Method and apparatus for producing carton packaging sleeves from used carton packaging

Abstract

A method for producing a carton packaging sleeve (8) from a used carton packaging (1), whereby the used carton packaging (1) has a top wall (2), a bottom wall (3), and side walls (4), longitudinal seals (5C), a first transverse seal (5A), a second transverse seal (5B), an opening, and an optional nozzle (6) associated with the opening; wherein the method comprises the steps of detecting the presence of the optional nozzle (6) and removing the optional nozzle (6) if its presence is detected; opening the first transverse seal (5A) and the second transverse seal (5B) to obtain the sleeve (8).

Description

Technical Field

[0001] This invention relates to a method for producing cardboard packaging sleeves from used cardboard packaging. The invention also relates to an apparatus for producing cardboard packaging sleeves from used cardboard packaging. Background Technology

[0002] Many liquid or pourable foods, such as juice, UHT (ultra-high temperature) milk, milk substitutes like oat and soy beverages, wine, ketchup, yogurt, and cooking oil, are sold in packages made of sterilized packaging materials.

[0003] A typical example is a parallelepiped-shaped package for liquids or pourable foods, called Tetra Pak Aseptic (registered trademark), which is made by sealing and folding laminated strip packaging material. The packaging material has a multi-layered structure, including a base layer (e.g., paper) covered on both sides by heat-sealable plastic material layers (e.g., polyethylene). In the case of aseptic packaging for long-term storage products (such as UHT milk), the packaging material also includes an oxygen barrier material layer (oxygen barrier layer), such as aluminum foil, which is stacked on top of a heat-sealable plastic material layer and covered by another heat-sealable plastic material layer, forming the inner surface of the package that ultimately contacts the food.

[0004] This type of packaging is typically produced on fully automated packaging equipment, which forms packages from corresponding packaging blanks. These packaging blanks can be provided either as individual packaging blanks or as continuous webs formed by multiple consecutively arranged packaging blanks.

[0005] In cases where the packaging equipment is designed to form packages from continuous webs, the equipment advances and sterilizes the webs, then forms the webs into tubes and fills them with pourable products, and then forms the tubes into individual sealed packages.

[0006] To facilitate the formation and definition of the packaging shape, the packaging blank is provided with multiple crease lines. The crease lines can define the specific shape required for the packaging.

[0007] The package being manufactured is known to have a bottom wall and a top wall spaced apart from each other along the longitudinal axis of the package, and a plurality of side walls inserted between the top wall and the bottom wall.

[0008] Typically, once these packages are used, they are collected and disposed of separately, thus separating and recycling the individual layers of the multi-layered structure of the packaging material.

[0009] Consumers are advised to cut open individual cardboard boxes at the top and bottom, as well as along the longitudinal seal, flatten them, rinse them clean, and finally return them for recycling in their completely flattened state, while keeping white-lined and silver-lined cardboard boxes separate, see example: It is necessary to make cardboard packaging reusable, thereby avoiding recycling and reducing the packaging's carbon footprint. Summary of the Invention

[0010] Therefore, the object of the present invention is to provide a method and apparatus for producing cardboard packaging sleeves from used cardboard packaging, which overcomes at least one of the aforementioned disadvantages.

[0011] This objective is fully achieved by the method described in accordance with one or more of the appended claims. Attached Figure Description

[0012] Non-limiting embodiments of the invention will be described by way of example with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of used cardboard packaging processed according to the method of the present invention; Figure 2 This is a schematic diagram illustrating different types of used cardboard packaging processed according to the method of the present invention; Figure 3 yes Figure 2 A diagram of the packaging, showing the flaps folding backwards; Figure 4 From Figure 2 A diagram illustrating the sleeves obtained from used cardboard packaging; Figure 5 This is a schematic diagram showing the insertion of a heating pin between the sealing surfaces forming the first and second transverse sealing portions; Figure 6 This is a schematic diagram of inserting a mechanical device between the sealing surfaces that form the first and second transverse sealing portions; Figure 7 This is a schematic diagram showing the sealing surfaces of the first and second transverse sealing parts formed by clamping with a suction clamp; Figure 8 This is a schematic diagram of a patch applied to the pouring opening of the sleeve; Figure 9 This is a schematic diagram of stacked sleeves. Detailed Implementation

[0013] This invention relates to a method for producing cardboard packaging sleeves from used cardboard packaging.

[0014] The term "carton packaging" refers to packaging typically made of laminated packaging materials, which include layers of paper, cardboard, or rigid cardboard as structural supports. The packaging material may also include barrier layers to provide barrier properties, such as blocking moisture, oxygen, and light, retaining its contents, and extending the shelf life of the contents. Barrier layers may include aluminum foil, polymer substrates (such as polyolefins or polyamides), or fiber-based substrates, all of which may be coated with one or more additional functional layers to enhance barrier properties. Laminated packaging materials may also include heat-sealable layers on their inner and outer surfaces to allow for the formation of a seal in the overlapping areas of the laminated materials when the carton is upright.

[0015] A cardboard box package may include a top panel, bottom panel, front panel, back panel, left panel, and right panel. Some or all of the panels may be joined by edges formed by folding the packaging material. This folding may be supported by forming crease lines in the packaging before folding. The folded panels are joined along certain edges (such as the front top edge and the front bottom edge). To form a sealed package from the initially flat packaging material, several seals may be formed in the overlapping areas of the packaging. A sealed cardboard box package may include a longitudinal seal extending along the body from the bottom panel to the top panel, and two transverse seals extending across the bottom and top panels. Alternatively, the cardboard box package may include two longitudinal seals extending along the body and one transverse seal, preferably extending across the bottom panel.

[0016] The term "carton sleeve" refers to a sheet of laminated packaging material designed and folded into a three-dimensional shape. Carton sleeves typically have a three-dimensional construction, which is achieved by folding initially flattened packaging material into a three-dimensional shape such that the packaging material overlaps along at least one edge, and then the package is sealed along the overlapping edge. Alternatively, a carton sleeve with a three-dimensional shape can be obtained from a fully sealed package by opening at least one seal, preferably two seals (such as two lateral seals). It typically comprises sections corresponding to the various panels of the finished carton package (such as front, back, left, right, top, and bottom panels). These sections can be outlined by crease lines, which facilitates accurate and easy folding.

[0017] Compared to sealed cardboard box packaging, a cardboard box sleeve has at least one open panel or edge, allowing access to the interior of the cardboard box packaging. Preferably, the cardboard box sleeve has at least two open panels or edges, allowing access to the interior of the cardboard box packaging. Preferably, apart from overlapping seals, and more preferably an overlapping seal line defining and maintaining the three-dimensional shape of the sleeve, the cardboard box sleeve has no overlapping areas or folds.

[0018] The cardboard packaging sleeve can further have a flattened construction. The three-dimensional construction is transformed into a flattened construction, wherein two segments of the laminated packaging material are adjacent to each other, except for overlapping areas. Preferably, during the transformation of the cardboard packaging sleeve from a three-dimensional construction to a flattened construction, one or more seals required to define and maintain the three-dimensional shape of the sleeve are not opened.

[0019] The term "used cardboard packaging" refers to cardboard packaging that has completed its initial use lifecycle. It may contain fully sealed containers used for storing and distributing contents, such as liquid consumables. Once the contents have been consumed or removed, the packaging becomes used cardboard packaging. Such packaging may show signs of use, such as signs of opening, and may contain residual contents or odors of stored materials.

[0020] Used cardboard packaging suitable for the method according to the invention typically includes certain sections and features designed integrally therewith. It may comprise a top section and a bottom section, with a main body section situated between them, thus forming the main structure. A longitudinal seal may be present along the main body section to ensure the integrity of the packaging. Furthermore, the packaging has a first transverse seal across the top section and a second transverse seal across the bottom section, thereby contributing to its completely sealed nature. An opening may be introduced in one of these sections—the top, bottom, or the main body—to allow access to the interior space of the packaging. Optionally, a nozzle may be associated with this opening to facilitate drinking, dispensing, or removing the contents of the packaging. The optional nozzle may be attached to any panel of the cardboard packaging by attaching (e.g., by adhesive) the flange of the nozzle to the interior or exterior of the cardboard packaging.

[0021] The method according to the invention for producing cardboard packaging sleeves from used cardboard packaging may include the steps of detecting the presence of an optional nozzle and removing the optional nozzle if its presence is detected.

[0022] This method may include an initial detection step to determine the presence of optional nozzles on used cardboard packaging. This detection can be performed using various techniques, such as vision inspection systems, sensors, or a combination of both. The detection is preferably aimed at accurately identifying the location and characteristics of the nozzles. Detecting the presence of optional nozzles on used cardboard packaging can be achieved through various methods, each focusing on identifying the unique features of the nozzles. A common method is to use a vision inspection system comprising a camera or scanner that captures images of the cardboard packaging. These images are then analyzed using image processing algorithms to identify the nozzles based on their shape and / or size and / or specific features. Another method involves using sensors, such as capacitive, inductive, or ultrasonic sensors, which can detect changes in the material properties or thickness at the location of the nozzle. These sensors provide signals indicating the presence of a nozzle based on changes in the electrical or acoustic properties compared to the rest of the cardboard material. Detection systems can also combine vision and sensor-based methods to improve the accuracy and reliability of nozzle identification. The choice of detection method may depend on factors such as the material and size of the optional nozzle and the overall design of the cardboard packaging.

[0023] Once the nozzle's presence is confirmed, the next step is its removal. Removing an optional nozzle from a used cardboard box package once its presence is detected may require a mechanical process. This can be achieved using a cutting or punching mechanism (specifically designed for this purpose). This mechanism typically includes sharp blades or molds configured to precisely aim at the nozzle area. The removal process must be carefully controlled to ensure the nozzle separates cleanly from the cardboard box without damaging the remaining material, which is crucial for subsequent steps in producing the cardboard box sleeve. This removal process is often integrated into automated production lines for efficient, high-volume processing. Another method for removing optional nozzles from used cardboard boxes involves loosening the adhesive or polymer attachments holding the nozzle to the packaging. This process can be achieved by applying solvents and / or heat treatment to weaken or dissolve the adhesive bond. The application of solvents or heat must be precisely controlled to affect only the nozzle area, avoiding damage to the rest of the laminated packaging material. Once the adhesive bond is sufficiently weakened, a mechanical device, such as a robotic arm or specially designed tool, can gently remove the nozzle from the packaging. One advantage of this method is that it minimizes the amount of packaging material damaged or removed from cardboard packaging, thereby reducing the workload of preparing used packaging for reuse.

[0024] The method for producing a cardboard packaging sleeve from used cardboard packaging according to this disclosure includes the step of opening a first transverse seal and / or a second transverse seal to obtain the sleeve. This step may include carefully cutting or mechanically separating this seal or these seals to open the sealing line. The cutting mechanism may be a blade or a laser. The cutting mechanism is precisely controlled, targeting only the sealed area without damaging the rest of the cardboard material. The aim is to allow the cardboard packaging to unfold into a sleeve in a controlled manner. Opening one or more seals allows the cardboard box to flatten, providing a basis for forming the sleeve.

[0025] Alternatively, opening the first and / or second transverse seals can also be achieved thermally. This involves applying heat to the polymer or adhesive forming the seal. The heat application is carefully controlled to target the sealed area, weakening the polymer bond without compromising the structural integrity of the rest of the laminated packaging material. Once the bond is sufficiently weakened, the seal can be easily opened, allowing the carton to unfold into a flat sleeve. This thermal method provides a precise and efficient way to open the seal and prepare the carton for transformation into a sleeve. Equipment suitable for applying heat for thermal separation includes hot air guns and / or infrared heaters and / or induction heating systems. Hot air guns direct a stream of hot air to the sealed area, precisely melting the adhesive without damaging the surrounding material. Infrared heaters emit infrared radiation to directly heat the sealed area, providing rapid and uniform heating. Induction heating systems use electromagnetic fields to heat metal elements (if present) in or near the sealed surface, providing rapid and localized heating. Each device offers different advantages in terms of precision, efficiency, and suitability for specific materials and seal types.

[0026] A combination of thermal and mechanical separation can be used to open the first and / or second transverse seals. Initially, heat is applied to the sealing area to weaken the polymer or adhesive bond. This thermal weakening makes the seal easier to mechanically separate. After the heat is applied, a mechanical device, such as a cutter or robotic arm, gently separates the weakened seal. This combined approach ensures controlled and effective opening of the seal, allowing the carton to unfold precisely into a flat sleeve without damaging the material.

[0027] The method for producing cardboard packaging sleeves from used cardboard packaging according to this disclosure may include a step of folding the sleeve into a flattened configuration. Folding the sleeve into a flattened configuration may include, before or during this step, folding the cardboard along pre-existing or new creases. This step can be achieved through a series of mechanical means or manual operation to ensure the sleeve is folded accurately and evenly. The process may include aligning the edges and panels of the sleeve and applying pressure along some folds to ensure a crisp, flat finish. This action not only saves space but also prepares the sleeve for efficient storage, transport, or further processing steps, maintaining the integrity and uniformity of the sleeve.

[0028] The method for producing cardboard packaging sleeves from used cardboard packaging according to this disclosure includes the step of adding sleeves to a stack of other sleeves. Adding sleeves to the stack can comprise an automated or manual process in which a flattened sleeve is carefully placed on top of or beside a previously flattened sleeve. This step is typically achieved using a conveyor system or robotic arm to ensure precise placement and alignment of each sleeve in the stack. The stacking process aims to maintain the flatness and integrity of each sleeve, optimizing space efficiency for storage or further processing. This step ensures that the sleeves are neatly arranged, prevents damage, and facilitates easy handling or transport.

[0029] In the method according to this disclosure, the first and / or second transverse seals of a used cardboard box package, each typically characterized by its originally bonded sealing surfaces, undergo a specific opening process. This may involve directly applying heat to these seals, preferably in a careful and controlled manner, to weaken the adhesive or polymer bond holding the sealing surfaces together. Careful and controlled heat application to the first and / or second transverse seals may involve using precise temperature control and timing to ensure uniform heat application to the sealed area while minimizing excessive heat exposure to other parts of the package. This can be achieved using a controlled hot air system, infrared heating, or induction heating, depending on the material properties of the seals. Careful and controlled heat application involves using precise heating equipment targeted at the sealed area without affecting the surrounding cardboard material. The temperature is set to a level that softens or melts the adhesive without damaging the cardboard material. The duration of heat application is closely monitored to avoid any degradation of the cardboard material, optimize the effective separation process of the sealing surfaces, and maintain the structural integrity of the sleeve. The heating process is monitored to ensure uniform application, prevent overheating, and ensure the integrity of the sleeve.

[0030] After heat is applied, mechanical action can be used to spatially separate the previously sealed surfaces of the first and / or second transverse seals. This careful application of heat, followed by mechanical separation, ensures the integrity of the sleeve while effectively opening the seal. Mechanical separation may involve using a device such as a robotic arm equipped with suction cups or grippers to gently pull open the softened seal. The device is designed to apply just enough force to separate the seal without tearing or damaging the carton material. A precision control system guides the separation process, ensuring a clean opening and an intact sleeve for further processing.

[0031] Furthermore, the separation of the seal can be performed using a mechanical device inserted between the sealing surfaces. This device can be heated to further soften the adhesive or polymer bond, facilitating the separation process and making it easier to mechanically separate the sealing surfaces without damaging the carton material. The use of a heated mechanical device combines thermal and mechanical action to achieve efficient and controlled separation, ensuring the integrity of the sleeve for subsequent processing steps.

[0032] The method for opening both the first and second transverse seals of a used cardboard box package can involve a mechanical process. A cutter or similar cutting tool is carefully inserted between the sealing surfaces of the first, second, or both transverse seals. This insertion is precisely controlled to avoid damaging the cardboard material outside the sealing area. Once inserted, the cutter functions to spatially separate the sealing surfaces from each other, effectively breaking the seal while maintaining the integrity of the cardboard box, transforming it into a sleeve. This process emphasizes precision and control in handling the sealing surfaces to ensure a clean separation, which is beneficial for subsequent sleeve production steps. In the case of separating the sealing surfaces of a cardboard box package, the term "cutter" includes all instrument variations equipped with one or more cutters suitable for this purpose. The size, shape, and sharpness of the cutter may vary depending on the specific requirements of the separation task. The surfaces of one or more cutters may be coated to reduce friction during the cutting process or to reduce the accumulation of polymer or adhesive residues on the surface during cutting.

[0033] A cutting tool designed for separating the sealed surface of a cardboard box package is characterized by a dual-blade configuration for enhanced functionality. A first blade, located at the first edge, is specifically designed to penetrate the seal. Its sharpness and design allow for a precise initial cut without damaging the surrounding cardboard material. After penetration, a second blade (preferably perpendicular to the first edge) on an adjacent edge facilitates the separation process, slicing along the length of the seal to effectively separate the sealed surface spatially. This dual-blade design ensures a seamless opening process, thus maintaining the integrity of the cardboard box for subsequent sleeve production.

[0034] The method according to this disclosure may involve using a laser scalpel to cut the sealing surfaces of a first transverse seal and / or a second transverse seal. This advanced tool precisely applies focused light energy to cut through the seal without physical contact, minimizing damage to surrounding material. The precision of the laser scalpel allows for precise cutting along the seal line. After laser cutting, the sealing surfaces are spatially separated, effectively opening the seal while maintaining the integrity of the carton for further processing into sleeves. This process emphasizes the accuracy and efficiency of separating the sealing surfaces. The term "laser scalpel" refers to a large class of instruments that utilize various laser types and configurations to separate sealing surfaces. This particularly includes CO2 lasers, fiber lasers, and diode lasers, each offering unique advantages in wavelength, power output, and precision. These laser systems can be finely tuned to cut through specific materials and seals while minimizing thermal damage to adjacent areas, making them suitable for precision tasks such as opening sealed carton packaging. The laser scalpel can be mounted on a robotic arm or similar actuator to move the laser scalpel along the length of the seal to be opened. The direction of the laser scalpel can be perpendicular to the length of the seal to facilitate the depth of laser penetration into the seal. The direction of the laser cutter can be adjusted during operation. For example, during the initial penetration of the seal, the laser cutter is oriented in a first direction and then adjusted to a second orientation to maintain the separation of the seal. The laser cutter can be equipped with a first laser and a second laser, each oriented in a different direction. This dual-laser configuration allows for multiple cutting angles, enabling more precise and efficient separation of the seal surface by aiming at it from multiple directions. This arrangement enhances the ability to cut complex seal geometries or perform sequential cuts with minimal adjustments, optimizing the process of opening the seal while maintaining the integrity of the carton for further processing.

[0035] A method for opening the first and / or second transverse seals may involve inserting a heated pin between the sealing surfaces. The heated pin can then move along the length of the seal, effectively weakening or preferably cutting the adhesive or polymer bond due to the applied heat and the mechanical separation of the pin body. As the pin moves, it forms a path that spatially separates the sealing surfaces from each other. This technique ensures precise control over the separation process, minimizing damage to the surrounding cardboard material and maintaining the integrity of the sleeve for further processing. The heated pin can be precisely controlled using a temperature control system, allowing the pin's temperature to be precisely adjusted to the optimal level required to weaken the adhesive or polymer in the seal. Furthermore, a timing mechanism ensures the pin is heated for the exact desired time period, preventing overheating and damage to the cardboard material. This high precision in temperature and time ensures effective and controlled separation of the sealing surfaces. Technical solutions for transferring heat to the pin in a controlled manner include resistance heating and induction heating, where resistance heating generates heat from the resistance and induction heating utilizes an electromagnetic field to heat the metal object. Both methods allow for precise temperature control through an integrated feedback system that provides adjustable power settings and real-time monitoring of pin temperature, ensuring consistent and accurate heat application tailored to the specific needs of the separation sealing surface.

[0036] Separation of the sealed surface can be facilitated by applying an external pulling force to the outer surface of the sealed area. Suitable mechanical devices for applying this pulling force include vacuum suction cups and robotic grippers, or a combination of both. These devices can firmly clamp the carton packaging and, after weakening it, apply controlled force to peel or pull apart the sealed surface, thus ensuring a clean and efficient separation process.

[0037] Optionally, the method may include a step of inserting mechanical devices (such as spreaders or spacers) between the separated surfaces to prevent re-adhesion. These devices maintain a certain gap to ensure the surfaces remain separated for subsequent processing or inspection. The adjustable nature of these mechanical devices allows for precise control of the separation distance, thereby ensuring the integrity of the separated surfaces for further processing or inspection.

[0038] In the method according to this disclosure, after forming a sleeve from a used cardboard package, an additional step may be included to check the integrity of the polymer surface of the sleeve, focusing particularly on areas of the previously sealed surface. This integrity check ensures that each sealed surface retains a sufficient amount of heat-sealable polymer, which is crucial for successful resealing when the package is reused. If the sleeve does not meet this criterion (indicating that the polymer surface is not adequately ready for resealing), it may optionally be discarded or sent for refurbishment, ensuring that only sleeves suitable for effective reuse can proceed. Suitable sensors and methods for checking the integrity of the sealed surface after separation include optical sensors and imaging systems that can analyze the uniformity and integrity of the polymer layer on the sealed surface. These systems can detect variations in thickness, gaps, pinholes, or areas lacking sufficient polymer. Furthermore, thermal imaging can assess the distribution of heat-sealable polymer by identifying differences in thermal conductivity. Ultrasonic testing can be used to detect inconsistencies that are not visible inside or outside the polymer layer. These methods ensure a thorough assessment of whether the sealed surface is ready for resealing, thereby improving the quality of packaging produced according to this disclosure by resealing cardboard package sleeves.

[0039] This method may include a step of refurbishing at least a portion of the sealing surface. The refurbishment step may be performed by applying additional adhesive or polymer to at least those areas of the seal that have been determined to be unsuitable for resealing.

[0040] This method may include the step of opening the longitudinal seal of a used cardboard box package. If the used cardboard box package includes additional seals, these can also be opened. This step helps to transform the geometry of the packaging material into an open structure, in which case the packaging material becomes its original flat structure, all inner surfaces are easily accessible, and no parts of the material overlap each other. Therefore, opening the longitudinal seal, and possibly all other seals, allows for thorough cleaning, inspection, or any additional processing required for reuse of the packaging material. This method ensures that the sleeve can be fully opened, maximizing access to the inner surfaces to ensure complete hygiene, utilization, and quality assurance in subsequent applications. Similar to opening the transverse seal, the step of opening the longitudinal seal may involve one or a combination of three techniques: mechanical cutting, laser technology, and thermal opening. Each method can be fine-tuned based on the specific requirements of the seal and the desired processing speed. After opening the seal, the sleeve unfolds into an open structure. This ensures that all inner surfaces of the used cardboard box package are accessible using robotic arms, rollers, or other suitable devices designed to gently expand without damaging the sleeve, preparing it for further processing or inspection.

[0041] This method incorporates a sleeve cleaning step, specifically designed to remove food residues or other contaminants in a manner suitable for achieving a level of cleanliness sufficient for reusing the sleeve in food packaging. This can be achieved through various methods, including applying detergents, mechanical surface cleaning, and / or using an ultrasonic bath to remove particles. Additionally, air jets or brushes can be used to remove dried contaminants. This step ensures that the sleeve, particularly its inner surface, is hygienically safe for further use in packaging applications. Simply rinsing with water (which might be considered sufficient to prepare used cardboard packaging for recycling) is often insufficient to reliably remove food residues and other contaminants to achieve the required level of hygiene before reusing the cleaned sleeve in packaging applications.

[0042] The method may also include a step of detecting the type and extent of contamination on at least a portion of the surface. To detect the type and extent of contamination on the sleeve, sensors, such as optical sensors containing a hyperspectral imaging system, can be used. These sensors can identify specific contaminants by analyzing the spectral characteristics of the surface. Furthermore, electronic noses or chemical sensors can be used to detect and quantify organic residues or microbial contamination through volatile organic compound analysis. The integration of these sensors allows for targeted cleaning strategies, ensuring that the sleeve is cleaned according to the specific contaminants present, thereby optimizing the efficiency and effectiveness of the cleaning process. The step of detecting the type and extent of contamination on at least a portion of the surface can be performed before the contamination removal step. In this case, the intensity of the contamination removal step can be adjusted based on the detected type and extent of contamination. Alternatively, the step of detecting the type and extent of contaminants can be performed after the contamination removal step to control the effectiveness of contaminant removal.

[0043] This method may include steps for closing defective openings. After closing the defective opening, the sleeve can be folded, filled, and then resealed to ultimately form a filled cardboard box package. Preferably, the defective opening is closed with a material patch. The patch can be formed to conform to the shape of the defective opening. The patch can have barrier properties similar to the packaging material of the cardboard box package. The material patch can consist only of a barrier layer and does not include a structural cardboard layer. The material patch can then be sealed to the cardboard box sleeve to form a waterproof sleeve. Alternatively, defective openings may be closed with a material patch that is larger than the defective opening and placed on the defective opening on the inside or outside of the sleeve. The enlarged patch can then be attached to the surface of the sleeve in the overlapping area by means of adhesives, heat sealing, or ultrasonic sealing. The choice of closure method depends on the material of the sleeve and the required seal strength. For example, heat sealing may include a hot air nozzle, induction heating, or a heating rod, which reactivates the polymer layer to achieve a secure seal. Adhesive application can use precise glue or other adhesive dispensers. Each method ensures that the sleeve is properly sealed for subsequent use or disposal.

[0044] This method may include a step of identifying the type of cardboard packaging used. This step can be performed using a visual inspection system, barcode reader, QR code reader, or RFID technology to determine the type and / or size and / or contents of the packaging, and subsequently determine its specific characteristics and material composition. Specific characteristics and material composition can be retrieved from a local information storage unit or alternatively from a cloud-based information storage unit via a wired or online connection. Based on this identification, the method steps for opening the first and second transverse seals and / or folding the sleeve into a flat configuration can be adjusted. Further adjustments can be made to the steps of identifying and removing optional nozzles. Adjustments may include changing the heating temperature or duration of different sealing materials, or changing the folding technique to accommodate different packaging structures, thereby ensuring optimal handling tailored to each packaging type.

[0045] This method can be adapted to accommodate used cardboard packaging characterized by having at least one folded and / or attached flap when initially in its folded configuration. For example, the flap may be folded and attached to a side panel of the packaging. The flap may include a first or second lateral seal or part of a longitudinal seal. The step may involve opening the attachment of one or more folded flaps and then folding them back to properly expose the first or second lateral seal for opening. This may involve using mechanical means and / or thermal techniques to remove and reposition the flap, depending on the type of attachment. This step ensures that the seal is available for subsequent opening processes.

[0046] This method may include a step of folding the sleeve into a flattened structure after it has been formed from used cardboard packaging. This step further refines the process of preparing the sleeve for storage, transport, or further processing. Initially, the sleeve formed from used cardboard packaging may undergo careful straightening and alignment. This ensures that all edges and creases are correctly oriented, resulting in a perfect transition to a flattened structure. Otherwise, this transition could result in unwanted new crease lines. Robotic actuators can manually adjust the sleeve, or specialized alignment tools can be used to achieve precision. After alignment, the sleeve is subjected to uniform pressure, possibly by using pressure plates or rollers, to ensure the sleeve reaches a uniformly flattened state. Optionally, crease reinforcement may be applied to ensure the durability of the refolded creases. This may involve using a crease machine that not only defines but also reinforces the creases, ensuring they remain intact during subsequent processing or finishing.

[0047] This method can involve adding flattened sleeves to other sleeve stacks. This can be achieved, for example, by automated equipment such as a robotic arm that carefully places each sleeve on top of the stack, ensuring alignment and neatness. The stacking process may also include sensors verifying the sleeve orientation before placement, minimizing errors and maximizing space efficiency. This systematic stacking facilitates easy storage and transport while preparing the sleeves for further processing or recycling, ensuring they are orderly and readily reusable. The sleeve stacks can optionally be placed in tins for transport and insertion into a filling machine to produce filled, sealed packages from the sleeves.

[0048] Another aspect of the invention is to provide an apparatus for producing cardboard packaging sleeves from used cardboard packaging. The apparatus designed for producing cardboard packaging sleeves from used cardboard packaging can be configured to efficiently perform some or all of the steps outlined in the preceding claims. The apparatus includes mechanisms for identifying the type of cardboard packaging, opening the seal, cleaning the sleeve, and folding it into a flat configuration. It may include a combination of sensors for identification and integrity checks, heating elements and / or lasers for opening the seal, a cleaning unit for cleaning, and a robotic arm or roller for folding. The apparatus can be configured to be placed at collection points, such as in supermarkets, where customers can use the apparatus to return used cardboard packaging. In this scenario, the apparatus is designed to have a small form factor and a user interface that allows for easy handling of used cardboard packaging, and may compensate customers according to a deposit scheme. Alternatively, the apparatus can be configured to process large quantities of used cardboard packaging in a factory environment.

[0049] In another aspect of this disclosure, a cardboard packaging sleeve obtained from used cardboard packaging according to the method of this disclosure is provided. The cardboard packaging sleeve according to the invention is easily distinguishable from the original packaging sleeve because the packaging material shows at least some indication of prior use. The unique feature of this sleeve is that it originates from material previously used as cardboard packaging. The sleeve can incorporate a re-closing pouring opening to enhance functionality. Furthermore, it may include at least one refurbished sealing surface integral with a first or second transverse or longitudinal seal, thereby ensuring a robust closure after resealing. The sleeve may also have at least one reinforced crease line, thereby enhancing its structural integrity and facilitating its reuse or recycling. This method ensures the sustainability of packaging materials and innovative reuse of materials. Detailed Implementation Mark 1 generally indicates used cardboard packaging. In particular, used cardboard packaging is used to contain pourable foods, such as pasteurized milk or juice.

[0051] Used cardboard packaging is formed from packaging materials with a multi-layered structure. Specifically, the packaging material includes a layer of fibrous material (usually paper) covered on both sides by corresponding heat-sealing plastic material layers (such as polyethylene).

[0052] Preferably, the packaging material further includes gas-barrier and light-blocking material layers, such as aluminum foil or ethylene vinyl alcohol (EVOH) film, and at least first and second heat-sealing plastic material layers. The gas-barrier and light-blocking material layers are stacked on the first heat-sealing plastic material layer and covered by the second heat-sealing plastic material layer. The second heat-sealing plastic material layer forms the inner surface of the packaging 1 that ultimately contacts the food.

[0053] Package 1 includes a top wall 2, a bottom wall 3, and a side wall 4 located between the top wall 2 and the bottom wall 3. The top wall 2 and the bottom wall 3 may be parallel to each other or inclined. The side wall may include at least one wall extending from the top wall 2 to the bottom wall 3, preferably multiple walls (e.g., four walls).

[0054] Package 1 includes a longitudinal seal 5C extending along the side wall 4. Package 1 includes a first transverse seal 5 extending across the top wall 2. Package 1 includes a second transverse seal (not visible in the figure) extending across the bottom wall 3.

[0055] The package 1 may optionally include an opening in any of the top wall 2, bottom wall 3, or side wall 4 for access to the interior space of the used cardboard package 1. The opening may extend on more than one wall, for example, it may extend partially on the top wall 2 and partially on the side wall 4.

[0056] Package 1 may optionally include a nozzle 6 associated with an opening. Nozzle 6 includes a base coupled to package 1 (in the example shown, coupled to the top wall 2 and side wall 4), and a collar integrally formed with the base. Optionally, nozzle 6 may also include a cap detachably coupled to the collar to open and close the opening.

[0057] This disclosure relates to a method for producing a cardboard packaging sleeve 8 from a used cardboard packaging 1.

[0058] The method may include detecting the presence of an optional nozzle 6 and removing the optional nozzle 6 upon detection. Specifically, the optional nozzle 6 may be detected by a sensor (such as a camera) or by a human operator. Removal of the optional nozzle may be performed by a machine (which clamps the package 1 and the nozzle 6 and pulls the nozzle 6 apart) or by a human operator.

[0059] The method includes the step of opening the first transverse seal 5A and / or the second transverse seal 5B to obtain the sleeve 8. Note that the longitudinal sleeve 8 is preferably kept intact.

[0060] Each of the first transverse sealing portion 5A and the second transverse sealing portion 5B is defined by a corresponding sealing surface, which are initially sealed to each other.

[0061] In one or more embodiments, the step of opening the first transverse seal 5A and the second transverse seal 5B includes applying heat to the first transverse seal 5A and / or the second transverse seal 5B and spatially separating the sealing surfaces from each other. The heat can be applied by induction heating and / or ultrasonic heating and / or dielectric heating.

[0062] In one or more embodiments, the step of opening the first transverse seal 5A and the second transverse seal 5B includes inserting a cutter 10 between the sealing surfaces forming the first transverse seal 5A and / or between the sealing surfaces forming the second transverse seal 5B, and spatially separating the sealing surfaces from each other. Optionally, the cutter 10 may be heated or heated during insertion. In particular, a pair of hot air nozzles 11 may be arranged on opposite sides of the sleeve 8 to heat them when the cutter 10 is inserted between the first transverse seal 5A and the second transverse seal 5B.

[0063] In one or more embodiments, the step of opening the first transverse seal 5A and the second transverse seal 5B includes using a suction cup or clamp 12 to pull open the sealing surfaces (preferably after softening).

[0064] In one or more embodiments, the step of opening the first transverse seal 5A and the second transverse seal 5B includes cutting the sealing surfaces forming the first transverse seal 5A and / or the second transverse seal 5B with a laser cutter, and spatially separating the sealing surfaces from each other. Cutting can be achieved by clamping the sealing surfaces and pulling them apart.

[0065] In one or more embodiments, the step of opening the first transverse seal 5A and the second transverse seal 5B includes the following steps: inserting a heating pin 9 between the sealing surfaces forming the first transverse seal 5A and / or the second transverse seal 5B, moving the pin 9 along the first and / or the second transverse seal, thereby spatially separating the sealing surfaces from each other.

[0066] Note that the manner in which the steps of opening the first transverse seal 5A and the second transverse seal 5B are performed can be provided in substitution or combination with each other. In particular, the first transverse seal can be opened in one manner while the second transverse seal can be opened in another manner.

[0067] In one or more embodiments, the method further includes the steps of: checking the integrity of the sleeve 8; and conditionally (or optionally) discarding the sleeve 8 if the integrity check fails. Note that the integrity of the sleeve means that the sleeve is free from defects such as tears and / or delamination, sufficient barrier properties, and / or stains. In particular, if the sleeve has defects that impair liquid tightness, it can be considered incomplete. In this case, the step of checking the integrity of the sleeve 8 may include detecting whether there are defects (or damage) on the sleeve 8.

[0068] Integrity checks can be performed visually (via camera or directly by the operator) and / or through a leak test. In particular, it is stipulated that sleeve 8 should be discarded if it fails the leak test (e.g., due to the longitudinal seal 5C not being tightly sealed).

[0069] In one or more embodiments, the method further includes the steps of: opening the longitudinal seal 5C; allowing the sleeve 8 into an open configuration in which all inner surfaces of the used carton package are accessible; and reclosing the opened longitudinal seal to obtain the carton package sleeve.

[0070] In one or more embodiments, the method further includes a step of cleaning the sleeve 8 to remove food residue or other contaminants. Cleaning can be performed by rinsing with detergent. In particular, the step of cleaning the sleeve may include applying a detergent, mechanical surface cleaning, using an ultrasonic bath to remove particles, or a combination of at least two of these steps. Preferably, the cleaning step includes a combination of at least two of the steps described above (e.g., the cleaning step may include: - Apply cleaning agents and clean machine surfaces; or - Apply cleaning agent and use an ultrasonic bath to remove particles; - Clean the mechanical surface using an ultrasonic bath to remove particles; or - Apply cleaning agents and mechanical surface cleaning, and use an ultrasonic bath to remove particles.

[0071] In this regard, care should be taken to ensure that the level of the cleaning mist is sufficient for use with the packaging sleeve. A simple rinse may not be enough.

[0072] In one or more embodiments, the method further includes the step of closing the opening. The opening can be closed by applying the patch 13 to the opening and attaching it to the packaging material, for example, by sealing or gluing.

[0073] In one or more embodiments, the method further includes a step of identifying the packaging type. The packaging type can be defined by the shape and / or volume of the packaging. The packaging type can be identified by reading a QR code on the packaging. Alternatively, the packaging type can be identified by scanning the packaging with a 3D camera. Optionally, the method further includes steps of adjusting the opening of the first transverse seal 5A and the second transverse seal 5B according to the identified packaging type, and / or folding the sleeve 8 into a flat configuration.

[0074] Preferably, the used cardboard box packaging is initially in a folded configuration and includes at least one folded flap 7. The folded flap 7 is part of the top wall 2 or the bottom wall 3, which: i) Folded over the edge between one of the top wall 2 or the bottom wall 3 and the side wall 4, and attached to the side wall 4, or ii) Fold back along the edge between the top wall 2 or the bottom wall 3 and the side wall 4 and attach it to the top wall 2 or the bottom wall 3.

[0075] The folded flap 7 includes a portion of either a first lateral seal 5A or a second lateral seal 5B.

[0076] The method may also include the steps of opening the attachment of the folded flap 7 and folding the folded flap 7 back to put the first or second lateral seal in an open configuration.

[0077] In one or more embodiments, the method further includes the step of folding the sleeve 8 into a flat configuration. Specifically, with the longitudinal seal closed, the sleeve 8 can be flattened by pressing it down, thereby obtaining a pressed sleeve 8. With the longitudinal seal open, the sleeve 8 can be flattened by unfolding it down, thereby obtaining a carton blank.

[0078] In one or more embodiments, the method further includes the step of adding sleeve 8 to a stack 14 of other sleeves.

[0079] This disclosure also provides an apparatus for producing cardboard packaging sleeves 8 from used cardboard packaging 1, wherein the apparatus is operable to perform the methods according to any aspect of the present disclosure. In particular, the apparatus is designed to perform the methods according to any aspect of the present disclosure.

Claims

1. A method for producing cardboard packaging sleeves (8) from used cardboard packaging (1), Therefore, the used cardboard box packaging (1) has the following characteristics: - Top wall (2), bottom wall (3), and side wall (4) located between the top wall (2) and the bottom wall (3); - Longitudinal sealing portion (5C) extending along the side wall (4); - A first transverse sealing portion (5A) extending across the top wall (2), and; - A second transverse seal (5B) extending across the bottom wall (3); - An opening in any of the top wall (2), bottom wall (3) or side wall (4) for accessing the internal volume of the used cardboard box package (1); - An optional nozzle (6) associated with the opening; Its features The method includes the following steps: - Detect the presence of the optional nozzle (6) and remove the optional nozzle (6) if its presence is detected; - Open the first transverse sealing part (5A) and / or the second transverse sealing part (5B) to obtain the sleeve (8).

2. The method according to claim 1, wherein each of the first transverse sealing portion (5A) and / or the second transverse sealing portion (5B) is defined by a corresponding sealing surface that initially seals against each other. The step of opening the first transverse sealing part (5A) and / or the second transverse sealing part (5B) includes the following steps: • Apply heat to the first transverse seal (5A) and / or the second transverse seal (5B). • To spatially separate the sealing surfaces of the first transverse sealing portion and / or the second transverse sealing portion from each other.

3. The method according to claim 1 or 2, wherein each of the first transverse sealing portion (5A) and the second transverse sealing portion (5B) is defined by a respective sealing surface that initially seals against each other. The steps of opening the first transverse sealing part (5A) and the second transverse sealing part (5B) include the following steps: • Insert a cutting tool between the sealing surfaces forming the first transverse sealing portion (5A) and / or between the sealing surfaces forming the second transverse sealing portion (5B). • This separates the sealing surfaces from each other in space.

4. The method according to any one of the preceding claims, wherein each of the first transverse sealing portion (5A) and the second transverse sealing portion is defined by a respective sealing surface that initially seals against each other. The step of opening the first transverse sealing part (5A) and / or the second transverse sealing part (5B) includes the following steps: • The sealing surfaces forming the first transverse sealing portion (5A) and / or the second transverse sealing portion (5B) are cut using a laser cutter. • This separates the sealing surfaces from each other in space.

5. The method according to any one of the preceding claims, wherein each of the first transverse sealing portion (5A) and the second transverse sealing portion (5B) is defined by a respective sealing surface that initially seals against each other. The steps of opening the first transverse sealing part (5A) and the second transverse sealing part (5B) include the following steps: • A heated pin (9) is inserted between the sealing surfaces forming the first transverse sealing portion (5A) and / or the second transverse sealing portion (5B). • Move the pin (9) along the first transverse sealing portion and / or the second transverse sealing portion. • This separates the sealing surfaces from each other in space.

6. The method according to any one of the preceding claims, further comprising the following steps: • Inspect the integrity of the sleeve (8), • If the integrity check fails, the sleeve (8) is conditionally discarded.

7. The method according to any one of the preceding claims, further comprising the following steps: • Open the longitudinal sealing section (5C); • The sleeve (8) is in an open configuration, in which all the inner surfaces of the used cardboard box can be accessed; • Reclose the opened longitudinal seal to obtain the carton packaging sleeve.

8. The method according to any one of the preceding claims, further comprising the following steps: • Cleaning the sleeve (8) to remove food residue or other contaminants, the steps of cleaning the sleeve include applying a cleaning agent, mechanical surface cleaning, using an ultrasonic bath to remove particles, or a combination of at least two of these steps.

9. The method according to any one of the preceding claims, further comprising the following steps: • Close the tilting opening of the sleeve (8).

10. The method according to any one of the preceding claims, further comprising the following steps: • Identify the type and / or size of the used cardboard packaging; • The steps of adjusting the opening of the first transverse seal (5A) and / or the second transverse seal (5B), and / or the steps of folding the sleeve (8) into a flat configuration, depending on the identified packaging type and / or size.

11. The method according to any one of the preceding claims, The used cardboard box packaging was initially in a folded configuration and included at least one folded flap (7). The folded wing (7) is part of the top wall (2) or the bottom wall (3), - Folded over the edge between one of the top wall (2) or bottom wall (3) and the side wall (4), and attached to the side wall (4), or - Fold back along the edge between one of the top wall (2) or bottom wall (3) and the side wall (4) back onto the top wall (2) or bottom wall (3) and attach to the top wall (2) or bottom wall (3); The folded flap (7) includes a portion of the first lateral sealing portion (5A) or the second lateral sealing portion (5B). The method further includes the following steps: • Open the attachment of the folded wing (7), • Fold the folded flap (7) back so that the first or second lateral seal is in an open configuration.

12. The method according to any one of the preceding claims further includes the step of folding the sleeve (8) into a flat configuration.

13. The method of claim 12, further comprising the step of adding the sleeve (8) to a stack (14) of other sleeves.

14. An apparatus for producing cardboard packaging sleeves from used cardboard packaging (1), wherein the apparatus is operable to perform the method according to any one of the preceding claims.

15. A cardboard packaging sleeve (8) obtained from a used cardboard packaging (1) by the method according to any one of claims 1 to 13, wherein the cardboard packaging (1) is characterized by having at least one of the following features: • Primarily made from packaging materials previously used for another cardboard box packaging; • The tilt opening has been reclosed; • At least one refurbished sealing surface that forms part of the first transverse sealing portion (5A) or the second transverse sealing portion (5B) or the longitudinal sealing portion (5C); • At least one reinforced crease line.

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