Method and equipment for manufacturing reinforced sachets

Abstract

The present invention relates to a method for manufacturing a flexible package suitable for containing food or beverage ingredients and suitable for use with a food or beverage manufacturing machine, the method comprising the step of punching a flexible flat blank sheet between a plunger and a cavity that are movable relative to each other. According to the present invention, the plunger has a concave end face and convex lateral faces, and the profile curvature of its end face is the same as the profile curvature of each of its lateral faces.

Description

Technology Field

[0001] The present invention relates to a method for manufacturing a flexible sachet, said sachet containing a beverage ingredient and adapted for use in a beverage manufacturing machine by perforating the sachet wall and injecting a liquid into the interior to mix with said ingredient. The present invention also relates to an apparatus for manufacturing such a pack using the said method. Background Technology

[0002] It is known in modern technology to produce a beverage by introducing a capsule containing a food or beverage ingredient, such as soluble coffee, milk, or chocolate, into a beverage dispensing machine and then injecting water into the capsule to mix with the ingredient. The soluble beverage or food ingredient is typically dissolved in water to form a beverage or desired end product, which flows out of the capsule through a suitable outlet. Sometimes, the ingredient may be tea leaves, and the beverage is produced by steeping the leaves with water introduced into the capsule. As with the aforementioned soluble ingredient, the steeped tea is then dispensed out of the capsule through a dispensing outlet. Such known capsules are typically rigid or semi-rigid capsules made of plastic material(s) or metal (e.g., aluminum).

[0003] Recently, a beverage manufacturing system containing flexible packages instead of capsules has been developed. These packages offer some interesting features compared to capsules, such as compactness, manufacturing speed (molding, filling, and sealing operations can be performed in a single line), and improved recyclability.

[0004] These music packages are, for example, EP 3 414 187 A1It includes a functional insert described in the heading, located at the bottom of the flexible wall and package and sometimes referred to as a "spout"—which is attached to the flexible wall or otherwise wrapped into the flexible wall. The insert is a plain element made of rigid or semi-rigid plastic and includes a hole and a channel for connecting the bottom surface of the flexible package to a beverage machine in a fluid-tight manner. When in use, when the flexible package is functionally connected to the beverage machine, the latter introduces water into the inside of the package through the fluid conduction channel of the insert, said water then mixes with ingredients to form a beverage product, which is distributed to the outside of the flexible package through the product distribution channel of the insert.

[0005] Importantly, fluid communication between the package and the beverage machine is achieved by connecting the machine's fluid conduction element to the flat wall surface of the package; the flatness of the surface between the ingredient package and the beverage machine ensures substantial leak-tightness of the connection between the two. Furthermore, the rigidity of the package's flat surface is essential to ensure that the package does not deform during the connection of the beverage machine. Generally, the connection is achieved by piercing or otherwise inserting the machine's connecting element, such as a needle or similar element, through the package's flat surface. The connection can also be achieved by opening the package wall and pressurizing the machine's nozzle against the package wall to create a leak-tight fluid communication. If the package's flat wall is mechanically too weak, the wall will bend or otherwise deform when the beverage machine's connecting element is pressed against or inserted through it, which will result in leakage or even prevent the fluid connection from being established at all. On the other hand, the opening of the package by the machine must be easy and reliable; to this end, the force required to open the package wall must be sufficiently small.

[0006] for example, EP 3 500 503 A1Ho or EP 3 500 504 A1 In some examples described in the heading, the functional insert comprises multiple parts, one movable relative to the other, so that the insert may operate to open or close itself, thereby allowing for complex sequences for water injection, mixing, and product dispensing, which are adapted to specific manufacturing requirements imposed by the type of beverage ingredient to be dissolved. The re-closability of the insert also provides excellent cleanliness for the beverage manufacturing system.

[0007] However, such conventional flexible packages have disadvantages. First, functional inserts are manufactured from materials that are not easily recyclable. Additionally, they are plain elements and are therefore heavy. Furthermore, they are expensive to manufacture.

[0008] Other flexible packages, such as gusseted bags or pouches, exist. These packages are manufactured by folding and sealing thermoplastic materials to form gussets on their bottom sidewalls. While it may be possible to form flat bottom sidewalls for these gusseted sachets that can be connected to beverage machines, manufacturing these sachets requires a complex multi-folding process to form the gusseted bottom. Due to the multi-folding, overlapping layers of material are created and subsequently sealed. This known manufacturing process requires materials with good sealing properties that can only be obtained with thermoplastic films. If non-thermoplastic films are used, weaker sealing leads to delamination or even the creation of unsealed spaces between the folded layers of the film, which is highly detrimental to the mechanical and barrier properties of the package. Again, these gusseted flexible packages are undesirable because they require the molding of thermoplastic materials that are not environmentally friendly.

[0009] Other types of flexible packages are known that are manufactured by various processes, such as folding or punching a flexible flat blank material, to form a three-dimensional volume. However, known processes often result in the formation of wrinkles on the surface of the package while deforming the flexible flat sheet into a three-dimensional volume. Wrinkles are highly undesirable because they cause inconsistent sealing of the package and thus lead to leakage. They also increase the risk of defective interactions between the package and processing units, such as beverage manufacturing machines, due to the irregular surface of the package.

[0010] Accordingly, the main objective of the present invention is to provide a method for manufacturing an environmentally friendly package comprising a regular surface for connection to a beverage making machine, which is generally flexible but also sufficiently rigid to prevent leakage.

[0011] The present invention relates to a method for manufacturing a flexible package suitable for containing food or beverage ingredients and suitable for use with a food or beverage manufacturing machine, wherein the method comprises, in order,

[0012] (i) providing a primary flat blank sheet made of a flexible material, preferably a fiber-based material—said that the blank sheet has an elongated shape having two flaps extending symmetrically around a transverse axis—,

[0013] (ii) a step of placing a primary flat blank sheet in a forming station such that its center is positioned between a plunger and a cavity having mutually movable and complementary shapes—said that the plunger has a concave lower end face and convex lateral faces, and the profile curvature of its end face is equal to the profile curvature of each of its lateral faces—,

[0014] (iii) deforming a primary flat blank sheet by moving the plunger and the cavity toward each other so that the blank is folded around its transverse axis to lift the flaps and form an unsealed U-shaped package having side walls forming a flat package body and optionally but preferably a bottom portion having a rigid flat surface, wherein the bottom portion is a cup-shaped hollow volume having the shape of the plunger -,

[0015] (iv) includes the step of sealing the lateral edges of the U-shaped package.

[0016] In a preferred embodiment, the plunger has a hexagonal prism shape, and the prism has two opposite vertical edges aligned with the plunger transverse axis that extend downward to form downwardly extending tips, and the extended edges have a height such that for each transverse cross section of the plunger measured along its transverse axis, the sum of the two heights of the plunger end portion plus the width of its lower end face is constant.

[0017] Advantageously, the tip of the plunger is round or otherwise has a smooth edge.

[0018] Preferably, the method of the present invention

[0019] (v) Once formed and sealed along its lateral edges, the step of filling the package with food or beverage ingredients, and then

[0020] (vi) Includes an additional step of sealing the top edge of the package to close it.

[0021] Advantageously, the method of the present invention

[0022] - Step (ii) of placing a pair of plates under the flexible blank sheet - both plates are initially coplanar, each plate supports the flap of the primary flexible blank sheet, and the plates are symmetrically pivotable around respective axes located on each side of the plunger -,

[0023] - The method includes the step of pivoting both plates during step (iii) so that the edge of each plate furthest from the plunger and cavity is lifted during the pivot movement, thereby facilitating (otherwise guiding) the primary flexible blank sheet to be folded into the unsealed U-shaped package.

[0024] In an advantageous embodiment of the present invention, the manufacturing method prior to step (ii),

[0025] - Preferably, a step of providing a secondary flexible flat blank sheet manufactured from a coated fiber-based material;

[0026] - A step of punching a secondary hole through the fiber-based material of at least a secondary flat blank sheet,

[0027] - A step of punching a primary hole centered across the entire primary flat blank sheet - The diameter of the primary hole is equal to or greater than the diameter of the secondary hole of the secondary flexible flat blank sheet -,

[0028] - A step of sealing or otherwise attaching the secondary flat blank sheet to the inner surface of the primary flat blank sheet so that the centers of both holes are aligned - the attachment or sealing area has a ring shape surrounding the holes and has a width included in 0.5 mm to 10 mm, preferably 2 mm to 7 mm - further comprises.

[0029] In the latter advantageous embodiment, the method

[0030] - Step of providing a 3rd degree flexible flat blank sheet;

[0031] - The method may additionally include the step of sealing or otherwise attaching the third flexible flat blank sheet between the first flexible flat blank sheet and the second flexible flat blank sheet.

[0032] In the latter case, the tertiary flexible flat blank sheet is preferably a thin layer selected from a list of polyethylene (PE), polypropylene (PP), polylactide (PLA), polyhydroxyalkanoate (PHA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyvinyl alcohol (PVOH), starch-based polymers, food-grade oxygen and / or moisture scavengers, or combinations thereof.

[0033] Additionally, in the latter case, the concave lower end face of the plunger includes a retractable projection aligned with the center of the plunger, the retractable projection extends downward during steps (i) and (ii), and is pressed into the plunger during step (iii) when the tip of the plunger comes into contact with the blank sheet and cavity below. Advantageously, the diameter of the retractable projection exceeds the diameters of the primary and secondary punched holes.

[0034] The present invention also relates to a machine for manufacturing a package according to the method described above, wherein the machine

[0035] - Flexible flat blank sheet feeder,

[0036] - A forming set comprising a plunger and a cavity having mutually movable and complementary shapes - said plunger has a concave lower end face and convex lateral faces, wherein the profile curvature of its lower end face is equal to the profile curvature of each of its lateral faces -,

[0037] - An actuator for forming an unsealed U-shaped package having side walls forming a flat package body and a bottom portion having a rigid flat surface by deforming the blank by moving the plunger and the cavity toward each other and folding it around its transverse axis - said bottom portion is a hollow volume portion having the shape of the plunger -,

[0038] - Includes a set of sealing jaws adapted to seal the lateral edges of the U-shaped package and the bottom portion of the cup shape.

[0039] In one possible and advantageous embodiment, the plunger has a hexagonal prism shape, said prism has two opposite vertical edges aligned with the plunger transverse axis that extend downward to form downwardly extending tips, said extended edges have a height such that for each transverse cross section of said plunger measured along its transverse axis, the sum of the two heights of the plunger end portion plus the width of its lower end face is constant.

[0040] The tip of the plunger is preferably round or otherwise has a smooth edge. This prevents very sharp contact between the plunger and the packaging material to be formed and sealed, thereby reducing the risk of friction, mechanical stress on the material, and accidental tearing or puncture of the material.

[0041] In another preferred embodiment, the machine according to the present invention further comprises a pair of plates adapted to support the flexible blank sheet, each plate supporting a flap of the primary flexible blank sheet, and the plates are symmetrically pivotable around respective axes located on each side of the plunger.

[0042] Also preferably, the concave lower end of the plunger includes a retractable projection aligned with the center of the plunger, and the projection is spring-mounted so as to retract within the plunger when pressed against the primary flat blank sheet and cavity below.

[0043] The package formed by the manufacturing method according to the present invention generally comprises flexible—or semi-flexible—lateral walls that allow for a high-quality beverage product through enhanced dissolution of the contained components by a mixed fluid (typically water) injected into the interior. At the same time, the interface portion of the package (i.e., its bottom portion) with the food or beverage manufacturing machine to which it is designed to be connected is sufficiently rigid to prevent deformation of the package when the machine is fluidly connected to it. Since its outer wall is manufactured from a single blank sheet with two folded sections, it is particularly ecologically friendly (furthermore, its constituent material is preferably selected from ecologically friendly materials, such as recyclable, biodegradable, industrially compostable, or domestically compostable materials). The three-dimensional folding of the bottom interface provides sufficient rigidity to allow proper opening during use by an external tool (e.g., a water injection needle of a food or beverage manufacturing machine), and furthermore, this three-dimensionally folded bottom portion eliminates folding creases that could be detrimental to the proper functioning of the package. Brief explanation of the drawing

[0044] Additional features and advantages of the present invention are described in the description of preferred embodiments of the present invention described below with reference to the accompanying drawings, and will become apparent from the description. Fig. 1 is a side perspective view of a package according to the present invention. Fig. 2 is a plan view of a primary flat blank sheet according to the present invention. Fig. 3a is a bottom view of the package in Fig. 1. Fig. 3bis a side view of the package in Fig. 3a. Fig. 4 is an enlarged perspective plan view of one embodiment of the blank of FIG. 2. Fig. 5 is a partial bottom perspective view of a package formed from the blank of Fig. 4. Fig. 6 is a schematic perspective view of a manufacturing machine for manufacturing a package according to the present invention. Fig. 7 This is a perspective view of a roll of material for manufacturing a blank sheet according to the present invention. FIGS. 8 and FIGS. 10 to 14 These are schematic side views of a first embodiment of the molding and sealing portions in a machine for manufacturing a package according to the present invention. Fig. 9 is an enlarged perspective view of a molding plunger for manufacturing a package according to the present invention. FIGS. 15 to 19 and FIG. 21 These are schematic side views of alternative embodiments of the molding and sealing portions shown in FIGS. 8 and FIGS. 10 to 14. Fig. 20 This is a partial perspective view of a sealing jaw in a seal forming machine for manufacturing a package according to the present invention. Fig. 22 is a schematic side view of a sealing chamber for sealing lateral sides of a package according to the present invention. Specific details for implementing the invention

[0045] The package produced by the manufacturing method and machine according to the present invention is adapted for use in a food or beverage manufacturing machine (not illustrated in the drawings). The beverage manufacturing machine may be of any suitable type, but for example, it is a machine as described in EP AN 19213419.5. Such a machine is well known in the art and comprises a brewing chamber adapted to receive an ingredient package, an injection element adapted to inject a fluid (typically water) into the ingredient package, a fluid (e.g., water) supply means comprising a fluid reservoir (or a water connection for tap water), a fluid pump, a fluid heater, and a fluid pipe for circulating said fluid from the fluid supply unit toward the brewing chamber, optionally through the heater.

[0046] In the case of the present invention, the package is adapted to be opened, preferably perforated, by the introduction of a sharp element, particularly through the bottom portion wall of the package, preferably through the lower face of the bottom portion wall, by the fluid supply means of the machine. Typically, the fluid injection element of the machine is a hollow needle-shaped element. Dispensing of the food or beverage product manufactured within the package by mixing the fluid and ingredients may be performed by gravity; however, withdrawal of the finished food or beverage product may also be performed through the same element injecting the mixed fluid. In this latter case, the injection and dispensing element of the machine includes at least two channels: one channel fluidically connects the inner compartment of the package to the machine so that the machine can inject the fluid (e.g., water) into the compartment, and the second channel connects the inner package compartment to the outside of the package. The injection means of the machine may also include a supplementary channel for injecting air into the inside of the package during food or beverage manufacturing. Injecting air can improve foaming during the preparation of specifically gasified products, such as dairy-based products (e.g., foamed milk), chocolate-based products (foamed chocolate drinks, chocolate mousse), or smoothies.

[0047] Generally, the package has any suitable possible shape compatible with forming by folding the flexible sheet in half ("U-shaped" forming), such as a pouch or sachet, pad, or any other container having a generally flat configuration.

[0048] Different package sizes can be used in the same machine adapted to store different amounts of ingredients. The size of the package (i.e., its height and / or width) does not limit the type of machine that can be used to extract the ingredients contained within. The package size is adapted to the volume of the beverage to be produced; for example, an Americano or soup requires a large package, while smaller sachets are used to produce small cups such as espresso. Medium-sized sachets are used to produce frothy milk for a cappuccino.

[0049] The external design of the bottom of the sachet—which is part of the package dedicated to a functional fluid connection with the beverage machine—is maintained unchanged regardless of the size or shape of the product and package to be produced. The main idea is that the interface between the machine and the package is always the same. Additionally, other parameters, such as the flow rate of the injected fluid and / or the temperature of the injected fluid and / or the total volume of the injected fluid, can be modified as a function of the ingredients to be processed and, accordingly, as a function of the food or beverage to be produced.

[0050] The package preferably includes identification means for a beverage machine to automatically identify the type of ingredients contained therein and adapt its settings for optimal beverage preparation. These settings include, but are not limited to, water injection pressure, water injection volume, water temperature, dissolution sequence (a complex sequence of water injection, air injection, and beverage dispensing in a sequential or simultaneous manner), injection of air with water (for foam enhancement), and total time for extraction. These identification means are selected from a list of mechanical codes, optical codes (including color codes and codes printed with non-visible ink), RFID tags, one-dimensional bar codes, two-dimensional bar codes, magnetic codes, conductive codes, detection holes, or any combination thereof.

[0051] As illustrated in the attached drawings, in a preferred embodiment, the package provides a planar shape oriented along a plane that is essentially vertically oriented during beverage preparation, and a fluid injection element of the beverage machine is inserted into the package to orient a jet of aqueous and / or gaseous fluid in a direction contained within the package plane. In practice, the fluid jet introduced into the package from the bottom develops into circular and spiral motions, creating turbulence, friction, and a high contact surface between the fluid molecules and the component particles. On average, the fluid molecules swirl multiple times within the container until they leave together as a finished beverage or food product.

[0052] Hereinafter, a preferred embodiment of a package manufactured according to the present invention will now be described with reference to the drawings. In this preferred embodiment, the package is a sachet.

[0053] Fig. 1 The figure illustrates a flexible or semi-flexible closed package (1) for containing a component according to the present invention. The package (1) is,

[0054] (i) Flexible or semi-flexible lateral walls (2) forming a flat package body, and

[0055] (ii) includes a hollow volume and a cup-shaped bottom portion (3) adapted for insertion of a fluid injection element of a food or beverage manufacturing machine (not exemplified) designed to be connected to the package (1).

[0056] The bottom part (3) of the hollow cup shape does not necessarily form the entire bottom of the package. Fig. 1 In the embodiment, it forms only the central part of the entire bottom of the package and is surrounded by the side edges (4) of the package, which are sealed flat areas.

[0057] Package (1) Fig. 2It is formed from a single, elongated primary flat blank sheet (5) made of a flexible material as exemplified in [the example]. The manufacturing process steps and manufacturing machine will be described in more detail later in this specification.

[0058] The primary flat blank sheet (5) of the paper-based material has its transverse axis of symmetry ( Lx It is a U-shape that is folded around and then sealed along its side edge (4) and upper edge (6).

[0059] According to the general principles of the present invention, Fig. 3a and also 3b As exemplified in [Image], the lower portion (3) of the cup shape is a hollow volume having a concave lower surface (7) and convex lateral surfaces (8), and the profile curvature of the concave lower surface ( P lw ) - Fig. 3b Can be seen when viewing the package from a plane as exemplified by a thick line in the profile drawing - is the profile curvature of each of the above lateral planes ( P lt ) - do 3a As exemplified by the thick line in the bottom view, it is visible when looking at the package from below - identical to.

[0060] More precisely, Figs. 1, 3a, 3b and do 5 In the embodiment exemplified in [here], the lower portion of the cup shape is a hollow volume having a hexagonal prism shape, and the prism is a package transverse axis ( Lx It has two opposite vertical edges (9) aligned with ), said vertical edges (9) extended to form a downwardly extending tip (10). The extended edges (9) are, its transverse axis ( Lx For each transverse cross-section of the package measured along ), it has a height such that the sum of the two heights of the bottom part of the cup shape plus the width of its bottom face is constant. An example of this rule is Fig. 3a and Fig. 3b It is exemplified in. Fig. 3a It illustrates the first width "W1" of the lower surface measured at the first cross-section of the lower part. Fig. 3b is A first height "H1" for the bottom part of the cup shape, measured for the same first cross-section, is illustrated. Fig. 3a It additionally illustrates the second width "W2" of the lower surface measured at the second cross-section of the lower part. Fig. 3b is Additionally, a second height "H2" for the bottom portion of the cup shape, measured over the same second cross section, is illustrated. According to the principles of the present invention, if the sum S1 = (2xH1) + W1 and then S2 = (2xH2) + W2 is calculated, S1 = S2, and more generally, S1 = S2 = Sn (where Sn is measured at any cross-sectional point of the bottom portion of the cup shape (3)).

[0061] The single-piece slender primary flat blank sheet (5) used to manufacture the package (1) is made of a paper material coated with a sealant layer on its inner surface (i.e., the surface that will become the inner surface of the package (1) after forming the sheet (5).

[0062] In addition, in this embodiment of the invention, the primary flat blank sheet (5) further comprises a barrier coating interposed between a fiber-based material and a sealant layer, said barrier coating is a coating that resists oxygen and moisture transfer. The barrier coating is selected from a list of metallization coatings, silicon oxide (SiOx) coatings, aluminum oxide (AlOx) coatings, atomic layer deposition (ALD) coatings, or combinations thereof.

[0063] Fig. 2In a preferred embodiment of the present invention illustrated herein, the package (1) further comprises a secondary thickness reinforcing sheet (11) positioned on the inner surface of the lower portion (3) of the cup shape of the package. The thickness reinforcing sheet (11) is made of a paper material coated with a sealant layer. This thickness reinforcing sheet (11) provides the possibility of reducing the thickness of the lateral walls (2) of the package (1). It has been found that reducing this thickness makes these lateral walls much more flexible, which has the advantage of improving the quality of the product manufactured within the package (1). More specifically, the applicant has surprisingly found that the swirling motion of the fluid injected into the package is improved, so that the lateral walls (2) of the package can bend and deform outward during beverage manufacturing. This deformation temporarily increases the internal space of the package compartment between the lateral walls (2) of the package. However, maintaining good rigidity of the bottom part (3) of the cup shape is essential as described above (to maintain a proper seal at the interface between the package and the beverage making machine, and also to ensure that when the package is perforated by the fluid injection element of the machine, it does not cause deformation or collapse that would impair or even prevent the perforation operation). The presence of a secondary thickness reinforcing sheet (11) makes it possible to achieve a balance between the flexibility of the single-piece wall of the package and the rigidity of its bottom part.

[0064] Advantageously, package (1) is Fig. 1, Fig. 3b and do 5 It additionally includes a centering transverse hole (12) as illustrated in the drawing, which is located at the sealed edge (4) of the package (1). The hole is adapted to a shape and diameter to accommodate a centering pin (not illustrated in the drawing) of a beverage making machine, thereby preventing movement of the package (1) relative to the machine during beverage making, and particularly during insertion of the machine's fluid injection element through the package wall.

[0065] In a highly desirable embodiment, Fig. 1 and Fig. 5 As exemplified in [Image], the concave lower surface (7) of the package (1) includes a flat portion (13) centered across the transverse and longitudinal axes of the bottom portion (3) of the cup shape.

[0066] Fig. 4 As illustrated in the example, in a preferred embodiment, the package (1) further comprises a tertiary thin layer between the material forming the wall of the package and the secondary thickness reinforcing layer (11). This tertiary thin layer is created by sealing or otherwise attaching a tertiary flexible flat blank sheet (14) within the space between the primary flexible flat blank sheet (5) and the secondary flexible flat blank sheet (11).

[0067] The above tertiary flexible flat blank sheet (14) is a thin layer selected from a list of polyethylene (PE), polypropylene (PP), polylactide (PLA), polyhydroxyalkanoate (PHA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyvinyl alcohol (PVOH), starch-based polymers, food-grade oxygen and / or moisture removers, or combinations thereof. It is preferably manufactured as a blown or cast polymer film having stretchable properties.

[0068] In these embodiments, Fig. 4As illustrated in the figure, the primary sheet (5) includes a primary hole (15) punched through its entire thickness. This primary hole (15) has a diameter selected to be at least equal to, but preferably slightly larger than, the outer diameter (or section) of the beverage machine dispensing means (which is typically a needle). Having a larger diameter prevents a material, such as paper fiber, from being separated by friction when the dispensing means is inserted through it. Typically, the diameter of the hole (which is preferably cylindrical) is between 1 mm and 20 mm, preferably between 5 mm and 12 mm.

[0069] Additionally, the secondary sheet (11) includes a secondary hole (16) that is punched through at least the paper layer of the sheet (11). The secondary hole (16) may also be punched through the entire thickness of the secondary sheet (11). The diameter of the secondary hole (16) is selected in relation to the diameter of the fluid injection element of the machine to which the package is to be connected, and is typically cylindrical with a diameter included in 1 mm to 20 mm, preferably 5 mm to 12 mm.

[0070] The diameter of the primary hole (15) is equal to or greater than the diameter of the secondary hole (16) in the secondary flexible flat blank sheet (11).

[0071] Having three overlapping layers in the area of ​​the lower part (3) of the cup shape of the package (1), Figures 4 and 5By this multilayer structure exemplified in [the image], a seal is ensured between the package (1) and the fluid injection element of the machine. When the fluid injection element of the machine is inserted through the wall of the package, it passes through the primary hole (15) and then perforates the tertiary sheet (14) (which is preferably—as previously described—a stretchable material) so that the edge of the perforated sheet (14) conforms closely to the surface of the fluid injection element. Subsequently, finally, the fluid injection element moves through the secondary hole (16) so that its tip is positioned within the inner compartment of the package, and a leak-proof fluid connection is established between the inside of the package (1) and the fluid supply circuit of the machine.

[0072] This configuration also has the advantage that, since the total package thickness in the area of ​​the holes (15, 16) and the tertiary sheet (14) is only that of the tertiary sheet, it requires low strength to puncture the package wall by the fluid injection element, while at the same time, the entire part of the package surrounding the area has a greater thickness due to the presence of three overlapping layers in the bottom part (3) of the cup shape of the package, and thus has mechanical resistance to deformation.

[0073] Fig. 4 In another preferred embodiment illustrated herein, the secondary thickness reinforcing sheet (11) is further processed by using a cutting tool that forms a plurality of radial cuts (22) extending radially outward from the edge of the hole (16) once the hole (16) is punched. These radial cuts (22) create a series of flaps between them, which, when the machine and the package are connected to each other, are found to reinforce the application of the package wall onto the outer surface of the fluid injection element of the machine, and in particular the application of the tertiary flexible layer (14). Thus, these plurality of radial cuts (22) enhance the anti-leaking effect.

[0074] The aforementioned package is Fig. 6 It is manufactured using the forming machine exemplified in [the example]. Generally, such a machine is partially based on forming and sealing technology machines known in the art.

[0075] It is first, preferably Fig. 6 As illustrated in [Figure], it includes a primary flexible flat blank sheet feeder portion (17) adapted to receive primary—and optionally secondary and tertiary—flat blank sheets (5, 11, 14) in the form of a roll of film. At this stage, and as previously indicated, if present, the secondary and tertiary flat blank sheets may already be assembled with the primary sheet (5), or alternatively, Fig. 6 As exemplified in, These can be supplied as separate rolls of material, namely, one roll (18) for a primary sheet, one roll (19) for a secondary sheet, and a third roll (20) for a tertiary sheet. In this case, the primary, secondary, and tertiary sheets are unwound and cut into small flat blanks, and the primary and secondary holes (15, 16) are punched through each of the primary and secondary blanks as described above, and then finally, all blanks Fig. 4 The array of individual primary flat blank sheets (5) to be cut from the roll (18) of the corresponding material is sealed together in the arrangement already described in relation to. Fig. 7 It is exemplified in.

[0076] The manufacturing machine further includes a package forming set section (21). Downstream of the package forming section (21) is a filling and sealing section (22) (where the package is filled with ingredients and then closed by sealing the upper edge of the package).

[0077] The molded part (21) Fig. 8 inside Fig. 22 It is illustrated in more detail in [link].

[0078] Fig. 8As illustrated in [Image], the forming portion of the machine comprises a forming plunger (23) and a forming cavity (24) having shapes that are movable and complementary to each other. The "cavity (24)" refers to a cylinder whose tip is hollowed out to a shape complementary to the outer shape of the lower end (25) of the plunger. The principle of such a forming station having a movable plunger and a cavity for deforming a material placed between them is generally known, and details thereof will not be described further. The end portion (25) of the plunger (23) (i.e., its lower end) is, Fig. 9 As exemplified in [Figure], it has a volumetric shape having a concave lower end (26) and convex lateral faces (27), such that the profile of its end face (26) is identical to the profile of each of its lateral faces (27). The principle of geometric equivalence between the profiles (26, 27) is Fig. 3a and Fig. 3b In relation to, the profiles of the lower part (3) of the cup shape ( P lt and P lw It is the same as what has already been stated regarding ).

[0079] In one particular embodiment, the end portion (25) of the plunger (23) has a hexagonal prism shape, and the prism has two opposite vertical edges (28) aligned with the plunger transverse axis (Lx) that extend downward to form a downwardly extending tip (29), and the extended edges (28) have a height such that the sum of the two heights of the end portion (25) plus the width of its lower face is constant for each transverse cross section of the plunger measured along its transverse axis (Lx). This principle is the same as that already described above for the height (H1, H2) and width (W1, W2) of the bottom portion (3) of the cup shape in relation to FIGS. 3a and 3b.

[0080] Preferably, the tip (29) of the plunger is round or otherwise has a smooth edge.

[0081] Fig. 9 As illustrated in the example, the lower end (26) of the plunger preferably includes a retractable projection (30) aligned with the center of the plunger (23). The projection (30) is spring-mounted to retract within the plunger (23) when it is pressed against a surface, particularly in this case against the primary flat blank sheet (5) and the forming station cavity (24) below. This projection has a diameter exceeding the diameters of the aforementioned primary hole (15) and secondary hole (16). Its function is to gently press the blanks before the plunger begins to deform the blanks (5, 11, 14). When the forming process begins and the blank sheets begin to deform, it holds the three blank sheets together within their sealing area (around the holes (15, 16) as described above) to prevent them from slipping and becoming unsealable due to the mechanical force applied to the material during the forming stage.

[0082] The machine moves the plunger (23) and the joint (24) toward each other, and also Fig. 8 It further includes an actuator (not exemplified) for moving relative to a blank sheet (5) placed between the two as illustrated in the figure.

[0083] FIGS. 15 to 19 and Fig. 21 As illustrated in [Figure], the machine further includes a pair of plates adapted to support the flexible blank sheet (5). Both plates are Fig. 15 As exemplified in [Figure], they are on the same plane at the start of the forming process. Each plate supports the flap of the primary flexible blank sheet. The plate (31) Fig. 8 and FIGS. 10 to 14It can be fixed as exemplified in. Alternatively, in another possible embodiment, the plate (31) is symmetrically pivotable about each axis located on each side of the plunger (23), which indicates various positions of the pivotable plate (31) during the forming process. FIGS. 16 to 19 and do 21 As described in [it].

[0084] In the following, the primary flat blank sheet (5) being processed is also thought to include a secondary blank sheet (11) and a tertiary blank sheet (14) attached thereto, as described above. The blank (5) is transported along the machine to the forming part (21) of the machine and Fig. 8 As shown in the figure, when the plunger (23) and the cavity (24) are in place, the forming process steps are as follows in order.

[0085] The plunger (23) is, Figures 10 and 11 As illustrated in, it It moves downward until it contacts the upper surface of the blank (5, 11, 14); and the movement of the plunger is along the transverse axis of the primary blank (5) ( Lx The blank that is folded around begins to deform; and after contact with the upper surface of the blank (5, 11, 14), due to the opposing pressure of the cavity (24) below, the retractable protrusion (30) of the plunger (23) is retracted into the cavity as shown in FIG. 11.

[0086] Fig. 12 As illustrated in [Image], the plunger (23) continues to move downward, and the cavity (24) likewise moves downward. Both of these pull the blank downward together as the blank (5, 11, 14) is pinched between the plunger (23) and the cavity (24).

[0087] During the preceding step, a pair (or "set") of sealing jaws (32) are positioned from both sides of the cavity (24), adapted to seal the lateral edges of the blank sheet (5) when the blank sheet (5) is folded into a U shape. During the forming step, the jaws are in an open position, that is, spaced apart from the group of plungers, cavities, and blanks.

[0088] After the cavity and plunger have moved downward as described above, Fig. 13 and Fig. 20 As exemplified in the lower part, the jaws (32) move toward each other to close around the blank. They seal the lateral edges of the U-shaped folded blank (by ultrasonic sealing or heat sealing process) to complete the forming of the bottom part (3) of the fully formed and sealed cup shape of the package (1).

[0089] Next, Fig. 14 As shown in the illustration, the jaws (32) are opened again, and the plunger (23) moves upward with the partially folded and sealed package (1).

[0090] A variation of the same molding sequence described above Fig. 15 inner figure 19 and Fig. 21 As exemplified in, the support plate (31) is pivoted during the movement of the plunger and cavity to guide the folding of the free ends of the blank into a U shape.

[0091] finally, Fig. 15 As illustrated in [Image], the package is folded completely into a U shape with an unsealed side wall (2) forming a flat package body and a sealed cup-shaped bottom part (3) which is a hollow volume having the shape of the plunger.

[0092] Next, Fig. 22As illustrated in [Image], it is transferred to a sealing station having elongated sealing jaws (33) that seal the lateral edges (4) of the package (1). The package (1) is now ready to be filled with components and then ready to be closed by sealing its upper edge (34).

[0093] In an embodiment in which the lower portion (3) of the cup shape of the package has improved wall thickness by attaching secondary and tertiary layers (11, 14) as described above, the primary, secondary, and tertiary flat blank sheets (5, 11, 14) can be attached to each other when the primary sheet (5) is manufactured as a roll of film (at a film manufacturer's facility), or alternatively, the secondary and tertiary flat blank sheets (11, 14) can be attached to the primary flat blank sheet at a subsequent stage immediately before the formation of the primary flat blank sheet (i.e., on a package manufacturing line).

[0094] According to the present invention, the food or beverage ingredient contained in the package is a water-soluble powder or a soluble concentrate in liquid or semi-liquid form selected from a list of soups, fruit juices, vegetable juices, bouillon, coffee, chocolate, tea, milk or creamer, smoothies, purees, coulis, cream, or combinations thereof. Preferably, the food or beverage ingredient is a soluble food or beverage ingredient selected from the following list:

[0095] - Instant coffee powder, milk powder, cream powder, instant tea powder, cocoa powder, soup powder, fruit powder, or a mixture of the above powders,

[0096] - Coffee concentrate, milk concentrate, syrup, fruit or vegetable concentrate, tea concentrate, fruit or vegetable puree.

[0097] The package may also include plant leaves for brewing, for example, tea leaves.

[0098] The powder may be aggregated or sintered. The powder or liquid concentrate may be mixed with solid pieces, for example, to prepare a soup having solid or encapsulated pieces. The food or beverage ingredient may also be an infused food or beverage ingredient, such as roasted and ground coffee or tea leaves. In the embodiment, water extracts the infused ingredient material.

[0099] In the present invention, the fluid encompasses any aqueous diluent, such as water, carbonated water, milk, etc. (preferably, water is the preferred aqueous diluent), or any gaseous fluid, such as, for example, air, which can be mixed with a soluble beverage component to produce a beverage. When referring to an aqueous fluid, water is the preferred fluid. When referring to a gaseous fluid, air is the preferred fluid.

[0100] According to the present invention, the package is essentially arranged vertically during the manufacture and distribution of a food or beverage product.

[0101] According to the present invention, an aqueous fluid, typically water, is supplied into a package at any temperature, i.e., low temperature, ambient temperature, or high temperature, depending on the type of food or beverage product to be manufactured.

[0102] In contrast to systems in known prior art where fluid is introduced from the top to the bottom, in this case, the beverage making machine injects water—and also optionally air—at high speed from the bottom to the top of the package, which enables optimal turbulence within the package compartment and thus enables optimal dissolution of the ingredients contained within. When air is also injected along with water through the injection means of the machine, it is not introduced at high pressure; the pressure is preferably contained in 0.1 to 1.5 bar, more preferably 0.3 to 0.5 bar. According to the present invention, optimal turbulence and dissolution of the ingredients are achieved by high speed rather than by high pressure.

[0103] It should be understood that various variations and modifications to the preferred embodiments of the invention described herein will be apparent to those skilled in the art. Such variations and modifications may be made without departing from the spirit and scope of the invention and without diminishing its incidental benefits. Accordingly, such variations and modifications are intended to be covered by the appended claims.

Claims

Claim 1 A method for manufacturing a flexible package (1) suitable for containing food or beverage ingredients and suitable for use with a food or beverage manufacturing machine, wherein the method comprises, in order: (i) providing a primary flat blank sheet (5) made of a flexible material - said primary flat blank sheet (5) having a transverse axis ( Lx A step of providing a secondary flexible flat blank sheet (11) manufactured from a coated fiber-based material having an elongated shape with two flaps extending symmetrically around it, a step of punching a secondary hole (16) through at least the fiber-based material of the secondary flexible flat blank sheet (11), a step of punching a primary hole (15) centered across the primary flat blank sheet (5) over the entire primary flat blank sheet (5), a step in which the diameter of the primary hole (15) is equal to or greater than the diameter of the secondary hole (16) of the secondary flexible flat blank sheet (11), or sealing the secondary flexible flat blank sheet (11) to the inner surface of the primary flat blank sheet (5) so that the centers of both holes (15, 16) are aligned. A step of attaching, (ii) placing the primary flat blank sheet (5) in a forming station (21) such that its center is positioned between a plunger (23) and a cavity (24) having mutually movable and complementary shapes, wherein the plunger (23) has a concave lower end surface (26) and convex lateral surfaces (27), and the profile curvature of its lower end surface (26) is equal to the profile curvature of each of its lateral surfaces (27), (iii) deforming the primary flat blank sheet (5) by moving the plunger (23) and the cavity (24) toward each other so that the primary flat blank sheet (5) is positioned along its transverse axis ( Lx A method comprising the steps of: (iv) folding the flaps around to lift them up and forming an unsealed U-shaped package having side walls (2) and a bottom portion (3) that form a flat package body, wherein the bottom portion (3) is a cup-shaped hollow volume portion having the shape of the plunger (23), and (iv) sealing the lateral edges (4) of the U-shaped package (1). Claim 2 In claim 1, the plunger (23) has a hexagonal prism shape, and the prism has a plunger transverse axis (10) that extends downward to form downwardly extending tips (10). Lx It has two opposite vertical edges (9) aligned with ), and the extended edges are, its transverse axis ( Lx A method having a height such that, for each transverse cross-section of the plunger (23) measured along the above, the sum of the two heights of the end portion (25) of the plunger (23) and the width of its lower end surface (26) is constant. Claim 3 In paragraph 2, the tips (10) of the plunger (23) are round or have a smooth edge shape. Claim 4 A method according to claim 1, further comprising: (v) filling the package (1) with a food or beverage ingredient; and (vi) sealing the top edge (34) of the package (1) to close it. Claim 5 A method according to claim 1, further comprising the step of placing a pair of plates (31) under the primary flat blank sheet (5) in step (ii) - both plates (31) are initially on the same plane, each plate supports the flap of the primary flat blank sheet (5), and the plates are symmetrically pivotable around each axis located on each side of the plunger (23) -, - pivoting both plates (31) during step (iii) so that the edge of each plate furthest from the plunger (23) and the cavity (24) is lifted during the pivot movement to facilitate the primary flat blank sheet (5) being folded into the unsealed U-shaped package. Claim 6 A method according to claim 1, wherein the attachment or sealing area of ​​the secondary flexible flat blank sheet (11) to the inner surface of the primary flat blank sheet (5) has a ring shape surrounding the holes and has a width included in 0.5 mm to 10 mm. Claim 7 A method according to claim 6, further comprising: a step of providing a third flexible flat blank sheet (14); and a step of sealing or attaching the third flexible flat blank sheet (14) between the first flat blank sheet (5) and the second flexible flat blank sheet (11). Claim 8 In claim 7, the tertiary flexible flat blank sheet (14) is a thin layer selected from a list of polyethylene (PE), polypropylene (PP), polylactide (PLA), polyhydroxyalkanoate (PHA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyvinyl alcohol (PVOH), starch-based polymers, food-grade oxygen and / or moisture scavengers, or combinations thereof. Claim 9 A method according to claim 6, wherein the concave lower end surface (26) of the plunger (23) comprises a retractable protrusion (30) aligned with the center of the plunger, and the retractable protrusion (30) extends downward during steps (i) and (ii), and is pressed into the plunger during step (iii) when the tip of the plunger comes into contact with the primary flat blank sheet (5) below and the cavity (24). Claim 10 In claim 9, the diameter of the retractable protrusion (30) exceeds the diameter of the primary and secondary punched holes (15, 16). Claim 11 A machine for manufacturing a package (1) according to the method claimed in any one of claims 1 to 10, comprising: a flexible flat blank sheet feeder; a forming set comprising a plunger (23) and a cavity (24) having shapes that are movable relative to each other and complementary shapes; wherein the plunger (23) has a concave lower end face (26) and convex lateral faces (27), and the profile curvature of its lower end face (26) is equal to the profile curvature of each of its lateral faces (27); an actuator for forming an unsealed U-shaped package having a lower portion having side walls and a rigid flat surface that deforms the primary flat blank sheet (5) by moving the plunger (23) and the cavity (24) toward each other and folding it around its transverse axis (Lx) to form a flat package body; wherein the lower portion is a hollow volume having the shape of the plunger; and wherein the U A machine comprising a set of sealing jaws (32, 33) adapted to seal the lateral edges of the package of the shape and the bottom portion (3) of the cup shape. Claim 12 In claim 11, the plunger (23) has a hexagonal prism shape, and the prism has a plunger transverse axis (which extends downward to form downwardly extending tips (10)). Lx It has two opposite vertical edges (9) aligned with ), and the extended edges (9) are, its transverse axis ( Lx A machine having a height such that, for each transverse cross-section of the plunger measured along ), the sum of the two heights of the end portion (25) of the plunger (23) and the width of its lower end surface (26) becomes constant. Claim 13 In paragraph 12, the tips (10) of the plunger (23) are round or have a smooth edge shape, a machine. Claim 14 In claim 11, the machine further comprises a pair of plates (31) adapted to support the primary flat blank sheet (5), each plate supporting a flap of the primary flat blank sheet (5), and the plates being symmetrically pivotable around respective axes located on each side of the plunger. Claim 15 In claim 11, the concave lower end surface (26) of the plunger (23) comprises a retractable protrusion (30) aligned with the center of the plunger, and the protrusion (30) is spring-mounted to retract within the plunger when pressed against the primary flat blank sheet (5) below and the cavity (24). Claim 16 In claim 6, the method wherein the attachment or sealing area has a width included in 2 mm to 7 mm.

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