CROSS-REFERENCE TO RELATED APPLICATION

[001 ] This application claims priority to U.S. Patent Application No. 17/809,318, filed June 28, 2022, entitled “METHOD OF OPERATING A MACHINE FOR FORMING, FILLING, CLOSING, AND SEALING GABLE TOP CARTONS WITH LIQUID SOAP COMPOSITIONS”, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[002] The present disclosure relates generally to systems, apparatus and methods for forming, filling, closing, and sealing gable-top cartons for use with liquid soap compositions (e.g., all-purpose cleaners, dish soaps, hand soaps). In one embodiment, a machine may include a plurality of forming, filling, and sealing positions, each arranged in particular order and with particular settings so that liquid detergents (soap compositions) do not leak or leach out of the gable-top cartons.

BACKGROUND

[003] Liquid detergents (used interchangeably with the word “soap”) are a part of every household, with mostly an everyday use. Many of these detergents are either based off surfactants or mixture of surfactants, with certain cleaning properties, diluted in either an oil-based (animal or vegetable) or water-based composition. It is desirable to provide such liquid soap compositions in biodegradable containers without incurring leaking and/or degradation of the liquid soap composition during its shelf life. There exists a need for systems, apparatus and methods for forming, filling, closing, and sealing gable-top cartons particularly with liquid soap compositions because of their innate reactions to environmental factors, as well as shell life, and leakages.

SUMMARY OF THE DISCLOSURE [004] In one embodiment, a method is provided, wherein the method may yield a simplification, an increase in throughput, as well as reduced scrap rates, in the forforming, bottom-sealing, filling, closing, and top-sealing gable-top cartons particularly with liquid soap compositions.

[005] In one embodiment,, a method comprises operating a machine (e.g., through a computer-controlled mechanism, such as a PLC) having a plurality of station units oriented around a circular rotary turret, that gets operated by air, water, and heat in order to form, fill, close, and seal gable top cartons with certain liquid soap compositions. The computer controller may position the gable top carton throughout the different station units of the locations of the machine and determine whether the operations or steps of removing, pre-forming, lifting, heating, folding, sealing, printing, extracting, disengaging, welding, detecting, indexing, moving, filling, crimping, and discharging were properly performed. The machine may determine whether the required temperatures, pressures, and speeds for liquid soap compositions to sustain the environmental factors, have an adequate shell life, and avoid leakages or leaching from the gable-top carton were realized.

[006] In one embodiment, a controller uses vertical servomotors to position the gable top carton at the different station units and/or provides for a cap-welding station unit that welds a plant-based cap to the gable top carton (e.g., at a controlled air pressure) using welding energy. Upon completing the forming, and the bottom sealing processes, the computer controller may place the gable top carton on a conveyor or carton guide rail for filling and sealing of the top of the gable-top carton. The carton guide rail may use a horizontal servomotor connected through a gear reducer to extend the fineness of positioning and the range of speeds required for the adequate processing of the gabletop carton. As may be appreciated, miniscule shifts in the horizontal placement of the carton throughout the carton guide rail would cause spillage of the liquid soap compositions during the filling process, inadequate welding of the plant-based cap, or even damages to the gable-top carton.

[007] In one embodiment, a computer controller fills the gable-top carton with a liquid detergent (soap) composition. The liquid soap composition may be any suitable liquid soap composition for use by an end user. In one embodiment, the liquid soap composition does not use any linear alcohol derived from a natural, renewable oil reduction (fatty alcohol or detergent alcohol); or any synthetic alcohol. The liquid detergent composition may use a concentrated coconut-derived natural surfactant (e.g., potassium cocoate) with deionized water, as its main ingredient by percent, in order to provide the properties typically observed with non-natural surfactants, which involve removing and loosing dirt and grease from the surface of objects and skin. To add to the strength of the liquid soap composition, other additives may be used and may form part of the base composition of the liquid detergent. In one embodiment, the additives are used in order to reduce the surface tension of liquids and/or to restrict/prevent the compounds in the rest of the liquid detergent composition from separating into separate chemicals. In one embodiment, the additives include one or more of potassium oleate, potassium olivate, and glycerin.

[008] In another embodiment, a liquid soap composition may be a conventional (off- the-shelf) liquid soap composition. In one embodiment, a liquid soap composition includes one or more linear alcohols, such as those derived from a natural, renewable oil reduction (fatty alcohol or detergent alcohol) and/or includes one or more synthetic alcohols.

[009] In one embodiment, a gable-top carton used by the machine is configured to contain liquid detergent compositions based on natural oils, such as coconut oil, in order to meet the needs of consumers who desire sustainable products with good performance at an affordable cost. The gable-top carton used by the present disclosure may achieve this with a unique construction of various layers, provided by a unique combination of one or more of rigidity, grammage and printability with a long shelf life (e.g., when kept at ambient temperatures, and in dry, clean places).

[0010] In one embodiment, one or more settings of the present disclosure may be important to achieving the steps of removing, pre-forming, lifting, heating, folding, sealing, printing, extracting, disengaging, welding, detecting, indexing, moving, filling, crimping, discharging, and combinations thereof. In one embodiment, one or more settings may be important because a gable-top carton travels throughout a supply chain that sees various environmental factors (e.g., warehouse with a controlled environment, a shipping vehicle, a retail store, and lastly a consumer house located anywhere in the world) that affects the liquid soap composition that it contains, wherein the liquid soap composition may be susceptible to leaking out or leaching out of its contained packaging.

[0011] As such, the various embodiments and implementations of the embodiments described herein provide a profusion of technical advantages and benefits in the areas of longevity, cleaning, cleansing, simplicity in manufacturing, adequate packaging and transportation without leaching, as well as minimizing the effects of the non-based compounds of the composition. Other technical advantages are readily apparent to one skilled in the art after review of the following description and claims associated herewith. Nevertheless, further details, examples, and aspects of the disclosure will still be described below in more detail.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The teachings of the present disclosure can be readily understood by considering the following detailed description in conjunction with the accompanying drawings.

[0013] FIG. 1 is a front plain view of the carton having each four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps, according to an embodiment of the present disclosure;

[0014] FIG. 2 is a rear plain view of the carton having each four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps., according to an embodiment of the present disclosure;

[0015] FIG. 3, is a bottom left perspective view of the carton having each four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps, according to an embodiment of the present disclosure;

[0016] FIG. 4A, and FIG. 4B illustrate examples of the different type of leaks observed in traditional cartons having each four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps when filled with liquid soap compositions, according to an embodiment of the present disclosure;

[0017] FIG. 5A, and FIG. 5B, illustrate other examples of the different type of leaks observed in traditional cartons having each four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps when filled with liquid soap compositions, according to an embodiment of the present disclosure;

[0018] FIG. 6A and FIG. 6B illustrates a simplified block diagram of a method of operating a machine for forming, filling, closing, and sealing cartons with a liquid soap composition, wherein the cartons having each four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps;

[0019] FIG. 7, illustrates a front perspective view of the machine used for forming, filling, closing, and sealing gable top cartons with liquid detergent compositions;

[0020] FIG. 8, is a right-side perspective view of the cartons in their flat form when loaded into the infeed conveyor belt attached to the machine, according to an embodiment of the present disclosure;

[0021] FIG. 9A, illustrates front perspective view of the machine used for forming, filling, closing, and sealing gable top cartons with liquid detergent compositions with two zoomed-in callout boxes showing the vacuum suction cups assembled to the inside of the machine as they initiate the process of removing a carton from the infeed conveyor belt, according to an embodiment of the present disclosure;

[0022] FIG. 9B, illustrates front perspective view of the machine used for forming, filling, closing, and sealing gable top cartons with liquid detergent compositions with one zoomed-in callout box showing the vacuum suction cups assembled to the inside of the machine as they remove a carton from the infeed conveyor belt and place the carton into a carton squaring cage located at the end of the infeed conveyor belt attached to the machine, for the carton to get formed, according to an embodiment of the present disclosure; [0023] FIG. 10, illustrates the step of lifting, using a lift table attached to the bottom of the squaring cage located at the end of the infeed conveyor, the formed carton into a square mandrel rod attached to a rotary apparatus placed inside the machine, according to an embodiment of the present disclosure;

[0024] FIG. 11, illustrates a top schematic view of the machine used for forming, filling, closing, and sealing gable top cartons with liquid detergent compositions;

[0025] FIG. 12A, illustrates the step of pre-forming, with the bottom pre-forming tool in its opened position, wherein the bottom pre-forming tool located inside the machine at the second 45-degree position the bottom panel of the formed carton, according to an embodiment of the present disclosure;

[0026] FIG. 12B, illustrates the step of pre-forming, with the bottom pre-forming tool in its closed position, wherein the bottom pre-forming tool located inside the machine at the second 45-degree position the bottom panel of the formed carton, according to an embodiment of the present disclosure;

[0027] FIG. 13, illustrates the step of heating, with a bottom heating tool placed at the third 90-degree position inside the machine, according to an embodiment of the present disclosure;

[0028] FIG. 14, illustrates the step of folding, with a bottom folding tool having two parallel crimping blades placed at the fourth 135-degree position inside the machine, the pre-formed and heated bottom panel of the carton, according to an embodiment of the present disclosure;

[0029] FIG. 15, illustrates the step of sealing, with a bottom sealing tool placed at the fifth 180-degree position inside the machine, the pre-formed, heated, and folded bottom panel of the carton, according to an embodiment of the present disclosure;

[0030] FIG. 16, illustrates the step of extracting, using a bottom suction cap placed at the seventh 270-degree position inside the machine, from the mandrel rod the carton having the pre-formed, heated, folded, seal, and printed bottom panel, according to an embodiment of the present disclosure; [0031] FIG. 17, illustrates the step of disengaging, by releasing air pressure of the machine the bottom suction cup placed at the seventh 270-degree position inside the machine from the carton having the pre-formed, heated, folded, seal, and printed bottom panel, according to an embodiment of the present disclosure;

[0032] FIG. 18, illustrates the step of moving, using the carton guide rail placed at the seventh 270-degree position inside the machine the carton having the pre-formed, heated, folded, seal, and printed bottom panel onto a second position on the carton guide rail placed inside the machine, according to an embodiment of the present disclosure;

[0033] FIG. 19A, and FIG. 19B illustrate the step of welding a cap at the second position on the carton guide rail placed inside the machine, using a welding cap applicator applying a maximum of 230 joules of energy to the circular hole on one of the top flaps of the formed carton having the pre-formed, heated, folded, seal, and printed bottom panel, according to an embodiment of the present disclosure;

[0034] FIG. 20, illustrates the step of detecting, using a photoelectric sensor placed inside the machine and having a potentiometer adjustment, that the formed carton having the pre-formed, heated, folded, seal, and printed bottom panel was extracted from the square mandrel rod at the seventh 270-degree position, according to an embodiment of the present disclosure;

[0035] FIG. 21 , illustrates the step of pre-fill top crimp steps of pushing down at a third position of the carton guide rail using a rectangular indexing tool attached to the inside of the machine, forming and holding at a fourth position of the carton guide rail by inserting a top mandrel attached to the inside of the machine and an L-shaped fixture, and crimping at a fifth position of the carton guide rail applying a top crimping tool placed at the fifth position on the carton guide rail placed inside the machine for a maximum time of 2 seconds, to the gable top structure of the carton having the pre-formed, heated, folded, seal, and printed bottom panel, according to an embodiment of the present disclosure;

[0036] FIG. 22A, illustrates the top re-crimping head placed at the seventh position on the carton guide rail placed inside the machine, according to an embodiment of the present disclosure; [0037] FIG. 22B illustrates the step of crimping the gable top structure of the carton filled the liquid soap composition and having the bottom panel pre-formed, heated, folded, seal, and printed by applying a top re-crimping head placed at the seventh position on the carton guide rail placed inside the machine for a maximum time of 2 seconds, according to an embodiment of the present disclosure;

[0038] FIG. 23A, illustrates the top heat oven placed at the eighth position on the carton guide rail placed inside the machine, according to an embodiment of the present disclosure;

[0039] FIG. 23B, illustrates the step of heating the gable top structure of the carton filled the liquid soap composition and having the bottom panel pre-formed, heated, folded, seal, and printed by applying a top heat oven placed at the eighth position on the carton guide rail placed inside the machine, according to an embodiment of the present disclosure;

[0040] FIG. 24 illustrates the step of sealing, using a top seal movable jaw against a top seal fixed jaw, while the gable top structure of the carton filled the liquid soap composition and having the bottom panel pre-formed, heated, folded, seal, and printed is position on the nineth position of the carton guide rail inside the machine, according to an embodiment of the present disclosure;

[0041] FIG. 25A, illustrates a perspective of the mandrel rod, according to an embodiment of the present disclosure; and

[0042] FIG. 25B illustrates a bottom view of the mandrel rod, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0043] Reference will now be made in detail, to several embodiments of the present disclosures, examples of which, are illustrated in the accompanying figures. It is noted that wherever practicable similar or like reference symbols may be used in the figures and may indicate similar or like functionality. The figures depict embodiments of the present disclosure, for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures, systems, and methods illustrated therein may be employed without departing from the principles of the disclosure described herein.

[0044] As noted above, any liquid soap compositions may be used in accordance with the present disclosure. Such liquid soap compositions include conventional liquid soap compositions and/or liquid soaps derived from linear alcohols and/or synthesized alcohols.

[0045] In one embodiment, the liquid detergent formula uses potassium cocoate as a base ingredient, which may be obtained after the process of coconut oil saponification. In one embodiment, the potassium cocoate does not contain any other by-product typically found being added during saponification, like glycerin. That is, in one embodiment, the potassium cocoate is essentially free of glycerin. In one embodiment, the potassium cocoate ingredient used in a liquid soap composition uses potassium as its lye-base against coconut-oil, which yields an alkaline compound that is later adjusted as part of the finished composition (not the saponification). In one embodiment, the adjustment comprises using no less than 0.4% wt. citric acid. In one embodiment, the total weight percent of potassium cocoate used in the present disclosure is greater than 6.8%, with a typical range of 7.4% to about 14.5%.

[0046] In one embodiment, additives such as potassium oleate and/or potassium olivate are used with a liquid soap composition, e.g., in order to further promote the break down and removal of tar, soil, dirt, and oils, which respectively act on proteins, starches, pectins, and fats. These compounds may also break down and remove bacteria. As detailed further below, the inclusion of these compounds in the present disclosure may improve the cleaning performance even during cold water washes, thereby allowing a reduction in energy consumed and realizing a cost savings in the process.

[0047] Accordingly, in one embodiment, a coconut-based liquid detergent composition comprises potassium oleate with a finished good weight percent greater than 6.0%, which may range from 6.2% to about 13.5%, and/or potassium olivate with a finished good weight percent greater than 1 .2%, which may range from 1 .9% to about 3.5%. Other nonsoap detergent actives may also be added to the composition of this disclosure after the saponification process. In particular, glycerin (e.g., USP 99.7% vegetable) may be added, and in a finished good weight percent greater than 0.8% to about 3.5%. In one embodiment, glycerin serves as an emollient to soften and moisturize the skin therefore decrease itching and flaking of human skin. In other embodiments, glycerin may act as a solvent to loosen sticky tar, soil, or dirt. Further plant-based humectants may be used, typically in the range of 0.1 % to 2.0% wt., in order to supplement glycerin’s softening and moisturizing effects. In one embodiment, the coconut-based liquid detergent composition realizes a pH of less than 7.0 but not lower than 4.0. To achieve the proper pH, a weak organic acid (e.g., citric acid), as a pH adjuster/buffer may be used. Sodium gluconate and/or sodium chloride may also be used (e.g., in combination with the weak acid). A mixture of sodium salts may also be used and in an amount of from 0.3 to 2.0 percent by weight. The sodium salts may be one or more of trisodium citrate, sodium gluconate, sodium chloride, and combinations thereof. In one embodiment, the use of sodium chloride is used as a thickening agent (e.g., to achieve the proper consistency/viscosity), therefore avoiding leaching from the gable-top corrugated carton as well as dripping or leaking during the filling step of the machine.

[0048] As it pertains to FIG. 1 and FIG. 2 there is illustrated a non-limiting example of a front plain view of the gable-top corrugate carton design and a rear plain view of the gable-top corrugate carton design, respectively. The gable-top carton 101 is fabricated from a carton blank into the gable-top carton illustrated in FIG. 1, whereby a plurality of score or fold lines are no longer observed as they are formed into the gable-top carton 101 but some are indicated in FIG. 1 as 103-106. Heat-sinked horizontal line 102 of FIG. 2 is shown because of its novel characteristic used to seal the gable-top carton 101 in order to restrict/prevent the liquid detergent from leaking, leaching, or even evaporating. Similarly, FIG. 2 shows the rear heat sink horizontal line 201 in the novel and inventive pattern that was found to achieve limited or no leakage of the liquid detergent, as performed by the method used to operate the machine of the present disclosure.

[0049] There is illustrated in FIG. 3 a bottom left perspective view of one embodiment of a carton 101 constructed in accordance with the teachings of the present disclosure, particularly four general sides (311-314), a gable top structure with the top flaps (315) meeting to form a top fin (316), a bottom panel (317), and a circular hole (318) on one of the top flaps. FIG. 3 also illustrates a plant-based cap 302 already assembled and welded to the carton circular hole 318 by the method used to operate the machine below discussed. Furthermore, FIG. 3 shows the heat sinking pin configurations 303-310 that restrict/prevent leaking or leaching of liquid detergents with high or low viscosity as well as high or low pH levels.

[0050] Referring now to FIG. 4 and FIG. 5, each illustrates examples of the different type of leaks observed in traditional gable-top cartons containing coconut-based liquid detergent compositions. Here, it is important to discuss the commonly observed leakages seen on gable-top cartons to better illustrate the importance of the novel and inventive disclosures presented herewith.

[0051] There are a number of different reasons a gable-top carton may leak. The first and perhaps largest factor is the product itself. While viscosity of the product has some impact, it has been recognized that low viscosity products may be sealed without leaking and/or realizing a low leak rate. Low leak rate may be defined as less than one leak per 1000 units manufactured assuming all other variables are constant.

[0052] Products that have a very low viscosity (similar to water), certain chemical compositions (liquid detergents with low surface tension), and a high pH (similar to hand, laundry and dish soap) may be highly susceptible to leaking in most configurations of gable-top carton designs. It has been observed that these low viscosity/high pH products leak at a rate of 90% and the best that can be achieved by varying the chemical composition of the product is approximately a 15% leak rate. As such, the chemical makeup of the liquid soap composition may be driving the leaking, because the composition is, by its very nature, designed to flow out and penetrate into cracks and crevices, thereby lifting and removing dirt. It does this very effectively on surfaces but does it equally effectively in gable-top cartons, thus the leaking issues occur.

[0053] Gable-top cartons can leak from several different spots on the carton bottom. Each of these spots has a different root cause and a different solution to solve. There are 4 primary leak points on the carton bottom as observed in FIG. 4 and FIG. 5: center pin leak FIG. 4A, fold leak FIG. 4B, corner leak FIG. 5A, and side leak FIG. 5B. All are discussed below. [0054] FIG. 4A - CENTER PIN LEAK: this is a very common paper carton leak point. This leak can be solved by using the proper middle pin configuration while ensuring proper heat sink settings.

[0055] FIG. 4B - FOLD LEAK: this is a type of like that occurs along the edges of the fold as observed by 403 and 404. The cause of this type of leak has been attributed to not forming a proper fin seal, which can be solved with a proper bottom former set up, a proper tucker setup, and to some extent proper heating.

[0056] FIG. 5A - CORNER LEAK: This is the most common leak issue observed when using gable-top carton in combination with liquid detergents. The causes of these types of leaks are manyfold and intertwined. First and foremost, the leak can occur due to channeling on the inside panel folds as observed by 502 and 503. Channeling occurs due to insufficient poly melt and thus sealing on the bottoms. This can be caused by a combination of temperature and bottom plate seal pressure. Even when processing at optimal settings, a leak rate of 15% continues to occur. This may be because, for instance, corner leaks may be caused by cracking the foil in the corners combined with insufficient PE flow back into those cracks. While all gable-top cartons have some level of cracking and pin holing, the function of the PE is to fill in these cracks and holes. Accordingly, embodiments of the present disclosure introduce several layers of PE.

[0057] FIG. 5B - SIDE LEAK: this is a very unusual leak, and is where a substantial amount of leaking was seen while trying to solve the leaking issues of liquid detergents. Side leaks typically occur above and below the score lines of either the front or rear of a gable-top carton as shown by 504 and 505. When viewed from the inside of the gabletop carton (e.g., while applying alcohol dye and a flashlight), one can observe the extreme foil cracking on the front side of the carton, 506 which was not filled with the PE.

[0058] As can be observed, multiple factors came into play when trying to solve the above depicted problems. Since many product features cannot be changed without significantly impacting a consumer’s experience with the liquid detergent product, modifications have been made to the folding, filling, and sealing process by means of the present disclosure. [0059] FIG. 6 illustrates one embodiment of steps for operating a machine (illustrated as 701 on FIG. 7). The steps may include one or more of forming, filling, closing, and sealing cartons with a liquid soap composition. In one embodiment, the cartons each have four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps. In one embodiment, the machine 701 houses most of the components needed to perform the steps of the present disclosure inside the machine, which should be understood as every component inside its cased structure. Components like the water supply intake, water drain outtake, compressed air supply intake, three-phased, 60 Hz, electrical terminal Human Machine Interface (HMI), the infeed conveyor belt, the liquid soap composition tank container, cap holder, or the discharge conveyor belt may be placed outside the machine but connect to the inside as further described herein.

[0060] From the lines that are connected to the machine and either feed into or discharge out to, the machine 701 would typically have a water supply intake which is used for transporting water (e.g., at a maximum temperature of 10 degrees Celsius, at a flow rate of 2 gallons per minute) and cools the machine down, including components like the mandrel rod tool, the heating tables, the crimping tools, the pre-forming and forming tools, as well as the sealing tools. The water drain outtake on the other hand is used for recirculating and draining the transported water (e.g., at a flow rate of 2 GPM). The compressed air supply intake is used to operate the machine cams and shafts (e.g., at a minimum pressure of 87 PSI at 23 SCFM and a maximum pressure of 120 PSI at 23 SCFM). The electrical terminal (e.g., three-phased, 60 Hz) connected to the outside of the machine may be configured to receive a control voltage for providing electricity to all the required components (e.g., the control voltage may be 480 VAC). In one embodiment, the electrical interface component panel for operating a machine for forming, filling, closing, and sealing cartons with the liquid soap composition may be connected to an electrical terminal for providing electricity to power the human-machine-interface (HMI) screen which also controls one or more of the PLC of the machine, a cycle counter, a plurality of heater controllers, a safety circuit reset button, a plurality of emergency stop buttons, the cap applicator speed control, and a main disconnect switch. [0061] Referring now to FIG. 6A and FIG. 6B, it is illustrated a simplified block or flowchart diagram using commonly known in the art process symbols in relation to a method of operating a machine for forming, filling, closing, and sealing cartons with a liquid soap composition, wherein the cartons having each four general sides, a gable top structure with the top flaps meeting to form a top fin, a bottom panel, and an optional circular hole on one of the top flaps. The steps of the method presently disclosed may begin after the machine 701 receives feedback that flat cartons 802 have been loaded or fed at step 601, into the infeed conveyor belt 801 (illustrated on FIG. 8) attached to the machine. In one embodiment, and as illustrated in FIG. 8, the feedback may be provided to the machine 701 when an operator pulls back on the side knob 803, which in turns engages a spring tensioning 804 unit that pushes the cartons forward and onto vacuum suction cup assembled to the inside of the machine.

[0062] Tension (e.g., constant tension) may then be applied to the carton blanks 802 by the spring-loaded tensioner 804, which advances the carton blanks 802 forward (i.e. , towards the inside of the machine). The plurality of vacuum suction cups 901 (illustrated by FIG. 9) assembled to the inside of the machine may then be triggered to remove at step 602, in the direction of arrow 902, a carton 802 from the infeed conveyor belt 801 attached to the machine, and into a carton squaring cage 903 located at the end of the infeed conveyor belt attached to the machine. The vacuum suction cups 901 may operate through a positive forward and return motion applied via the main cam, located on the main shaft of the machine 701. Concurrently, the vacuum suction cups solenoid energizes, and the vacuum cups attach to a carton blank 802 to perform step 602 of removing a carton 802 from the infeed conveyor belt attached to the machine 801, into the carton cage (e.g., squaring cage) 903 located at the end of the infeed conveyor belt attached to the machine. The purpose of the cage 903 is to place at step 603 the flat or blank cartons 802 in an expanded state, using the plurality of vacuum suction cups assembled to the inside of the machine the removed carton, such as by snapping the removed carton four general sides to the carton squaring cage located at the end of the infeed conveyor belt attached to the machine. In the expanded (formed and opened-up) state, the carton 904 can then be lifted at step 604 in the direction illustrated by arrows 1001 and 1002 of FIG. 10, using a lift table 1003. The lift table 1003 may be attached to the bottom of the squaring cage located at the end of the infeed conveyor. The lift table 1003 may lift the formed carton 904 into a mandrel rod 1004 (e.g., a square mandrel rod) attached to a rotary apparatus (also known in the art as turret) 1101 placed inside the machine. When the lift table 1003 has moved all the way up (meaning that is has reached its maximum electrical and mechanical output), the system may consider the carton 904 to have been lifted to the top of the of the rotary apparatus 1102. The air pressure provided to the lift table 1003 will be removed, the lift table 1003 will come down, and the next steps can begin.

[0063] In particular, a first step 605 may include rotating, using the rotary apparatus 1101 placed inside the machine, the mandrel rod 1004 with the formed carton 904 to a second 45-degree position 1102. Upon reaching 1102, the machine will initiate the preforming step 605, with a bottom pre-forming tool 1201 located inside the machine at the second 45-degree position 1102. At the second 45-degree position 1102, the lower section of the formed carton 904 is pre-formed, at step 606, along the carton score lines, using the bottom pre-forming tool 1201 through a series of cam and linkage driven crimp arms. As illustrated by FIG. 12B, the triangular bottom area of the formed carton 904 bottom is pushed-in 1202 while the large flat areas are pushed-up simultaneously with the crimp arms 1203. Thereafter, using the rotary apparatus 1101 placed inside the machine, the mandrel 1004 rod with the formed carton 904 having the pre-formed bottom panel, is rotated at step 607 to a third 90-degree position illustrated by 1103 of FIG. 11. At this third position 1103, which is at a 90-degree angle from the first position 1109 (also referred to as the 0-degree or 360-degree angle position), the pre-formed bottom panel of the carton 1301 may be indexed against heating tool 1302. In one embodiment, the heating tool 1302 raises 1103 and begins heating (shown by step 608 of FIG. 6A) the lower section of the pre-formed bottom panel of the carton 1301 around the pre-crimped score lines of step 606. The heating step may be conducted at any suitable temperature and for any suitable time. In one embodiment, the heating of the pre-formed bottom panel of the carton 1301 is to a heating temperature of from between 110 and 150 degrees Celsius. In one embodiment, the heating time is for a maximum time of 2 seconds. The temperature may be measured using heat guns. The proper heating temperature and/or heating time may be important to an absence of leaking because it is desirable to activate the poly-coating of the pre-formed bottom panel of the carton 1301. Next, the heating tool 1302 returns to its lowered position to allow the formed carton 904 having the preformed (606) and heated bottom panel (608) rotate (illustrated by step 609 of FIG. 6A flowchart) to a fourth 135-degree position 1104. At 1104, given the activation of the polycoating of the carton’s bottom panel, folding 610 occurs. In one embodiment, the folding 610 comprising using a bottom folding tool, 1401 , placed at the fourth 135-degree position inside the machine, 1104. In one embodiment, the folding tool 1401 comprises two parallel crimping blades (a left crimping blade 1402 and right crimping blade 1403). In one embodiment, folding 610 occurs when the left crimping blade 1402 and the right crimping blade 1403 rotate upwards 1404 and 1405 (e.g., using a series of cams and shafts linked to the electrical and air connections of the machine). Typically, the left crimping blade 1402 and the right crimping blade 1403 will remain in their closed position for a time sufficient to maintain the heated bottom panel (608) in position as the carton 904 moves to the next step. In one embodiment, the left crimping blade 1402 and the right crimping blade 1403 remain closed for at least one or two seconds. Embodiments of the present disclosure also illustrate at 1406, a pseudo-ramp wherein the folding done at step 610 will be held in place as the bottom of the carton 904 glides through this pseudo-ramp 1406 as a secondary quality control measure to assure that the folding is held in place before the next steps.

[0064] Next, the mandrel rod 1004 holding the formed carton 904 having the preformed, heated, and folded bottom panel rotates at step 611 to a fifth 180-degree position 1105, using the rotary apparatus placed inside the machine 1101. Through this rotation 611, the mandrel will be positioned over a bottom sealing tool 1501 wherein the sealing step 612 can begin. Particularly, the machine’s 701 main cam will actuate the bottom sealing tool 1501 by pressing it against the bottom 2602 of the mandrel rod tool 1004 at a suitable maximum pressure (e.g., a maximum pressure of 0.188 PSI), which, in combination with the cooling liquid running through the rods 2601 of the mandrel rod tool 1004 and some bottom sealing tool 1501 pins together will seal at 612, the bottom of the carton. As illustrated, the bottom 2602 of the mandrel rod tool 1004 is configured to provide an improved seal, e.g., through increased pressure, at critical areas where liquid soap compositions have been shown to leak or leach (see FIG. 4A, FIG. 4B, FIG. 5A, and FIG. 5B).

[0065] Next, the bottom sealing tool 1501 may be lowered by the machine’s main cam, shafts and air system. Next, the rotary apparatus placed inside the machine 1101 rotates, at step 613 the mandrel rod 1004 with the formed carton 904 now having the pre-formed, heated, folded, and seal bottom panel, to a sixth 225-degree position 1106. At this sixth 225-degree position 1106, a printing system (e.g., a continuous ink jet printing system such as model Jet2 NEO produced by Leibinger), prints at step 614 characters (e.g., DataMatrix characters ) onto the pre-formed, heated, folded, and seal bottom panel of the carton. These characters are generally preloaded into the printing system and may include, for instance, a two-letter manufacturer’s code followed by dates formed by the last digit of the manufacturing year, and the Julian period (e.g., CC2131 , wherein CC would stand for Cleancult, the 2 for the year 2022, and the 131 representing May 11 ^th ).

[0066] The rotary apparatus placed inside the machine then rotates at step 615 the mandrel rod with the formed carton having the pre-formed, heated, folded, seal, and now a printed bottom panel to a seventh 270-degree position, illustrated by 1107 of FIG. 11. At this position, the carton 904 having the pre-formed, heated, folded, seal, and now printed bottom panel is extracted at step 616 from the mandrel rod 1004, as illustrated by the downward arrow 1601, using a plurality of bottom suction cups 1602 placed at the seventh 270-degree position inside the machine, illustrated by 1107 of FIG. 11. The extraction step 616 may be performed by retracting down the plurality of suction cups 1602 that pulls the carton 904 from the mandrel rod tool 1004 and onto the carton guide rail 1701. Once the carton 904 is extracted at 616 the plurality of bottom suction cups 1602, it may be loaded

617 onto a first position of the carton guide rail 1701 placed at the seventh 270-degree position inside the machine. Once carton 904 reaches the bottom of the carton guide rail 1701 , the machine’s 701 blow-off cam disengages, e.g., by releasing air pressure from machine 701 at step 618, the plurality of suction cups 1602 from the bottom of the carton 904, which allows the carton to be moved throughout the carton guide rail 1701 to different positions and towards the next steps as illustrated by FIG. 18.

[0067] Next, the carton 904 is then moved at step 619, onto a second position of the carton guide rail 1701 wherein a welding step 620 of the cap 302 may occur (for embodiments that include a cap - no cap is required, however). Embodiments of the present disclosure illustrate a cap 302 holder 1901 located outside the machine, that feeds a cap escalator 1902, also located outside the machine, which is used to transport the caps up from the cap holder 1901 using steps, and onto the cap hopper 1903. Due to the center of gravity of the cap 302, it will only be able to settle on the cap escalator 1902 steps with the hole facing outwards and any cap 302, that is not loaded in such way will fall back onto the cap holder 1901, until it gets acquired again by one of the cap escalator 1902 steps. Once cap 302 reaches the top of escalator 1902, the cap falls into a cap hopper bowl 1903, that in turns feeds a cap chute 1904 which accumulates a plurality of caps 302 for the rotary spout welding cap applicator 1905 will use to weld the caps to the carton. The welding step 620 may be achieved by welding, using welding cap applicator 1906 which applies energy to the circular 318 hole on one of the top flaps 315 of the formed carton 904 having the pre-formed, heated, folded, seal, and printed bottom panel. The welding cap applicator 1906 may apply, for instance, a maximum of 230 joules of energy. The welding step 620 forms a liquid tight bond between the cap 302 and one of the top flap 315. In one embodiment, while welding step 620 is happening, an empty mandrel rod 1004 (i.e. , without a carton 904 attached to it) is rotated at step 621 using the rotary apparatus placed inside the machine 1101 to an eighth 315-degree position 1108. In one embodiment, a photoelectric sensor 2001 placed inside the machine and having a potentiometer adjustment, will detect at step 622, that the formed carton having the pre-formed, heated, folded, seal, and printed bottom panel was extracted from the mandrel rod at the seventh 270-degree position 1107.

[0068] At step 623, the carton 904 having the pre-formed, heated, folded, seal, and printed bottom panel is moved onto a third position 2101 on the carton guide 1701 rail placed inside the machine using the carton guide rail 1701 placed at the seventh 270- degree position inside the machine occurs. In one embodiment, a three-step operation occurs that basically involves setting the carton 904 into position, forming the top flaps 315 over a mandrel, and then crimping the top flaps 315. This three-step approach may be used, for instance, in order to achieve the top score lines of the carton prior to filling it with a liquid soap composition. In particular, the first step of this three-step method begins at step 624 by indexing the carton 904 having the pre-formed, heated, folded, seal, and printed bottom panel to the carton guide rail 1701, such as by pushing down on the carton 904 using an indexing tool 1702 attached to the inside of the machine and placed at the third position of the carton guide rail 1701. In one embodiment, the indexing tool is a rectangular indexing tool. The carton 904 having the pre-formed, heated, folded, seal, and printed bottom panel is then moved at step 625 onto a fourth position 2103 on the carton guide rail 1701 placed inside the machine. Forming the carton 904 having the preformed, heated, folded, seal, and printed bottom panel at step 626 occurs by inserting a top mandrel 2104 attached to the inside of the machine, and holding the gable top structure of the carton using an L-shaped fixture 2105 (or other suitably shaped fixture). The carton 904 having the pre-formed, heated, folded, seal, and printed bottom panel, is then moved at step 627 onto a fifth position 2106 on the carton guide rail placed inside the machine. Crimping occurs at step 628 by applying a top crimping tool 2107 (e.g., for a maximum time of 2 seconds) to the gable top structure of the carton having the preformed, heated, folded, seal, and printed bottom panel. The carton 904 now having the crimped gable top structure and the bottom panel pre-formed, heated, folded, seal, and printed is then moved at step 629 onto a sixth position 2201 on the carton guide rail placed inside the machine. At this sixth position on the carton guide rail 2201, the machine 701 performs the step of filling 630 the carton having the gable top structure crimped and the bottom panel pre-formed, heated, folded, seal, and printed with a liquid soap composition. In one embodiment, the filing is completed using a filling system nozzle 2202 placed at the sixth position on the carton guide rail, connected to a liquid soap container tank 2203, which tank may be located outside of the machine and which contains the liquid soap composition.

[0069] In one embodiment, the container tank 2203 is filled to a particular level based on properties of the liquid soap composition. In one embodiment, when a liquid soap composition has a viscosity of 200 centipoise (cp) the container tank 2203 may only be filled up to 90% of its volumetric capacity. In one embodiment, when a liquid soap composition has a viscosity of less than 200 centipoise (cp) the container tank 2203 may only be filled up to 40% of its volumetric capacity.

[0070] Feeding of the liquid soap compositions to the machine occurs via a fill line and /or a fill valve. To avoid spillage during the filling step 630, the filling system nozzle 2202 may use a plug spout and/or a plurality of filter net screen meshes each stacked-on top each of other and surrounded by a rubber compound to form the seal with the inside of the filling system nozzle 2202. Such plug spouts and/or filters may be useful with liquid soap compositions having a viscosity of 200 centipoise (cp) or higher.

[0071] The carton 904 now having the gable top structure crimped and the bottom panel pre-formed, heated, folded, seal, and printed moving, is moved at step 631, using the carton guide rail 1710 placed at the seventh 270-degree position inside the machine to a seventh position 2204 on the carton guide rail placed inside the machine. At this seventh position 2204, re-crimping (illustrated by step 632 of FIG. 6B) of the gable top structure now filled with the liquid soap composition occurs, such as by applying in a downward direction (shown by arrow 2205) a top re-crimping head 2206 placed at the seventh position 2204 on the carton guide rail placed 1710 inside the machine. In one embodiment, the re-crimping occurs for a maximum time of 2 seconds. The top recrimping head 2206 generally applies pressure to the carton’s inside flaps to ensure the tucked-in portion of the gable-top is properly positioned prior to entering the heating step. The carton filled with the liquid soap composition, having the gable top structure crimped and the bottom panel pre-formed, heated, folded, seal, and printed is then moved 633 using the carton guide rail placed at the seventh 270-degree position inside the machine, onto an eighth position 2301 on the carton guide rail 1701 placed inside the machine.

[0072] The entire gable-top structure of the carton 904 is heated at step 634, such as by applying heat from a heating oven. In one embodiment, the heating oven is a top heating oven having an outside 2302 and an inside 2303 heating structure, which will heat the gable top structure of the carton at step 635 by moving the top heat oven downwards 2304. The heating 634 may be conducted at any suitable temperature and for any suitable time. In one embodiment, the heating of the pre-formed bottom panel of the carton 1301 is to a temperature of from between 110 and 150 degrees Celsius. In one embodiment, the heating time is for a maximum time of 2 seconds. At the end of the heating step, the heating oven having an outside 2302 and an inside 2303 heating structure may return to its upper position to allow the carton 904 move to the next position. [0073] The carton filled with the liquid soap composition, having the gable top structure crimped and heated, and the bottom panel pre-formed, heated, folded, seal, and printed is then moved at step 635, using the carton guide rail placed 1701 at the seventh 270- degree position inside the machine, onto a ninth position 2401 on the carton guide rail placed inside the machine. Sealing 636, is then performed, such as by using a top seal movable jaw 2402 against a top seal fixed jaw 2403. The seal shafts of the machine move (illustrated by 2404) the seal jaws 2402 and 2403, causing them to compress the top flap 316 of the gable-top which, when combined with the pressure applied and the cooling liquid running through the seal jaws 2402 and 2403, seals (636) the carton 904. To assist with the hard to seal areas of the top flap 316, heat sink horizontal lines protrude from the seal jaws 2402 and 2403 to from the rear heat sink horizontal lines 201 of FIG. 2.

[0074] The carton filled with the liquid soap composition, having the gable top structure crimped, heated, and sealed, and the bottom panel pre-formed, heated, folded, seal, and printed is then discharged at step 637, using the carton guide rail placed at the seventh 270-degree position 1701 inside the machine, onto a conveyor belt positioned outside the machine. The rotary apparatus placed inside the machine rotates at 638 the square mandrel rod to a starting 0-degree position 1109 and one or more of the steps 602 through 637 or (i) - (xxxvii) are repeated 639, for a subsequent carton 804 on the infeed conveyor belt attached to the machine, until no more cartons are available in the infeed conveyor belt.

[0075] The carton that started having four general sides (311, 312, 313, 314), a gable top structure with the top flaps (315) meeting to form a top fin (316), a bottom panel (317), and a circular hole (318) on one of the top flaps (315) has now been formed, filled, capped (302) and sealed so the machine (701) now discharges this formed, filled, capped, and sealed carton to an end conveyor belt for further processing and shipping. [0076] As may be appreciated, while several methods steps are illustrated and explained herein, it is to be appreciated that the novel and inventive aspects of the present disclosure may be encompassed in a single step or in combinations of two or more of the steps described herein.

[0077] As may be appreciated, while several apparatus are described in relation to the machine and systems described herein, it is to be appreciated that the novel and inventive aspects of the present disclosure may be encompassed in a single apparatus or component, or in combinations of two or more of the apparatus or components described herein.

[0078] Although the foregoing is a description of exemplary methods of operating a machine for forming, filling, closing, and sealing cartons with a liquid soap composition; it is to be understood that the present disclosure is not limited to the particular descriptions disclosed. The present disclosure also comprises any modifications or equivalents within the scope of the claims.

[0079] As used herein, "and/or" placed between a first entity and a second entity means one of (1 ) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple elements listed with "and/or" should be construed in the same fashion, i.e., "one or more" of the elements so conjoined. Furthermore, the terms "comprising," “consisting,” "including," and "having," as used in the claims and specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms "a," "an," and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term "one" or "single" may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as "two," may be used when a specific number of things is intended.

[0080] Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions. [0081] All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.