Method for producing packaging from recyclable materials

Abstract

The present invention relates to a method for producing a package that encloses a substance. [Solution] A flat sheet made from a recyclable paper material and having two opposite side edges is provided and formed into a tube by folding the sheet so that the two side edges overlap each other at an overlap. The tube is heat-sealed along the overlap to form a longitudinal joint and across the overlap to close the tube at a first lateral joint at a first end. The tube is filled with a substance and heat-sealed across the longitudinal joint to close the tube at a second end at a second lateral joint. First and second amounts of glue are applied to the flat sheet at first and second triple points where the longitudinal joint and each lateral joint intersect, respectively. The glue seals each triple point when each tube end is heat-sealed to form a lateral joint.

Description

[Technical Field]

[0001] The present invention relates to a method for producing a package by providing a flat sheet, folding the flat sheet into a tube, filling the tube with a substance and heat sealing a portion of the tube to enclose the substance within the package. The present invention further relates to a package enclosing a substance and a machine for producing the package. [Background technology]

[0002] Typically, the majority of single-serve and multi-serve packaging used, for example, for coffee beans, is made from plastic materials due to their beneficial properties. For example, these materials offer advantages such as durability, flexibility, low weight, providing a long shelf life, and not altering the taste of the enclosed product. Furthermore, packaging can be efficiently and reliably manufactured from such materials. Unfortunately, it is difficult to reuse and recycle such packaging materials.

[0003] Therefore, several approaches have been taken to replace such established materials with alternative materials that facilitate and simplify the recycling of packaging after use. For example, paper-based materials have been proposed as alternative packaging materials because they can be recycled more easily compared to plastic materials.

[0004] However, a drawback of such alternative materials is that they do not have the same or significantly different material properties as established materials such as plastic or aluminum. For example, packaging made from alternative materials often has a limited shelf life because it does not provide the same oxygen and moisture barrier as aluminum or plastic. Furthermore, alternative materials also differ from known materials in material properties related to forming and sealing the package, requiring different manufacturing methods.

[0005] For example, stick packs or sachet packaging can be provided from established materials such that the contents within each package are hermetically sealed, thereby reducing the risk of bacterial contamination, oxidation or biological degradation due to moisture, whereas providing stick packs or sachet packaging made from paper materials does not allow the packages to be sealed reliably and consistently.

[0006] In particular, the bending stiffness and deformation resistance of paper materials hinder reliable sealing of packages, for example, where three or more layers of paper material are joined or where seal lines intersect. Furthermore, to provide sufficient tear strength, the paper material must have a relatively large thickness compared to the dimensions associated with the package's bend radius and joint. Therefore, different layers tend to spring back to their original position or peel immediately after attempted joining. This results in gaps, holes, or voids within the designated seal line, making it impossible to provide a hermetically sealed package using paper-based materials. This is particularly disadvantageous for packages intended for use with food or pharmaceutical products.

[0007] A possible solution to overcome this problem would be to add more sealant or adhesive to the paper material before or during sealing. However, this is not an option because paper materials can only be recycled if they contain a limited amount of adhesive or sealant. Therefore, it is clear that this approach would not overcome the problems already present in the established materials currently in use. An alternative solution would be to provide special packaging production machines, which would require special equipment to ensure high bond strength over a long period of time. However, this would increase production and manufacturing costs due to the new design of entirely new production machines, and its success is uncertain.

[0008] It is therefore an object of the present invention to provide a method for producing packaging from recyclable paper material which hermetically seals the packaging, is fully recyclable and facilitates that existing machines can be used after simple or minor modifications to produce the packaging.

[0009] These and other objects that will become apparent on reading the description are solved by the subject matter of the independent claims. The dependent claims refer to preferred embodiments of the invention. Summary of the Invention

[0010] A first aspect of the present invention relates to a method for manufacturing packaging for enclosing a substance, the method comprising the steps of providing a flat sheet made of a recyclable paper material and having two opposite side edges.

[0011] The expression "flat sheet" may thus be understood as a piece of paper which may be thin, for example, compared to its length, and which may have at least one flat surface.

[0012] The term "recyclable" can be understood as a material that can be completely reused for a new product or a new purpose, for example, after being mechanically or chemically treated using industrial or natural processes. For example, the paper material used in the present invention can be collected after use and mixed with water and chemicals to decompose it. It can be heated and broken down into cellulose strands. Plastic coatings and inks can be removed, for example, by filtration, as long as they do not exceed a certain amount. Here, to successfully recycle paper materials, the amount of plastic coating on the recycled material or the polymer content in the recycled material can be about 20% or less, preferably about 15% or less, more preferably about 10% or less, and most preferably about 5% or less of its total weight.

[0013] The flat sheet is formed into a tube by folding the flat sheet so that at least a portion of two side edges overlap at an overlap. The tube is heat-sealed along the overlap to form a longitudinal seal joint. The tube is further heat-sealed across the longitudinal seal joint to close the tube at a first transverse seal joint at a first tube end. The tube is filled with the material to be packaged.

[0014] The expression "substance" here may be understood as any kind of solid, liquid, at least partially soluble and / or permeable substance, which may have a specific or defined chemical structure, for example. Examples of substances may include cosmetics, pharmaceuticals, or food products such as cereals, roasted and ground coffee, instant coffee, coffee mixes, creamers, tea leaves, chocolate or dairy products, or dehydrated edible substances.

[0015] The tube is heat-sealed across the longitudinal seal joint and closed at a second tube end opposite the first tube end with respect to the substance to be packaged at a second transverse seal joint, thereby forming a package enclosing the substance. A first amount of glue is applied to the flat sheet at a first triple-fold location where the longitudinal seal joint and the first transverse seal joint intersect. A second amount of glue is applied to the flat sheet at a second triple-fold location where the longitudinal seal joint and the second transverse seal joint intersect. The glue seals each triple-fold location upon heat-sealing each tube end to form each transverse seal joint.

[0016] Here, the expression "glue" may be understood as any substance that can be applied to the surfaces of parts between which a (structural / permanent / temporary) bond is to be established, for example.

[0017] In other words, the present invention provides a method that facilitates the production of packaging that not only (hermetically) seals, encases or covers the material to be packaged, but can also be easily and efficiently recycled after use.

[0018] Thus, the method provides for providing a flat, thin-compared-to-length section of paper-based material having two opposite side edges. Here, a side edge can be understood as any part or portion of the flat sheet extending from one of the two opposite side edges toward the other. The method further provides for folding the flat sheet into a tube by folding the flat sheet so that the two side edges at least partially overlap. Thus, the two side edges can be arranged in the folded state so that they can both extend over each other, covering a portion of the tube that may be the overlap. It is also conceivable that, in the folded state, one of the side edges may protrude / overhang the other. Thus, it is not necessary, although not excluded, for the two side edges to be arranged flush with each other. In the overlap, the side edges may face each other on the same side of the flat sheet. Preferably, the overlap can be formed to protrude from the packaging. Preferably, the overlapping portion can be formed so that both side edges or the overlapping portion are located on the outside of the package.

[0019] The tube is then sealed lengthwise by heat sealing. Thus, in this case, the sealing direction may include at least one component corresponding to the longitudinal axis of the tube. During heat sealing, heat and pressure may be applied to affect the material of the sealed surface. The two ends of the tube are heat-sealed at transverse seal joints across the longitudinal seal joints. Here, the transverse seal joints may extend obliquely or meanderingly relative to the longitudinal seal joints, and the transverse seal joints do not necessarily (but are not excluded) need not intersect the longitudinal seal joints at right angles. This allows the substance to be contained / enclosed / wrapped from all sides. Naturally, there are no limitations on the number of transverse seal joints and longitudinal seal joints, nor on the number of triple-point portions. A certain amount, e.g., a (defined) amount, mass, or volume of glue is applied (dispensed / spread) to the longitudinal seal joints and the triple-point portions where the respective transverse seal joints intersect with each other.

[0020] This allows glue to be applied directly only to locations that require additional adhesive or sealant to achieve reliable sealing and closure of the package. This overcomes the problem of adhesive failure, where the adhesive itself does not establish a sufficiently strong bond with the substrate. Thus, this targeted and precise application of glue allows the amount of glue on the package to be kept to a very low level that still allows the package to be recycled. Furthermore, this method can be applied to a wide variety of packaging applications and material combinations, largely independent of the package design details. Thus, the method of the present invention overcomes the aforementioned problems of the prior art.

[0021] According to a preferred embodiment, the respective amounts of glue may be applied before the step of forming the flat sheet into a tube. Preferably, the first amount of glue and / or the second amount of glue may be applied as glue dots.

[0022] This allows for precise and accurate application and dispensing of the glue, ensuring that the glue stays in its dispensed shape and intended location, and avoiding problems caused by glue spreading, thereby improving sealing accuracy and reliability.

[0023] According to further preferred embodiments, the glue may be a structural adhesive that can harden through processes such as evaporation of a solvent, reaction with UV radiation, chemical reaction, or temperature adaptation. Additionally or alternatively, the glue may be a pressure-sensitive adhesive that forms a bond by applying a certain amount of pressure to bond the adhesive to the surfaces to be joined. For example, the glue may be (configured to) change from a liquid state in which the glue may be flowable to a solid state in which the glue may dry. The physical state of the glue may depend on temperature and / or pressure. For example, the glue may melt at a temperature between 50°C and 220°C, preferably between 90°C and 180°C. The glue may be, for example, a hot-melt glue.

[0024] Preferably, the glue may be dried before the step of forming the flat sheet into a tube, or at least before the step of heat-sealing the tube to form the longitudinal seal joint. The dried glue may be reactivated during each heat-sealing step by melting the glue, so that the glue becomes flowable and seals each triple-point portion after drying. Preferably, the glue seals each triple-point portion such that the longitudinal seal joint and the first and second transverse seal joints form a hermetic seal of the package. Here, the expression "hermetic seal" may be understood, for example, as an airtight seal.

[0025] The term "drying" may be understood, for example, as the glue changing from a liquid and / or flowable state to a hardened state. Preferably, in the hardened state, at least the outer contour of the glue may be solid. Alternatively or additionally, in the hardened state, the glue may be completely solidified. Preferably, the glue may be capable of bonding only in the liquid state, or may be more capable of bonding in the liquid state. However, this is only one example. The term "flowability" may be understood, for example, as the property of a viscous liquid or paste to move or spread freely without being strongly restricted or limited by intermolecular forces. Furthermore, the term "reactivated" may be understood, for example, as changing the ability of the glue from a state in which new bonds cannot be formed to a state in which the glue can form new (intermolecular / surface) bonds.

[0026] This allows for an improved process for sealing packages at triple-point locations, since the glue can be remelted when it reaches the desired sealing location. Furthermore, because the glue can be applied in a liquid state from a gluing pistol and then allowed to dry, subsequent process steps are not affected by the glue being wet, which can be a disadvantage when folding a flat sheet, for example. This improves the manufacturing process for the packages. Therefore, existing equipment from the prior art can be retrofitted to manufacture the packages of the present invention, resulting in lower manufacturing costs.

[0027] Preferably, the glue may be a recyclable, incinerable, biodegradable, and / or compostable material. Here, the expression "biodegradable material" may be understood as any material that can be decomposed into environmentally harmless products by (the action of) living organisms (microorganisms, such as bacteria, fungi, or algae). Examples of suitable glue substances may be polyvinyl alcohol (PVOH), ethylene vinyl alcohol (EVOH), polyvinyl acetate (PVAc), wax, polyolefin (PO), and / or acrylic components. For example, the glue may be a PO-based or acrylic-based hot melt adhesive or glue.

[0028] This allows the packaging to be recycled and composted after use, and using such packaging can reduce the ecological impact of single-use packaging.

[0029] According to a preferred embodiment, the flat sheet material may have a laminated and / or multi-layer structure with a base layer made of paper material and a sealant layer, where the glue may be applied (directly) to the sealant layer. The flat sheet may have various (layer) configurations, forms and shapes.

[0030] Here, the expression "laminated / layered structure" can be understood as a structure comprising different parts configured as plies, slats, steps or strata, for example, where a flat sheet can be provided with any number of layers, each capable of providing a desired function, such as a layer for sealing, (further layers) for forming a (moisture / oxygen) barrier, and / or a sealant or adhesive (e.g., a sealant layer in question, etc.).

[0031] This allows the material properties of the flat sheet to be tailored to the needs of each application.Furthermore, the packaging manufacturing process can be improved as the packaging can be produced on retrofitted, existing and accessible manufacturing equipment.

[0032] According to a further preferred embodiment, the step of providing a flat sheet may include unwinding a longitudinal flat sheet material from a paper reel. Preferably, the step of providing a flat sheet may further include longitudinally cutting the flat sheet material into separate flat sheets, each having two side edges opposite each other. A plurality of packages may be formed in succession, where adjacent packages may share a transverse seal joint that forms a first transverse seal joint of one of the packages and a second transverse seal joint of the adjacent package. Alternatively or additionally, a first amount of glue in one of two adjacent packages may be provided together with a second amount of glue in the adjacent package. Preferably, the step of heat-sealing the tube to form the second transverse seal joint may be followed by a step of separating the packages. Preferably, the separation may be completed by a transverse cutting step. Alternatively, the step of heat-sealing the tube to form the second transverse seal joint may be followed by a step of weakening the connection, which may preferably be the shared transverse seal joint, to form a tear line.

[0033] This allows for increased packaging production speed and quality.

[0034] A further aspect of the invention relates to a package having two opposite side edges and made from a flat sheet made from a recyclable paper material, the package enclosing a substance.

[0035] Here, the expression "enclose" may be understood as surrounding, covering, enclosing and / or enclosing something, such as a substance, preferably in a sealing manner.

[0036] The package includes a longitudinal seal joint along the overlap where two opposing side edges meet when the flat sheet is folded to form the flat sheet into a tube. The package further includes a first transverse seal joint extending across the longitudinal seal joint and closing the tube at a first tube end. The package also includes a second transverse seal joint extending across the longitudinal seal joint and closing the tube at a second tube end opposite the first tube end with respect to the enclosed substance. The package includes a first amount of glue sealing a first triple-folded portion where the longitudinal seal joint and the first transverse seal joint intersect, and a second amount of glue sealing a second triple-folded portion where the longitudinal seal joint and the second transverse seal joint intersect.

[0037] This makes it possible to provide packaging that not only seals the substance to be packaged but is also easily and efficiently recyclable after use.

[0038] According to a preferred embodiment, the flat sheet may have a multi-layer structure including a base layer made of a paper material and a sealant layer. Preferably, the sealant layer may be provided on at least one of the two opposing surfaces of the flat sheet. Alternatively or additionally, the sealant layer may be provided as a coating or laminate that acts as a sealant during heat sealing.

[0039] This allows the material properties of the packaging to be tailored to the needs of each application, as the layers can provide different functions such as sealing properties or water resistance.

[0040] Preferably, the base layer may have a thickness of at least 50 μm (microns) (microns = micrometers), preferably at least 60 μm. Preferably, the base layer may have a thickness of up to 120 μm. For example, the base layer may have a thickness of at least 50 μm and up to (at most) 120 μm. Alternatively or additionally, the sealant layer may have a thickness of 5 to 10 μm, preferably 6 to 8 μm.

[0041] This allows for a stable package that provides sufficient tear resistance while limiting the amount of sealant to a minimum level. In particular, it allows for a paper-based material to be provided with a relatively thin sealant layer (compared to paper-based materials). Thus, the physical properties and quality of the package can be improved.

[0042] According to further preferred embodiments, the packaging may be a single-serve pack such as a stick pack, or a multi-serve pack such as a stand-up pouch, pillow pack, and / or gusseted bag. Preferably, in the overlapping portion, the side edges may face each other on the same side of the flat sheet. Preferably, the overlapping portion may be configured such that the overlapping portion protrudes from the packaging, or such that both side edges or the overlapping portion are located outside the packaging. Preferably, the packaging may be configured to hermetically seal the enclosed food product as a substance.

[0043] This allows for an improvement in the manufacturing process of the package as the filling can be completed at approximately the same time as the sealing process, which reduces the time that the material is exposed to the environment, and therefore a filled package having this configuration can provide an improved shelf life for the product.

[0044] Of course, the packaging may comprise all the aforementioned features or characteristics described above for the method according to the first aspect of the invention, and for the sake of brevity, an explicit repetition of these features will be omitted here.

[0045] A further aspect of the invention relates to a machine for producing a package for enclosing a substance as described in detail above.

[0046] The machine includes a feeding system for feeding a flat sheet made of a recyclable paper material and having two opposite side edges. The machine further includes a folding section for folding the fed flat sheet so that the opposite side edges overlap each other at an overlap to form the flat sheet into a tube. The machine includes a first heat-sealing section for heat-sealing the tube along the overlap to form a longitudinal seal joint. The machine further includes a second heat-sealing section for heat-sealing the tube across the longitudinal seal joint and closing the tube at a first transverse seal joint at a first tube end. The machine also includes a filling section for filling the tube with a substance to be packaged. The machine further includes a third heat-sealing section for heat-sealing the tube across the longitudinal seal joint and closing the tube at a second transverse seal joint at a second tube end opposite the first tube end with respect to the substance to be packaged to form a package enclosing the substance.

[0047] The machine further comprises a glue applicator adapted (and / or configured) to apply a first amount of glue to the flat sheet at a first triple-fold location where the longitudinal seal joint and the first transverse seal joint intersect, whereby the glue seals the first triple-fold location upon heat-sealing the tube at the second heat-seal location to form a first transverse seal joint. The glue applicator is further adapted (and / or configured) to apply a second amount of glue to the flat sheet at a second triple-fold location where the longitudinal seal joint and the second transverse seal joint intersect, whereby the glue seals the second triple-fold location upon heat-sealing the tube at the third heat-seal location to form a second transverse seal joint. Preferably, the second and third heat-seal locations may be identical or integral.

[0048] This makes it possible to provide a machine that not only (tightly) seals the material to be packaged, but also produces packaging that can be easily and efficiently recycled after use. In particular, the machine can provide a reduced amount of glue to the starting material, which makes it possible to maintain the sealant / adhesive content at a level that facilitates recycling of the produced packaging. Here, the application of glue in the machine is carried out in the described manner, which allows glue to be applied only to places that require additional sealant / adhesive during heat sealing.

[0049] According to a preferred embodiment, the glue application section may be positioned within the machine such that the glue is dry before reaching the folding section and any one of the first to third heat sealing sections. Preferably, the machine may be configured (adapted) to complete any or all of the above-mentioned steps of the method of the first aspect of the present invention.

[0050] This allows the glue to be applied in a way that maintains its intended shape and does not interfere with subsequent manufacturing steps completed by the machine, thereby facilitating improvements to the manufacturing process in a simple and cost-effective manner.

[0051] According to a further preferred embodiment, the feeding system may comprise a reel feeding system for unwinding longitudinal flat sheet material from a paper reel to feed the flat sheet. Furthermore, the machine may preferably further comprise a cutting section for separating the successively formed packages. Preferably, the third heat sealing section may be configured to transport the flat sheet from the feeding system to the cutting section, preferably by gripping and pulling the second tube end.

[0052] Thereby, in accordance with the machine configuration of the present invention, it is possible to produce packages in a high speed, fully automated process without the excessive costs of reconfiguring or retrofitting existing machines. [Brief explanation of the drawings]

[0053] Further features, advantages, and objects of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the embodiments of the invention in conjunction with the accompanying drawings. For example, where numerals are omitted from a figure for clarity, the corresponding features may still be present in the figure. [Figure 1] 1A-1C are schematic front and side views of a flat sheet used in the method of the present invention and for packaging of the present invention. [Figure 2] 2A and 2B are schematic front and side views of the flat sheet of FIG. 1 after it has been folded into a tubular configuration. [Figure 3] FIG. 3 is an enlarged schematic side view of the tube of FIG. 2 with an end cut away. [Figure 4] FIG. 3 is a schematic side view of the tube of FIG. 2 during a heat sealing process. [Figure 5] 1A-1C are schematic front, back and side views of a package according to the present invention. [Figure 6] 1 shows a machine for producing packaging according to the invention; [Figure 7] FIG. 7 is a detailed view of the geometric dimensions and proportions of the flat sheet used in the machine of FIG. 6 for the packaging of FIG. 5. DETAILED DESCRIPTION OF THE INVENTION

[0054] The drawings show various views and embodiments of the present invention. For example, Figures 1-4 illustrate several steps of a method for producing a package 200 according to the present invention. Figure 5 shows an embodiment of a package 200 according to the present invention. Figures 6 and 7 exemplarily show an embodiment of a machine 600 for producing a package 200 according to the present invention.

[0055] A method for manufacturing a package 200 for enclosing a substance 500 includes the step of providing a flat sheet 100 made of a recyclable paper material and having two opposite side edges 101, 102. The side edges 101, 102 may extend from each side edge of the flat sheet 100 toward the opposite side edge portion 101, 102, respectively. The two side edges 101, 102 may together completely form a surface of the flat sheet 100. Preferably, the flat sheet 100 may also have two opposite surfaces 111, 112. The flat sheet 100 may have any shape or form. For example, the flat sheet may have a (substantially) square or rectangular form, as exemplarily shown in FIG. 1 . However, this is not an exhaustive list.

[0056] Generally, for example, flat sheet materials may include paper (e.g., made (exclusively or at least primarily) from cellulose fibers, such as cellulose fibers derived from wood, grass, and / or bamboo) and additional (optional) components that may or may not be recyclable or biodegradable. Here, the additional components (which may be, for example, plastic coatings or other polymeric content) are limited to an amount of up to about 20%, preferably up to about 15%, more preferably up to about 10%, and most preferably up to about 5% of the total weight of the flat sheet material (together) (so that the flat sheet material remains recyclable). The additional components may be provided as a layer, a laminate, on the paper material, although it is also contemplated that the additional components may be mixed or blended into the paper material itself. However, these are merely examples and do not represent an exhaustive list.

[0057] The flat sheet material may have a laminated and / or multi-layer structure. Here, the flat sheet 100 (or flat sheet material) may include a base layer and a sealant layer (not shown). It is also contemplated that the flat sheet material may include additional layers, which may or may not be preferably recyclable, biodegradable, and / or compostable materials. Preferably, the base layer may be made from a paper material.

[0058] Base layer: 40 g / m 2 ~120g / m 2 , preferably 50 g / m 2 ~80g / m 2 The paper may have a basis weight of 100g. The expression "gsm" may be used as an abbreviation for the unit of basis weight, meaning "grams per square meter." Examples of suitable recyclable paper materials may include single-sided glazed paper or metallized paper. For example, single-sided glazed paper may be uncoated paper with one smooth side and the other rough side. Metallized paper may be paper coated with a layer of metal, such as aluminum, and preferably the coating may be applied by lamination or vacuum metallization.

[0059] The sealant layer may have a thickness of 5 to 10 μm, preferably 6 to 8 μm. Examples of materials used as the sealant layer may include polyolefin dispersions or acrylic coatings. The sealant layer may have a thickness of 1 g / m 2 ~15g / m 2 , preferably 4 g / m 2 ~10g / m 2 The sealant layer may have a basis weight of 111. The sealant layer may be configured to melt by applying a temperature in the range of 150°C to 220°C to the flat sheet 100. Alternatively or additionally, the sealant layer may change its physical state or bonding properties under pressure or exposure to (UV) radiation. Preferably, the sealant layer may be provided on at least one of the two opposing surfaces 111, 112 of the flat sheet 100. The sealant layer may be a coating that acts as a sealant in the heat-sealing process.

[0060] Preferably, the flat sheet 100 may be provided by unwinding a longitudinal flat sheet material. For example, the flat sheet 100 may be unwound from a paper reel 611 arranged in the machine 600. Alternatively or additionally, the flat sheet 100 may be provided by unwinding a wide longitudinal flat sheet material and cutting it longitudinally (e.g., by a circular blade) into separate flat sheets 100, each having two opposite side edges 101, 102. This is exemplarily shown in Figures 6 and 7.

[0061] The flat sheet 100 is folded to form the tube 120 by folding the flat sheet 100 so that the two side edges 101, 102 at least partially overlap each other at an overlap 123. At the overlap 123, the side edges 101, 102 may face each other on the same side of the flat sheet 100. Thus, the two side edges 101, 102 may be folded to rest on top of each other on the same side of the flat sheet 100. This is exemplarily shown in Figures 2-4, where the two side edges 101, 102 face each other at the first surface 111. The tube 120 is heat-sealed along the overlap 123 to form a longitudinal seal joint 130. Figures 2 and 3 exemplarily show this. Preferably, the tube 120 may have a first tube end 121 and a second tube end 122, between which preferably extends a longitudinal seal joint 130 at least partially, preferably completely, as shown in Figures 2 and 5.

[0062] The (sealed) overlapping portion 123 may be formed so that the overlapping portion 123 protrudes from the package 200, preferably in a sealed state. The (sealed) overlapping portion 123 may also be formed so that the overlapping portion 123 protrudes from the package 200, or so that both side edges 101, 102 or the overlapping portion 123 are located outside the package 200. Figures 2 and 5 exemplarily show this.

[0063] The tube 120 is heat sealed across the longitudinal seal joint 130 to close the tube 120 at the first tube end 121 at a first transverse seal joint 141 (shown, for example, in FIG. 5).

[0064] To achieve this, a second heat seal section 642 may be provided, which may include two heat seal jaws 645, 646 positioned opposite each other. FIG. 4 shows an exemplary embodiment of the second heat seal section 642. The two heat seal jaws 645, 646 may be movable (linearly and / or rotationally) relative to each other. The heat seal jaws 645, 646 may be moved between a treatment state in which the tube 120 is pressed between the two heat seal jaws 645, 646 to apply a bonding force (e.g., 500 N to 1500 N), pressure (e.g., 2 bar to 10 bar), and / or heat (temperature of 150°C to 220°C) to the tube 120 for a period of time (e.g., 0.1 to 10 seconds). The heat seal jaws 645, 646 may be moved to a release state in which the tube 120 may be movable between (and released from) the two heat seal jaws 645, 646. 4 exemplarily shows the provision of the first transverse seal joint 141, whereby the heat seal jaws 645, 646 are exemplarily shown in a treatment state, where it is contemplated that both heat seal jaws 645, 646 may be movable, or only one of the two heat seal jaws 645, 646 may be movable.

[0065] Similarly, the tube 120 is heat-sealed across the longitudinal seal joint 130 to close at the second tube end 122, which is opposite the first tube end 121 with respect to the material 500 packaging the tube 120, with a second transverse seal joint 142. This is not explicitly shown in the figures. However, the second transverse seal joint 142 may be provided in a manner similar to (or identical to) that exemplarily shown in FIG. 4. There, a third heat seal portion 643 may be provided, which may have a similar or identical configuration to the second heat seal portion 642 described above (e.g., as shown in FIG. 4). However, it is also contemplated that the same device may be used to heat-seal the first transverse seal joint 141 and the second transverse seal joint 142. Thus, the second and third heat seal portions 642, 643 may be the same / identical device. Furthermore, it is also contemplated that the second heat seal portion 642 may be integral with the third heat seal portion 643. 4, where the third heat seal portion 643 is indicated by a dashed arrow, since the third heat seal portion 643 may be hidden (when viewed in side view) behind the second heat seal portion 642. It is further conceivable that one of the heat seal jaws 645, 646 forms the second heat seal portion 642, and the other of the two heat seal jaws 645, 646 forms the third heat seal portion 643. However, these are merely examples and different configurations are possible.

[0066] By providing the second transverse seal joint 142, the package 200 is formed to enclose the packaged substance 500.

[0067] It is also contemplated that the longitudinal seal joint 130 may be sealed and secured to the tube 120 in a heat sealing step, preferably at the first or second transverse seal joints 141, 142. Figure 3 may be suitable to exemplarily illustrate such a possible configuration.

[0068] At some point in the process, the tube 120 is filled with a substance to be packaged 500. The substance 500 may be a food product or a pharmaceutical product.

[0069] The method further includes applying a first amount of glue 301 to the flat sheet 100 at a first triple point 151 where the longitudinal seal joint 130 and the first transverse seal joint 141 intersect, as shown exemplarily in Figures 2, 3 and 5.

[0070] The method also includes applying a second amount of glue 302 to the flat sheet 100 at the second triple point 152 where the longitudinal seal joint 130 and the second transverse seal joint 142 intersect, as shown illustratively in Figures 2, 3, and 5.

[0071] The first amount of glue 301 and / or the second amount of glue 302 may be applied as dots of glue 300. This is exemplarily shown in FIGS. 1-6. Preferably, any of the glues 300-302 may be applied to a sealant layer. For example, in FIGS. 1-7, the sealant layer may be provided on the first surface 111 of the flat sheet 100, which may form the inner surface of the tube 120 after the folding step. In the following description, the term "glue" may include each of the glues 300-302.

[0072] The glues 300-302 seal the respective triple-section portions 151, 152 when the respective tube ends 121, 122 are heat-sealed to form the respective transverse seal joints 141, 142. This is exemplarily shown in Figures 4 and 5.

[0073] It is also contemplated that the respective amounts of glue 300-302 may be applied prior to the step of forming the flat sheet 100 into a tube 120. This is shown in Figures 1-3, 6 and 7.

[0074] Preferably, the glues 300-302 may be dried before forming the flat sheet 100 into the tube 120 or before heat-sealing the tube 120 to form the longitudinal seal joint 130. Thus, the glues 300-302 may change from a solid state in which the glues 300-302 are dry to a liquid state in which the glues 300-302 are flowable. The change in physical state of the glues 300-302 may be activated by changing the temperature and / or pressure surrounding the glues 300-302. Here, the (dried) glues 300-302 may be reactivated (configured to be reactivated) by melting the glues 300-302 during the respective heat-sealing steps, so that the glues 300-302 become flowable and seal the respective triple-layer portions 151, 152 after drying. This is exemplarily shown in FIGS. 3 and 4.

[0075] For example, FIG. 3 exemplarily illustrates the tube 120 being mechanically compressed at the first tube end 121 (e.g., by / between two heat seal jaws 645, 646) prior to heat sealing the first transverse seal joint 141. In this configuration, glue 301 may be applied to the first surface 111 within the tube 120, and the glue 301 may be located (as a dot) directly beneath the longitudinal seal joint 130 and may be dry. FIG. 3 also illustrates that a space S may be formed between the overlap 123 and the pressed-together coated portions of the tube 120. As exemplarily illustrated in FIG. 4, heat sealing the first tube end 121 to form the first transverse seal joint 141 may result in an increase in temperature and / or pressure such that the glue 301 can melt and flow into the space S. This may fill and seal the space S with the glue 301. The same can be found for the second transverse seal joint 142 having a second amount of glue 302, where in each case the respective amounts of glue 301, 302 can be provided (or present) as dots of glue 300. The glues 300-302 can thus (be configured to) seal the respective triple points 151, 152 such that the longitudinal seal joint 130 and the first and second transverse seal joints 141, 142 (together) form a hermetic seal of the package 200.

[0076] Thus, the size, thickness, shape, and / or location of the first and second quantities of glue 301, 302 can affect, for example, the reliability of the seal of package 200. Figure 7 shows examples of suitable locations for glue application, indicated by solid circles, which may correspond to triple point portions 151, 152. Similarly, the shape and / or configuration of sealing jaws 645, 646 can affect, for example, the melt direction and / or melt behavior of glue 300-302.

[0077] Examples of suitable materials for the glues 300-302 may include wax or any polyolefin (PO) or acrylic based hot melt glue or adhesive.

[0078] A plurality of packages 200 may be formed in succession. This is exemplarily shown in FIGS. 6 and 7. Adjacent packages 200 may thereby share a shared transverse seal joint that may form a first transverse seal joint 141 of one of the packages 200 and a second transverse seal joint 142 of the adjacent package 200. Also, a first amount of glue 301 of one of two adjacent packages 200 may be provided together with a second amount of glue 302 of that adjacent package 200. The method may conclude the process of manufacturing the packages 200 by separating the packages 200 through a transverse cutting step. This is exemplarily shown in FIG. 6, where a cutting section 670 having a horizontal cutter 672 may be provided. Alternatively, the process of manufacturing the packages 200 may be concluded by weakening the connection 170 to form a tear line. FIG. 7 exemplarily shows that a shared transverse seal joint may be provided (or planned) as the connection 170.

[0079] A further aspect of the present invention relates to a package 200. Figure 5 shows an example of the package 200. The package 200 may be a single-serve pack, such as a stick pack, or a multi-serve pack, such as a stand-up pouch (e.g., a Doypack), a pillow pack, or a gusseted bag. The package 200 may be suitable for enclosing a food product.

[0080] The package 200 is made from the aforementioned flat sheet 100 having two opposite side edges 101, 102 and is made from a recyclable paper material. The package 200 encloses a substance 500 and includes a longitudinal seal joint 130. As described in detail above, the longitudinal seal joint 130 extends along the overlap 123 where the two opposite side edges 101, 102 overlap when the flat sheet 100 is folded to form the tube 120. This is exemplarily shown in FIG. 5 . A first transverse seal joint 141 extends across the longitudinal seal joint 130 to close the tube 120 at the first tube end 121. A second transverse seal joint 142 extends across the longitudinal seal joint 130 to close the tube 120 at the second tube end 122. In package 200, a first amount of glue 301 seals said first triple point portion 151, and a second amount of glue 302 seals said second triple point portion 152. Preferably, package 200 may be configured to hermetically seal a food product enclosed as substance 500. Preferably, glues 301, 302 may seal transverse seal joints 141, 142 at locations that may be laterally offset from the longitudinal axis and / or longitudinal seal joint 130. However, it is also contemplated that glues 301, 302 may be found in the center of transverse seal joints 141, 142, respectively.

[0081] FIG. 7 shows an exemplary unprocessed flat sheet 100 with the geometric dimensions and proportions of the fold seal lines that may be found in the finished package 200.

[0082] A further aspect of the present invention relates to a machine 600 for producing the aforementioned package 200. An example of the machine 600 is shown in FIG.

[0083] The machine 600 includes a feed system 610 for supplying the flat sheet 100. The feed system 610 may include a reel feed system 612 for unwinding longitudinal flat sheet material from the above-mentioned paper reel 611 to supply the flat sheet 100. Here, the reel feed system 612 may include a buffer section for holding a sufficient amount of sheet material available for processing. This is exemplarily shown in Figure 6.

[0084] The machine 600 further comprises a folding unit 620 for folding the supplied flat sheet 100 so that two opposite side edges 101, 102 overlap each other at an overlap 123 to form the flat sheet 100 into a tube 120. The folding unit 620 may be configured to fold the sheet 100 into the tube 120 and / or to position / hold the tube 120 so that the glue 300-302 is disposed below the longitudinal seal joint 130. The folding unit 620 may also define the diameter of the tube 120 and the size of the overlap 123.

[0085] The machine 600 further comprises a filling section 650 for filling the tube 120 with the material 500 to be packaged. The material 500 is exemplarily shown as a white arrow in Figure 6. The folding section 620 and the filling section 650 may be a single unit, for example a foam plate. The machine 600 may be a horizontal (HFFS) or vertical form, fill and seal (VFFS) machine, such as the machine 600 shown in Figure 6.

[0086] The machine 600 also includes a first heat sealing station 630 for heat sealing the tube 120 along the overlap 123 to form the longitudinal seal joint 130. The first heat sealing station 630 may be a vertical heat sealer.

[0087] Additionally, the machine 600 includes the aforementioned second heat sealing station 642 for heat sealing the tube 120 across the longitudinal seal joint 130 to close the tube 120 at the first tube end 121 at the first transverse seal joint 141. Examples of the second heat sealing station 642 can be seen in FIGS. 4 and 6. Preferably, the second heat sealing station 642 may be a horizontal heat sealer. The aforementioned third heat sealing station 643 is disposed in the machine 600 for heat sealing the tube 120 across the longitudinal seal joint 130 to close the tube 120 at the second transverse seal joint 142 at the second tube end 122 to enclose the substance 500. Preferably, the third heat sealing station 643 may be a horizontal heat sealer.

[0088] The second and third heat-sealed portions 642, 643 may be identical. This is exemplarily shown in Figure 6, where the second and third heat-sealed portions 642, 643 are not only integrated with each other but also form the same component. Preferably, the glue 300-302 can be reactivated in the second and third heat-sealed portions 642, 643.

[0089] The machine 600 further includes a glue application section 660 for applying a first amount of glue 301 to the flat sheet 100 at the first triple fold portion 151 to seal the first triple fold portion 151 and form a first lateral seal joint 141 when the tube 120 is heat-sealed at the second heat-sealing section 642, and for applying a second amount of glue 302 to the flat sheet 100 at the second triple fold portion 152 to seal the second triple fold portion 152 and form a second lateral seal joint 142 when the tube 120 is heat-sealed at the third heat-sealing section 643.

[0090] The glue application unit 660 may be positioned within the machine 600 so that the glue 300-302 dries before reaching the folding unit 620 and any one of the first to third heat-sealing units 630, 642, 643. This is exemplarily shown in FIG. 6, where a defined distance is set between the glue application unit 660 and the folding unit 620. For example, the dots of glue 300 shown in FIG. 6 leaving the glue application unit 660 may be dots of wet glue 300, while the four lines following the dots of glue 300 closer to the folding unit 620 may be dots of (already) dried / hardened glue 300. The glue 300 may also be dried using additional means such as a cooler or fan (not shown).

[0091] The machine 600 may further include a cutting section 670 for separating the plurality of successively formed packages 200 prior to releasing the packages at an exit system 680. The exit system 680 may be a chute. The cutting section 670 may include the horizontal cutter 672 described above. The cutting section 670 may also include a longitudinal cutter 671 for cutting the wide flat sheet material into a plurality of separate flat sheets 100. The longitudinal cutter 671 may be one or more circular blades.

[0092] Additionally, the second heat-sealing unit 642 and / or the third heat-sealing unit 643 may be configured to transport the flat sheet 100 from the feeding system 610 to the cutting unit 670 by gripping and pulling the second tube end 122. This is exemplarily shown in FIG.

[0093] Furthermore, the machine 600 may further comprise two sensor units 711, 712 for controlling and monitoring the production process. The sensor units 711, 712 may be optical sensors such as photocells or laser-based sensors. The sensor units 711, 712 may be connected to a control unit which may be configured to automatically complete the steps of the method for producing the packaging 200 according to the present invention.

[0094] The present invention is not limited by the above-described embodiments, as long as it is encompassed by the scope of the appended claims. All features of the above-described embodiments can be combined in any possible way and provided interchangeably.

Claims

1. A package (200) made from a flat sheet (100) made of recyclable paper material, having two opposite side edges (101, 102), said package (200) enclosing a substance (500); a longitudinal seal joint (130) along an overlapping portion (123) where the two opposite side edges (101, 102) overlap each other when the flat sheet (100) is folded to form the flat sheet (100) into a tube (120); a first transverse seal joint (141) extending across the longitudinal seal joint (130) to close the tube (120) at a first tube end (121); a second transverse seal joint (142) extending across the longitudinal seal joint (130) to close the tube (120) at a second tube end (122) opposite the first tube end (121) with respect to the enclosed substance (500); The packaging (200) a first amount of glue (300, 301) sealing a first triple location (151) where the longitudinal seal joint (130) and the first transverse seal joint (141) intersect; and The package (200) is characterized by a second amount of glue (300, 302) sealing a second triple location (152) where the longitudinal seal joint (130) and the second transverse seal joint (142) intersect.

2. the flat sheet (100) comprises a multi-layer structure including a base layer made of paper material and a sealant layer, preferably provided on at least one of the two opposing surfaces (111, 112) of the flat sheet (100), the sealant layer preferably being provided as a coating or laminate that acts as a sealant during heat sealing; Preferably, the base layer has a thickness of at least 50 μm, preferably at least 60 μm, and / or the sealant layer has a thickness of 5-10 μm, preferably 6-8 μm.

3. 3. The packaging (200) according to claim 1 or 2, wherein in the overlapping portion (123), the side edges (101, 102) face each other on the same side of the flat sheet (100), and preferably the overlapping portion (123) is formed so that the overlapping portion (123) protrudes from the packaging (200) or so that both of the side edges (101, 102) or the overlapping portion (123) are located outside the packaging (200).

4. The packaging (200) according to any one of claims 1 to 3, wherein the packaging (200) is a single-serve pack such as a stick pack, or the packaging (200) is a multi-serve pack such as a stand-up pouch, a pillow pack, a gusset bag, and / or the packaging (200) is configured to hermetically seal an enclosed food product as the substance (500).

5. A machine (600) for manufacturing a package (200) for enclosing a substance (500) according to any one of claims 1 to 4, comprising: a feeding system (610) for feeding a flat sheet (100) made of recyclable paper material and having two opposite side edges (101, 102); a folding section (620) for folding the supplied flat sheet (100) so that the two opposite side edges (101, 102) overlap each other at an overlapping section (123) to form the flat sheet (100) into a tube (120); a first heat seal portion (630) for heat sealing the tube (120) along the overlap portion (123) to form a longitudinal seal joint (130); a second heat seal (642) for heat sealing the tube (120) across the longitudinal seal joint (130) to close the tube (120) at a first transverse seal joint (141) at a first tube end (121); a filling section (650) for filling the tube (120) with the substance to be packaged (500); a third heat seal portion (643) for heat sealing the tube (120) across the longitudinal seal joint (130) to close the tube (120) at a second transverse seal joint (142) at a second tube end (122) opposite the first tube end (121) with respect to the substance (500) to be packaged, to form the package (200) enclosing the substance (500); The machine (600) The adhesive tape further includes a glue application unit (660), wherein the glue application unit (660) applying a first amount of glue (300, 301) to the flat sheet (100) at a first triple-point area (151) where the glue (300-302) will intersect the longitudinal seal joint (130) and the first transverse seal joint (141) so as to seal the first triple-point area (151) upon heat-sealing the tube (120) at the second heat-sealing section (642) to form the first transverse seal joint (141); and a machine (600) for applying a second amount of glue (300, 302) to the flat sheet (100) at a second triple-point portion (152) where the glue (300-302) intersects the longitudinal seal joint (130) and the second transverse seal joint (142) so as to seal the second triple-point portion (152) upon heat-sealing the tube (120) at the third heat-seal section (643) to form the second transverse seal joint (142).

6. the feeding system (610) comprises a reel feeding system (612) for unwinding longitudinal flat sheet material from a paper reel (611) to feed the flat sheet (100), the machine (600) preferably further comprising a cutting section (670) for separating a plurality of successively formed packages (200), preferably wherein the third heat sealing section (643) is configured to transport the flat sheet (100) from the feeding system (610) to the cutting section (670), preferably by gripping and pulling the second tube end (122); and / or the glue application section (660) is positioned within the machine (600) so that the glue (300-302) dries before reaching the folding section (620) and any one of the first to third heat-seal sections (630, 642, 643); and / or 6. The machine (600) of claim 5, wherein the second heat seal portion (642) and the third heat seal portion (643) are integral or identical.

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