A METHOD AND A MOLD ASSEMBLY

Abstract

A method for manufacturing a solid formulation product comprising the steps of: placing a platform in a container comprising an open end comprising a rim, such that the platform is at least partially received by the container; then filling the container with the liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; solidifying the liquid formulation in the container to form a solid formulation; once the solid formulation is formed, deforming and then releasing the rim.

Description

A METHOD AND A MOLD ASSEMBLY FIELD OF INVENTION This invention relates to a method for manufacturing a solid formulation product and a mold assembly for carrying out the same. More particularly, though not exclusively, the invention relates to a method and mold assembly for manufacturing a solid deodorant and / or antiperspirant formulation product suitable for refilling a reusable solid formulation product container. However, the invention also applies to the manufacture of other solid formulation products in fields such as cosmetics and healthcare. For example, the solid formulation may be formulated to provide skin care or facilitate the topical application of a drug. BACKGROUND OF THE INVENTION Deodorant formulations reduce body odor after topical application, while antiperspirant formulations reduce perspiration. Topical application is achieved by rubbing a solid deodorant or antiperspirant formulation across the skin, particularly in the underarm area. Products known for applying a formulation topically to the skin of the human body, herein referred to as single-use sticks, comprise a container that houses a solid formulation product, and that can be held by a user of the solid formulation stick. In known single-use bars, the container comprises a reservoir that surrounds the solid formulation product on all sides and some means, typically a platform and associated spindle, designed to lift the solid formulation product out of the reservoir. The container can be used until the solid formulation is exhausted and is then discarded entirely. Such known single-use bars may be undesirable to consumers due to the amount of single-use packaging material required for each product. Alternative products for applying a formulation topically to the skin, herein referred to as refillable sticks, comprise a reusable container into which a solid formulation product can be removably mounted. The refillable stick can be used until the solid formulation is exhausted, after which the old solid formulation product can be removed and replaced with a new solid formulation product. Such solid formulation products can be manufactured by filling a mold with a liquid formulation and then solidifying the formulation to form a solid within the mold. However, known methods for manufacturing such solid formulation products can result in the solid formulation becoming stuck in the mold. Following such manufacturing methods, tests were conducted on removing solid formulations from their respective molds. It was found that high forces were required to remove the solid formulations and that there was a high risk that the act of removing the solid formulation would cause damage due to the tensile forces involved. BRIEF DESCRIPTION OF THE INVENTION According to a first aspect of the invention, a method is provided for manufacturing a solid formulation product comprising the steps of: placing a platform in a container comprising an open end comprising a rim, such that the platform is at least partially received by the container; then filling the container with the liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; solidifying the liquid formulation in the container to form a solid formulation; once the solid formulation is formed, deforming and then releasing the rim, wherein deforming the rim comprises compressing the rim along the compressible axis of the rim, causing the rim to expand along an expansion axis of the rim that is substantially normal to the compressible axis of the rim. The invention allows for the manufacture of a solid formulation product comprising a solid formulation and a platform inserted within the solid formulation. The platform can be attached to a reusable container to mount the solid formulation to the container for use. Accordingly, the solid formulation product can be a solid formulation filler suitable for filling a refillable bar. Furthermore, the step of deforming and then releasing the rim causes the container to deform in shape (at least temporarily, depending on the elasticity or plasticity of the container), which in turn causes the container (acting as a mold for the formulation) to separate, at least partially, from the solid formulation (at least temporarily). The inventors hypothesize that, in known methods for manufacturing solid formulation products, a solid formulation formed due to one, or a combination, of adhesion, vacuum formation, and capillary action may become stuck in the mold. However, separating the container from the solid formulation by means of the invention eliminates the issues of adhesion, vacuum formation, and / or capillary action. Testing has confirmed that this separation greatly reduces the required withdrawal forces and lowers the risk of damaging the solid formulation during the withdrawal process. In some embodiments of the invention, the step of solidifying the liquid formulation in the container can be carried out after filling the container to a predetermined level, such that the complete solidification step occurs after the complete filling step. In other embodiments of the invention, the step of solidifying the liquid formulation in the container can begin while additional liquid formulation is still being added to the container, such that the filling and solidification steps coincide. The edge deformation stage involves compressing the edge along the compressible axis of the edge. The rim compression stage causes the rim to deform, reducing the dimensions of the compressible axis. This stage also causes the rim to deform, increasing the dimensions along an extensible axis substantially normal to the compressible axis. Furthermore, the container may deform similarly to the rim. This deformation of the container may cause it to separate, at least partially, from the solid formulation. For example, gaps may form between the container and the solid formulation because the second diameter of the container is increasing while a corresponding diameter of the solid formulation remains substantially the same. In the embodiments of the invention, the rim can be oval or oblong in cross-section, and the step of compressing the rim along the compressible axis can comprise radially compressing the rim so as to reduce a maximum diameter of the cross-sectional shape. In such embodiments of the invention, the maximum diameter is the largest diameter across the oblong or oval cross-section of the rim. Accordingly, the cross-section may also include a minimum diameter, which is the smallest diameter across the oblong or oval cross-section of the rim. If the container is deformable such that its cross-sectional area remains constant, the deformation of the rim that causes a reduction in its maximum diameter will in turn cause an increase in its minimum diameter. Furthermore, although the reduction in the maximum diameter may be small relative to the maximum diameter itself, the associated increase in its minimum diameter may be larger relative to the minimum diameter. Therefore, radially compressing the rim to reduce its dimensions along its compressible axis can result in a compression of the solid formulation that is advantageously small relative to the maximum diameter. Furthermore, radially compressing the rim can also result in gaps forming between the solid formulation and the container that are advantageously large relative to the minimum diameter, because the dimensions along the extensible axis increase while the corresponding dimensions of the solid formulation remain substantially constant. In other words, deformation may cause relatively small compression of the solid formulation along the compressible axis but can result in relatively large gaps opening between the container and the solid formulation due to the container expanding along the extensible axis, which is normal to the compressible axis. In other embodiments of the invention, the rim and the container can be of any suitable cross-sectional shape. For example, the rim can have a circular cross-section. In the embodiments of the invention, the platform may comprise a retention structure, and the step of filling the container with the liquid formulation to a predetermined level comprises filling the container so that the retention structure is completely submerged in the liquid formulation. In such embodiments of the invention, once the container is filled with the liquid formulation to the predetermined level, the liquid formulation can flow around and / or through the retention structure. Therefore, once the liquid formulation solidifies into a solid, the retention structure can be inserted into the solid formulation. The retention structure thus facilitates the retention of the solid formulation in contact with the platform. In the embodiments of the invention, the platform may comprise a connecting element, and the step of filling the container with the liquid formulation to a predetermined level comprises filling the container in such a way that the connecting element is not submerged in the liquid formulation. In such embodiments of the invention, once the stage of filling the container with the liquid formulation to a predetermined level is completed, the connecting element can be separated from the liquid formulation. Subsequently, once the stage of solidifying the liquid formulation to form a solid formulation is completed, the connecting element can be separated from the solid formulation, which can ensure that the connecting element is free to be coupled with a reusable container, for example. In the embodiments of the invention, the method may comprise a subsequent step of attaching a reusable container to the joining element. Therefore, a user can hold the solid formulation using the reusable holder to move it across the skin, for example. This allows the user to avoid directly handling the solid formulation, which can result in unwanted residue remaining on their hands. In the embodiments of the invention, the liquid formulation can melt and solidify upon cooling below its melting point. In such embodiments of the invention, the solidification stage can be controlled by regulating the ambient and / or container temperature to lower the temperature of the molten liquid formulation below its melting point, thereby causing it to solidify. Furthermore, the container and / or ambient temperature can be configured to control the rate at which the liquid formulation solidifies. In other embodiments of the invention, the step of solidifying the liquid formulation may comprise increasing the pressure in it or may comprise a combination of reducing temperature and increasing pressure. In the embodiments of the invention, the method may comprise the additional, subsequent step of placing a label on the solid formulation. In such embodiments of the invention, a label can be applied directly to the solid formulation product. Labeling the solid formulation product as part of its manufacturing process can reduce the risk of the product being mislabeled or misdirected at a later stage of packaging or shipping. In the embodiments of the invention, the method may comprise the additional, subsequent step of attaching a lid to the container. In such embodiments of the invention, the solid formulation and platform can be sealed within the container. Sealing the solid formulation can help ensure that it maintains optimal chemical and physical properties during later stages of processing, such as storage and shipping. For example, sealing the solid formulation can prevent it from drying out. According to a second aspect of the invention, a mold assembly is provided comprising a container, such container comprising an open end comprising a rim, and a platform that is received within the container; wherein the rim is formed so that when the platform is received within the container, a space is defined between the platform and the rim. By means of the invention, the shape of the container can be easily deformed by compressing the rim where such compression is possible due to the space between the rim and the platform. During the manufacture of a solid formulation product, the platform can be positioned so that it is at least partially submerged in the container. The container can then be filled with the liquid formulation ii zznn / eznz / R / vi so that the platform is at least partially submerged, and the liquid formulation can solidify to form a solid formulation. In other words, the container can act as a mold for the formation of a solid formulation with the platform embedded within it. After the solid formulation forms, the rim may compress, which can deform the container and cause it to separate from the solid formulation. Separating the container from the solid formulation can avoid potential issues of adhesion, vacuum formation, and / or capillary action between the solid formulation and the container, allowing the solid formulation to be removed from the container with minimal risk of damage. In the embodiments of the invention, the container may comprise any suitable material such as paper, cardboard, wood, metal, or plastic. In some embodiments of the invention, the container may comprise recycled and / or recyclable material such as recycled polyethylene terephthalate (rPET) or recycled polypropylene (rPP) so that the solid formulation product can be manufactured sustainably. In the embodiments of the invention, the container can be deformable in any suitable manner (i.e., elastically, plastically, or otherwise deformable), allowing the container to deform and separate from the solid formulation when the rim is deformed. In some embodiments of the invention, the container can be elastically deformable. In such embodiments of the invention, the container can be deformed, through compression of the edge for example, and can then return to its original shape. In use, once a solid formulation formed inside the container has separated from the container by deforming the rim, limited testing of some formulations indicates that it is highly unlikely the solid formulation will become stuck in the container again. This is even true if the container returns to its original shape—that is, the shape in which the solid formulation was formed. The container can be reused as packaging for the solid formulation, as the solid formulation, platform, and container can form a solid formulation product suitable for shipping and sale to retailers and / or consumers. The end user can remove the platform and solid formulation from the container to attach the platform to a reusable container for topical application of the solid formulation to the skin. Therefore, it can be advantageous for the packaging to be elastically deformable since, after deformation, the packaging can return to its original shape. The original shape can be known, and subsequent packaging and shipping processes can be based on the known shape of the packaging. For example, a plurality of solid formulation products can be packaged together for sale to consumers as a 'multi-pack'. The multi-pack packaging can be designed to compactly hold the solid formulation products based on the known shape of the elastically deformable packaging. In the embodiments of the invention, the container can be oval or oblong in cross-section. In such embodiments of the invention, the cross-sectional shape may comprise a maximum diameter of the oval or oblong shape and a minimum diameter of the oval or oblong shape. The maximum diameter may extend along the compressible axis, and the minimum diameter may extend along an extensible axis. If the container is deformable such that its cross-sectional area remains constant, rim deformation that causes a reduction in the maximum diameter (smaller relative to the maximum diameter itself) can, in turn, cause an increase in the minimum diameter (larger relative to the minimum diameter). Therefore, in use, radially compressing the rim to reduce its maximum diameter can result in a compression of the solid formulation (formed in the container) that is advantageously small relative to the maximum diameter. Furthermore, such radial rim compression can also result in spaces forming between the solid formulation and the container that are advantageously large relative to the minimum diameter, because the minimum diameter increases while a corresponding diameter of the solid formulation remains substantially constant.In other words, the deformation causes a relatively small compression of the solid formulation in the direction of the maximum diameter but results in relatively large spaces opening up between the container and the solid formulation due to the container expanding in the direction of the minimum diameter. Therefore, the container being oval or oblong in cross-section can advantageously improve the ability to separate the container from the solid formulation when the container is in use. In addition, the oval or oblong shape can be determined so that a solid formulation formed in the container is shaped to fit economically against a user's armpit. Additionally, the oval or oblong shape of the resulting solid formulation may exhibit higher resistance to shear forces in the direction of maximum diameter, which is likely the same direction in which a user would move the solid formulation across their skin. Therefore, the oval or oblong cross-sectional shape of the container may improve the performance of a solid formulation formed within it. In the embodiments of the invention, the platform can be oval or oblong in cross-section. In such configurations, the platform can be adjusted in a complementary manner within the container if the container is also oval or oblong in cross-section. Furthermore, if the platform is inserted into a solid formulation formed within the container, the platform may exhibit better retention of the solid formulation in the direction of its maximum diameter, which is likely the same direction in which a user would move the solid formulation across their skin. Therefore, the oval or oblong cross-sectional shape of the platform may improve the performance of a solid formulation formed around it. In other embodiments of the invention, each part of the container and the platform can be of any suitable cross-sectional shape. For example, the container and / or the platform can be circular in cross-section. In the embodiments of the invention, the platform may comprise a retention structure. In such embodiments of the invention, the retention structure can be adapted so that the liquid formulation is able to flow around and / or through the retention structure as it is added to the container. For example, the retention structure may comprise one or more openings through which the liquid formulation can flow. Therefore, when the liquid formulation solidifies, it solidifies around and / or within the retention structure so that the retention structure is embedded within the solid formulation. Furthermore, the retention structure can be adapted so that, once inserted into the solid formulation, it maintains the solid formulation in contact with the platform during use. For example, the retention structure can be adapted to ensure that the solid formulation's attachment to the platform is resistant to shear forces applied to the solid formulation when a surface of the formulation moves across the user's skin. In the embodiments of the invention, the platform may comprise a joining element. In such embodiments of the invention, the connecting element can be any suitable means for facilitating the attachment of the platform to a reusable container. For example, the connecting element can be a bayonet fitting that can be coupled with a socket forming part of a reusable container, or it can be a threaded protrusion that can be coupled with a complementary threaded socket forming part of a reusable container. In use, a solid formulation may form in the container with the platform inserted. The solid formulation can be removed from the container before attaching the platform to a reusable container using the connecting element. Alternatively, the platform can be attached to a reusable container before the solid formulation is removed from the container. This allows a user to hold the reusable container while removing the solid formulation from the container, avoiding direct contact with the solid formulation. In the embodiments of the invention, the mold assembly may include a label that can be placed inside the container. The label can provide useful information for subsequent packaging and shipping processes, such as a product identification code. The label can also, or alternatively, provide useful information to a future consumer / user of the product, such as ingredients used in the solid formulation and allergy information. In the embodiments of the invention, the mold assembly may comprise a lid that is removably attached to the open end of the container. In such embodiments of the invention, the lid can seal the contents of the container, which, in use, may include a solid formulation, the platform inserted into the solid formulation, and a label placed on the solid formulation and platform, for example. In such embodiments of the invention, it may be particularly advantageous for the container to be elastically deformable, as this can ensure that the open end of each container is of a consistent and reliable shape to allow the lid to be attached. BRIEF DESCRIPTION OF THE FIGURES The invention will now be described by way of example only with reference to the accompanying figures in which: Fig. 1 is a schematic representation of a mold assembly according to an embodiment of the second aspect of the invention; ii zznn / cznz / B / vi Fig. 2 is a schematic representation of a method according to a modality of the first aspect of the invention; Fig. 3 is a schematic representation of a mold assembly according to another embodiment of the second aspect of the invention; Fig. 4 is a further schematic representation of the mold assembly shown in Fig. 3; Fig. 5 is a top view of the mold assembly shown in Fig. 3; Fig. 6 is a schematic representation of a method according to another embodiment of the first aspect of the invention; Figs. 7 and 8 are schematic representations of a container and platform forming part of the mold assembly shown in Fig. 3 with a solid formulation; Fig. 9 is a schematic representation of the mold assembly shown in Fig. 3 with a solid formulation; and Fig. 10 is a schematic representation of a method for using a solid formulation product manufactured using the method shown in Fig. 5. DETAILED DESCRIPTION OF THE INVENTION Referring initially to Fig. 1, a mold assembly 12 comprises a container 14 and a platform 20 that can be received inside the container 14. The container 14 further comprises an open end 16 comprising a rim 18 formed such that when the platform 20 is received inside the container 14, a space is defined between the platform 20 and the rim 18. Additionally, the platform 12 comprises a retaining structure 22 and a connecting element 24. In this embodiment of the invention, the container 14, open end 16, rim 18, and platform 20 are each formed such that the platform 20 can be placed across the open end 16 to remain level with the rim 18 without needing to be held to prevent it from falling into the container 14. This is achieved due to the change in the circumference of the container 14 as it transitions to the rim 18; the changing circumference forms a ridge 19 on which the platform 20 can balance. Referring now to Fig. 2, a method for manufacturing a solid formulation product according to an embodiment of the invention is generally designated by reference number 100. Method 100 comprises a placement step 102, a filling step 103, a solidification step 104, and a deformation step 105. Method 100 can be used with any suitable mold assembly, and in one embodiment of the invention, mold assembly 12 of Fig. 1 is used to carry out the method. Method 100 is therefore described below with reference to mold assembly 12. The placement step 102 comprises placing a platform 20 into a container 14 comprising an open end 16 comprising an edge 18, such that the platform 20 is received at least partially by the container 14. Container 14 can be of any size or shape suitable to act as a mold for forming a solid formulation. Platform 20 can be of any size and shape suitable so that it can be at least partially received by container 14 through the open end. The filling step 103 follows the placement step 102 and comprises filling the container 14 with the liquid formulation to a predetermined level, determined such that the platform 20 is at least partially submerged in the liquid formulation. In the embodiments of the invention, the liquid formulation may be a liquid deodorant formulation and / or a liquid antiperspirant formulation. The solidification step 104 includes solidifying the liquid formulation in the container to form a solid formulation and may begin either as soon as the liquid formulation is present in the container or once the filling step is complete. In the embodiments of the invention, the solid formulation may be a solid deodorant formulation and / or a solid antiperspirant formulation. Solidifying a liquid formulation can involve reducing the temperature of the liquid formulation, increasing the pressure within the liquid formulation, or adding an additive to the liquid formulation to cause it to solidify. For example, a liquid formulation can melt and solidify by reducing its temperature below its melting point. The deformation step 105 can be performed once the solid formulation is formed and comprises deforming and then releasing the rim 18 of the container 14. Deforming rim 18 can cause deformation of container 14, which in turn can cause the container to separate from the solid formulation formed inside it. Separation of container 14 from the solid formulation can eliminate potential issues such as adhesion, vacuum formation, and / or capillary action that might otherwise cause the solid formulation to become stuck in container 14. In this way, deformation step 105 can reduce the likelihood of damage to the solid formulation when it is removed from container 14. Referring now to Fig. 3, a mold assembly 112 comprises a container 14 and a platform 20, similarly to the mold assembly 12 shown in Fig. 2, and further comprises a label 26 and a lid 28. The label 26 can be placed inside the container 14 and can also be placed on the platform 20 such that the joining element 24 extends through the openings 27 in the label 26. The lid 28 is removably attached to the open end 16 of the container 14. In Fig. 4, the lid 28 is attached to the open end 16, thus forming a closure over the container 14 and sealing the platform 20 and label 26 inside the container 14. In this embodiment of the invention, the container 14 is elastically deformable, which can be advantageous since, after deformation, the container 14 can return to its original shape. This means that, even after deformation of the container 14, the lid 28 can be attached to the open end 16. Both container 14 and platform 20 are oval in cross-section. In Fig. 5, the cross-section of the container mold assembly 112 is shown and comprises a maximum diameter X and a minimum diameter Y. Referring now to Fig. 6, a method 200 for manufacturing a solid formulation product is similar to method 100 shown in Fig. 1 except that it comprises additional steps. Just as method 200 comprises a placement step 202, a filling step 203, a solidification step 204, and a deformation step 205, which correspond respectively to steps 102, 103, 104, and 105 of method 100, method 200 further comprises a preliminary step 201 carried out before the placement step 202. Method 200 also comprises a labeling step 206 and a covering step 207, each carried out after the deformation step 205. Method 200 can be carried out using any suitable mold assembly, and in one embodiment of the invention, mold assembly 112 of Figs. 3 and 4 is used. Method 200 is therefore described below with reference to mold assembly 112. The preliminary stage 201 involves placing the container 14 on a base 60, on a manufacturing line for example. Placement step 202 comprises placing platform 20 in container 14 so that platform 20 is received at least partially by container 14. The filling step 203 comprises filling the container 14 with a liquid formulation 32 to a predetermined level, determined such that the platform 20 is at least partially submerged in the liquid formulation 32. In addition, the predetermined level is determined such that the retention structure 22 is fully submerged in the liquid formulation 32 but the joining element 24 is not submerged in the liquid formulation 32. The solidification stage 204 comprises solidifying the liquid formulation 32 to form a solid formulation 34 within the container 14. Figures 7 and 8 show the container 14 with the solid formulation 34 formed inside it and the platform 20 partially inserted into the solid formulation 34. In particular, due to the predetermined level to which the container 14 is filled with the liquid formulation 32, the retention structure 22 is fully inserted into the solid formation 34 while the joining element 24 separates and extends away from the solid formulation 34. The deformation stage 205 comprises deforming and then releasing the edge 18. This may be possible due to a space 19 defined between the platform 20 and the edge 18 (shown in Figs. 7 and 8). In particular, deformation step 205 comprises radially compressing the rim 18 along the compressible axis to reduce its maximum diameter X. This may cause the container 14 to deform, which may include an expansion of the minimum diameter Y along an extensible axis. Meanwhile, the corresponding diameter of the solid formation 34 may not expand, or may not expand to the same degree, meaning that gaps may form between the solid formulation 34 and the container 14. Such separation of the container 14 from the solid formulation 34 may facilitate the removal of the solid formulation 34 from the container 14 with low risk of causing damage to the solid formulation 34. The labeling step 206 involves placing a label 26 on the solid formulation 34. Finally, the cover stage 207 comprises attaching a lid 28 to the container 14, specifically to the open end 16. Method 200 thus uses each component of the mold assembly 112 to manufacture a solid formulation product 40. ii zznn / cznz / B / vi For this stage, it can be particularly advantageous for the container 14 to be elastically deformable, as this can ensure that the cap 28 bonds correctly to the container 14, even after deformation step 205. For example, Fig. 9 shows that the cap 28 can be adapted to fit precisely over the open end 16, such that if the container 14 were to be permanently deformed by deformation step 205, the cap 28 might not bond to the container as intended. If the closure of the container 14 fails, the solid formulation 34 inside could deteriorate before it reaches the consumer. Referring now to Fig. 10, a solid formulation product such as solid formulation product 40 manufactured according to method 200 shown in Fig. 6 can be attached to a reusable container 50 to fill a refillable bar 52. A method 300 for using the solid formulation product 40 comprises a first step 301, a second step 302, a third step 303, and a fourth step 304. The first step 301 involves removing the lid 28 from the container 14. This reveals both the label 24 (which may provide information about the solid formulation such as its brand, ingredients and allergy information) and the binding element 24. The second step 302 comprises placing the solid formulation product 40 in contact with the reusable support 50. In particular, the joining element 40 can be aligned with a complementaryly adapted element forming part of the reusable support 50, such as a fitting with which the joining element 24 is coupled. The third step 303 comprises coupling the solid formulation product 40 with the reusable support 50 via the joining element 24. This may include rotating the solid formulation product 40 through 90° relative to the reusable support 50, for example. The fourth step, 304, involves removing container 14 from solid formulation 34 and platform 20, thereby revealing solid formulation 34 for topical application to the skin. Early separation of container 14 from solid formulation 34 during method 200 (shown in Fig. 6) can facilitate the removal of container 14 with low risk of causing damage to solid formulation 34. A reusable lid (not shown) can then be attached to the reusable holder 52, over the solid formulation 34, to protect the solid formulation 34 between uses. Accordingly, a solid formulation 34 can be mounted onto a reusable container 50 via a platform 20 without the user needing to touch the solid formulation 34 with their hands. Furthermore, the solid formulation product 40 can facilitate the repeated use of a refillable stick 52, which can be more sustainable than purchasing a new single-use stick each time the solid formulation is depleted. Preferences and options for a given aspect, feature, or parameter of the invention, unless the context indicates otherwise, may be considered as having been described in combination with any and all preferences and options for all other aspects, features, and parameters of the invention. For example, each step or feature of Method 200 (shown in Fig. 6) that is not explicitly included in Method 100 (shown in Fig. 1) may be considered as having been described in combination with the steps and features of Method 100.

Claims

1. A method for manufacturing a solid formulation product comprising the steps of: placing a platform in a container comprising an open end comprising a rim, such that the platform is at least partially received by the container; then filling the container with the liquid formulation to a predetermined level such that the platform is at least partially submerged in the liquid formulation; solidifying the liquid formulation in the container to form a solid formulation; once the solid formulation is formed, deforming and then releasing the rim, characterized in that deforming the rim comprises compressing the rim along a compressible rim axis causing the rim to expand along an expansion axis of the rim that is substantially normal to the compressible rim axis.

2. The method according to claim 1 further characterized in that: the rim is oval or oblong in cross-section; and the step of compressing the rim along the compressible axis comprises radially compressing the rim so as to reduce a maximum diameter of the cross-sectional shape.

3. The method according to any of the preceding claims, further characterized in that: the platform comprises a retention structure; and the step of filling the container with the liquid formulation to a predetermined level comprises filling the container so that the retention structure is completely immersed in the liquid formulation.

4. The method according to any of the preceding claims further characterized in that: the platform comprises a connecting element; and the step of filling the container with the liquid formulation to a predetermined level comprises filling the container in such a way that the connecting element is not submerged in the liquid formulation.

5. The method according to claim 4 further characterized in that it comprises a subsequent step of joining a reusable container to the joining element.

6. The method in accordance with any of the preceding claims, further characterized in that the liquid formulation melts and solidifies upon cooling below its melting point.

7. The method in accordance with any of the preceding claims, further characterized in that it comprises a subsequent step of attaching a lid to the container.

8. A mold assembly comprising a container, said container comprising an open end comprising a rim, and a platform that is received within the container; characterized in that the rim is formed so that when the platform is received within the container a space is defined between the platform and the rim.

9. The mold assembly according to claim 8, further characterized in that the container is elastically deformable.

10. The mold assembly according to claim 8 or claim 9, further characterized in that the container is oval or oblong in cross-section.

11. The mold assembly according to claim 10, further characterized in that the platform is oval or oblong in cross-section. ii zznn / cznz / B / vi 12. The mold assembly according to any of claims 8 to claim 11, further characterized in that the platform comprises a retention structure.

13. A mold assembly according to any of claims 8 to 12, further characterized in that the platform comprises a connecting element.

14. A mold assembly according to any of claims 8 to 13, characterized in that it comprises a lid that is removably attached to the open end of the container.

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