from a blank comprising: first and second side panels; a back panel having a first side; and a base panel having a first side, the first side of the back panel and the first side of the base panel being spaced apart from, and substantially parallel to one another, the blank further comprises a first flap extending from the first side of the back panel, a first glue line formed on the first flap, and a second glue line formed proximate the first side of the base panel.

Preferably, the first side panel is folded in a direction towards the second side panel to form a first side wall of the container and the second side panel is folded in a direction towards the first side panel to form a second side wall of the container such that the first side wall is opposite the second side wall, and the first and second side walls are substantially perpendicular to the back panel; and the base panel is folded to lie substantially perpendicular to each of the first side wall, the second side wall and the back panel to form a base.

According to a third aspect of the present invention there is provided a lid comprising a hinged flap moveable between the first position in which first information is visible, and a second position in which second information is visible.

Alternatively, the lid may comprise a separate label, removeably attachable to the lid. or a label formed integrally with, the lid, and extending therefrom.

According to a fourth aspect of the present invention there is provided a label for foodstuff packaging comprising a hinged flap moveable between a first position in which the first information is visible, and a second position in which the second information is visible.

According to a fifth aspect of the present invention there is proλήded a method for forming a container for packaging foodstuff, the container comprising a first side wall, a second side wall, a base, a back wall; the method comprising the steps of a. ^■ providing a card blank for forming the container, the blank. comprising first and second side panels each having a first side, a back panel having a first side, and a base panel having a first side, a first flap extending from the first side of the back panel, a second flap extending from the first side of the first side panel, the first side of the back panel and the first side of the base panel being spaced apart from, and substantially parallel to one another; b. applying a first glue line on the first flap, and a second glue line on the first side of the of the base panel; c. folding the blank such that the first and second side panels are opposite each other and that they are each perpendicular the base panel; d. folding the second flap towards the first side panel such that it is perpendicular the second side panel; e. folding the base panel to abut the second flap, the second glue line securing the base panel onto the second flap; f. folding the first flap onto the base panel, the first glue line securing the first flap onto the base panel; thereby creating a hollow cavity for receiving a food product.

The steps set out . above, may be carried out sequentially in any order, or simultaneously.

According to a sixth aspect of the present invention there is provided a method for packaging foodstuff, the method comprising the steps of a. providing a container comprising a first side wall having a first side, a second side wall having a first side, a base having a first side, a back wall having a first side, a first flap extending from the first side of the second side wall, a lid having a first side coincident with the first side of the first side wall, a second and third flap extending from a second and third side respectively of the lid perpendicular to the first side of the lid and a fourth flap extending from a fourth side of the lid opposite the first side; b. placing the food product into a container; c. applying a glue line to each of the base and the back wall proximate the first sides of the base and the back wall; d. folding the lid towards the first side of the second side wall hi order to close the container; e. folding the second and third flaps to connect with the glue line on the base and back wall respectively; f. rotating the container 90 degrees; g. apply a glue line to the second side wall proximate the first side of the second side wall; h. folding the fourth flap to connect with the glue hue on the second side wall;

The steps set out ■ above, may be carried out sequentially in any order, or simultaneously.

According to a seventh aspect of the present invention there is provided an automated production sj'stem for packaging foodstuff using a blank according to a first aspect of the present invention, the system comprising: a first storage location;

an assembly area having an assembly unit, the assembly unit comprising a dolly and a glue gun; a packaging area; a sealing area having a sealing unit, the sealing unit comprising a plurality of glue guns, a conveyor system, a rotatable fitment and a cam system for rotating the fitment; and a second storage location; the system farther comprising a delivery device for transferring a blank from the first storage location to the assembly area, a first conveyor for transferring a container from the assembly unit of the assembly area to the packaging area, a second conveyor for transferring a packed container from the packaging area to the sealing area and a third conveyor for transferring a sealed container from the sealing unit to the second storage area.

According to an eighth aspect of the present invention there is provided an automated process for packaging foodstuff comprising the steps of: a. obtaining a of blanlc for forming a container from a first storage location; b. transferring the blank to an assembly area having an assembly unit, the assembly unit comprising a dolly and a glue gun; c. assembling the blank in the assembly unit; d. transferring an assembled container to a packaging area; e. inserting a food product into the assembled container; f. transferring a packed container to a sealing area having a sealing unit; g. sealing the packed container in the sealing unit; h. transferring a sealed container to a second storage location.

The term "side" as used herein to describe the shape of a portion of a panel forming part of a blanlc according to an aspect of the present invention is understood to mean either an edge of the blanlc, or a fold line.

B2006/001532

The invention will now be farther described by way of example only with reference to the accompanying drawings in which:

Figure 1 is a schematic representation of a first embodiment of a blank according to an aspect of the present invention;

Figure 2 is a schematic representation of a second embodiment of a blank according to an aspect of the present invention;

Figure 3 is a schematic representation of a third embodiment of a blank according to an aspect of the present invention;

Figure 4 is a schematic representation of an embodiment of a carton according to an aspect of the present invention formed from the blank of Figure 1;

Figure 5 is a schematic representation of a die-cutting layout for forming a plurality of blanks of the type shown in Figure 1;

Figure 6 is a schematic representation of a fifth embodiment of a blank according to an aspect of the present invention;

Figures 7a to 7f are schematic representations shown as steps for forming a blank of the type shown in Figure 6;

Figure 8 is a schematic representation of a carton formed from the blank shown in Figure 6;

Figures 9 and 10 are schematic front and rear views of an embodiment of a lid panel suitable for use in closing the carton shown in Figure 8;

Figure 11 is a rear view of the lid panel of Figure 9 covered with PLA;

Figure 12 is a schematic representation of any one of the lids shown in Figures 9 to 11 showing the front flap in a lifted positioned;

Figure 13 is a schematic representation of a sj'stem for assembling a carton according to an aspect of the present invention;

Figures 14a and 14b are schematic representations of a system for forming and filling a carton according to an aspect of the present invention;

Figure 15 is a schematic representation of an in-line pack closing system;

Figures 16 and 17 are schematic representations of a lid according to an aspect of the present invention; and

Figures 18 and 19 are schematic representations of another lid according to an aspect of the invention.

Referring to Figure I ₅ an embodiment of a blank according to an aspect of the present invention is designated generally by the reference numeral 2. The blank comprises a first side panel 4, a second side panel 6, a back panel 8, and a base panel 10. The first side panel comprises a first side 12, and a second side 14, and the second side panel comprises a first side 16 and a second side 18. The base panel comprises a first side 20, and an opposite second side 22 that is coincident with the first side 12 of the first side panel 4. The back panel comprises a first side 24 that is colinear with the first side 12 of the first side panel 4, and first side 16 of the second side panel 6. The back panel further comprises a second side 26, and an opposite third side 28. The second side 26 is coincident with the second side 14 of the first side panel 4, and the second side 28 is coincident with the second side 18 of the second side panel 8.

Extending from the first side 24 of the back panel is a first flap 29 comprising a first glue line 30.

The base panel further comprises a second glue line 32 positioned proximate to a first side 20 of the base panel. The first and second glue lines 30, 32 respectively are therefore positioned such that the}' are substantially parallel to one another. The first side panel 4 further comprises a third side 36. The blank 2 further comprises a lid panel 38 having a first side 40 which is coincident with the third side 36 of the first side panel 4. The blank further comprises flap 42 which could also be positioned at position 33 indicated by dotted lines.

The blank comprises further flaps 43 which serve to allow the lid panel 38 to be heat sealed to the body of a container formed from the blank 2.

The lid panel comprises an aperture 44 which will be described in more detail hereinbelow.

The blank 2 may be formed into a container according to an aspect of the present invention as will be described in more detail hereinbelow. In particular, flap 42 will be pressed against glue line 32 when the container is assembled.

Referring to Figure 4, a container according to an aspect of the present invention is designated generally by the reference numeral 46. The container has been formed from the blank illustrated in Figure 1.

Referring to Figures 2 and 3, further embodiments of a blank according to the present invention are designated generally by the reference numerals 48 and 50 respectively. Parts of the blanks 48, 50 which are common to blank 2 have been allocated corresponding reference numerals for each reference.

The blank 48 has components that correspond to the components of Figure 1. However the lid portion 38 contains additional flaps 53 which enable the container to be more readily sealed once a sandwich has been placed in the container.

Turning now to Figure 3, the blank 50 lias parts similar to the parts shown in Figure 1 with respect to blank 2. However in this embodiment, the lid panel 38 is connected to the base panel 10 rather than to the first side panel 4.

Turning to Figure 5, a die-cutting layout showing how blanks of the type shown in Figure 1 may be cut from a piece of card shown schematically.

Turning now to Figure 6, a blank according to an aspect of the present invention suitable for forming a container having no lid is designated generally by the reference numeral 52. Parts of the blank 52 which correspond to parts of the blank 2 shown in Figure 1 have been given corresponding reference numerals for ease of reference. It will be seen that the parts of the blank 52 correspond to those shown in Figure 1 except that the blank 32 does not include a lid panel 38.

A container 54 formed from the blank shown in Figure 6 shown schematically in Figure 8.

Turning now to Figures 9 and 10, a lid according to an aspect of the present invention is designated generally by the reference numeral 60. Figure 9 is a front view of the lid 60, and Figure 10 is a rear view of the lid 60. The lid 60 comprises a hinged flap 62 that contains information on an underside 63 of the flap as shown in Figure 10. The lid further comprises an aperture 64 covered by a window patch. The window patch 65 may be formed from any suitable material but preferably is formed from PLA. As can be seen from Figure 10, the window patch 65 extends over an area which is slightly bigger than the sides of the aperture.

Turning now to Figure 11, the underside of the second embodiment of a lid 60 is illustrated. Pails of the lid 60 that correspond to the parts of the lid shown in Figures 9 and 10 have been given corresponding reference numerals for ease of reference. The front side of the lid 60 corresponds to the front side of Hd 60 shown in Figure 9.

The back of the lid shown in Figure 11 comprises a window patcli 65 that extends across substantially the entire underside of the lid 60. The presence of the window patch as shown in either Figure 10 or Figure 11 , means that any printed material on the flap 62 will not come into contact with the contents of the container.

In the embodiments shown in Figures 9, 10 and 11, the lid comprises angled comers 66, which corners reduce production costs. However, any desirable shape of comers may be used such as square comers or rounded corners.

Preferably, the lid is formed from cardboard with or without a plastic base or biodegradable coating. The lid may however also be made of solid plastic materials or a biodegradable starch based material such as PLA.

IQ the embodiments illustrated in Figures 9, 10 and 11, the lid is caused to adhere to a container of the type shown in Figure 8 by means of gluing or by a heat sealing method.

The container whether lidded or unlidded according to an aspect of the present invention may be made from fully biodegradable materials including any glues and waterbased inks used in connection with the container.

Turning now to Figure 12, an embodiment of a lid 60 of the type shown in Figures 9, 10 or 11 is illustrated schematically showing the flap 62 in an open position.

Heat sealing is however a relatively slow process as it requires time to raise the component parts to the correct temperature so that they may be sealed. In addition, the process requires that the components of the containers being sealed has some element of integral plastic space material to allow the sealing to take place. A more environmentally friendly process is therefore to use gluing to attach, for example lids to containers.

Referring now to Figures 16, 17, 18 and 19, further embodiments of the lid according to an aspect of the present invention are illustrated schematically.

In the embodiment illustrated in Figure 16, a lid 60 having a label 62 attached thereto, and extending therefrom, is attached to a container in such a manner that the label 62 is adhered to the container by means of a sticker or an adhesive.

Turning now to Figure 17, a lid 60 is illustrated in which the label 62 extends from the lid.

In Figure 18, a lid 60 is illustrated in place on a container 70 according to an aspect of the invention. The lid 60 is attached to the container 70 by adhering the label 62 to a side 72 of the container 70 using a sticker or an adhesive material.

Turning now to Figure 13, a system for assembling a container 46 from a blank 2 according to an aspect of the present invention is designated generally by the reference number 100. The assembly unit 100 is an adaptation of a 3 flap gluing system.

A magazine of carton blanks 102 is loaded into the assembly unit 100. Once inside the unit 100, the blanks are separated and individually fed into a gluing station 104. Glue is applied to the blank 2 along the first and second glue lines 30, 32 using a glue gun 106. The blanks are then fed to an assembly station where the blank is folded to erect the container. The assembly at the assembly station 108 is shown in more detail in Figures 7a to 7a. Figure 7 shows the assembly of the blank 52 having no lid panel, but the method of assembly is the same for all the blank embodiments described above.

A blank 52 as it would appear in the assembly station is shown in Figure 7a. A 'male' form or dolly 110 is placed onto the blank along the first side panel 4. The blank is firstly folded along the first side 22 of the back panel until the back panel 8 abuts the dolly 110 (see Figure 7b). and then folded along the second side of the back panel until the second side panel 6 abuts the dolly 110 (Figure 7c).

The second flap 42 is folded towards the dolly until it abuts the dolly (Figure 7d) and is perpendicular to the second side panel 6. The base panel 10 is folded towards the second flap 42 (Figure 7e). The base panel 10 being adhered to the second flap 42 by means of the second glue line. Finally the first flap 29 is folded towards the base panel 10 (Figure 7f) to form a fully erected container 54, the first glue line 30 adhering the first flap 28 to the base panel 10. Once erected the container is ejected downward into a production line.

Turning now to Figures 14a, 14b and 15 an in-line pack erection unit illustrated schematically and designated generally by the reference numeral 200. The unit comprises a pack erection and de-nesting unit 202, which is preferably situated at the head of the production system. However, if space is at a premium, the machine may be situated in a separate area of the production facility, or may be housed in a separate manufacturing facility. The unit further comprises a heat/glue sealing unit 204.

Use of the unit 200 reduces the cost of erecting and filling packs since food producers are able to construct containers by blanks themselves rather than having to use preassembled containers brought from carton manufacturers.

Further, since the machine includes the facility to pack and de-nest containers at the same time, the need for specialist de-nesting machinery is reduced or even eliminated.

Further, the system produces fully erected solid skillets which are known to be more efficient from a production point of view as they seal more consistently and therefore produce less wastage.

Once within the production system, the containers would be sealed using external flaps using known heat seal technology or alternatively using gluing technology.

Referring now particularly to Figure 15, the in-line pack closing system 300 of the sealing unit 204 is shown. The container shown is one formed from a blank 48 as

shown in Figure 2. However the system would work equally well with any of the containers having a lid 38 formed from ^" blanks according to the present invention. The packed container 302 is placed onto a rotatable fitment 304 (not shown) on a conveyor system 306 within the sealing unit. The flaps 43b located on the base panel 8 and back panel 10 are then simultaneously folded inwards in a direction towards each other. A glue line 308 is then applied simultaneously to each of the base and the back panels proximate the sides of the base and the back panels coincident with a side of the flaps 43b. Next, the lid 38 is folded towards the second side panel 6 so as to close the container. At the same time, the flaps 53b on the lid 38 are simultaneously folded towards each order so that the}' connect with the glue lines 308 on the base and back panel and are adhered to the container 302. The rotatable fitment 304 then rotates the container 302, 90 degrees so as to allow the second side of the container to be sealed in parallel motion. A glue line 310 is applied to the second side panel 6 proximate a third side 312 of the second side panel. The flap 53a is then folded down adhering it to the container 302. Alternatively the glue line 310 can be applied onto the flap 43a connected on the second side panel 6. If the lid does not comprise the flap 53a. the container is sealed by adhering the lid to the flap 43a connected to the side panel.