Packaging for a plurality of food items, packaged food product, flow wrap packaging sealing jaws, flow wrap packaging apparatus, method of packaging food items

Abstract

Packaging for food items, a packaged food product, and methods for packaging food items are disclosed. Such packaging has a sealed cavity for containing food items, and comprises a continuous sheet of packaging material that wraps around and defines the cavity and which is sealed at the ends of the cavity by end seals and along the cavity by a longitudinal seal. The first end seal and the longitudinal seal are each permanent seals and the second end seal is an openable and recloseable seal. A packaged food product comprises food items packaged in such packaging. Also disclosed is a method for packaging food items, sealing jaws for forming such first and second end seals, and packaging apparatus comprising such sealing jaws.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a U.S. national phase application of PCT International Application No. PCT / GB 2024 / 051152, filed May 2, 2024, which claims priority to GB Application No. 2306539.4, filed May 3, 2023, the entireties of all of which are incorporated by reference herein for all purposes.FIELD OF THE INVENTION

[0002] The present invention concerns packaging. More particularly, but not exclusively, this invention concerns re-sealable packaging having a cavity for containing a plurality of food items. The packaging may include a combination of permanent and re-sealable / re-closeable seals. For example, the packaging may comprise a continuous sheet of packaging material that wraps around and defines a cavity, and which is sealed at a first end of the cavity by a first end seal, at a second opposed end of the cavity by a second end seal, and along the cavity by a longitudinal seal that extends from the first end seal to the second end seal, wherein the first end seal and the longitudinal seal are each permanent seals, and the second end seal is an openable and re-closable seal. The invention also concerns a method of packaging a plurality of food items, and packaged food items.BACKGROUND OF THE INVENTION

[0003] Various forms of packaging have been utilised to contain, protect and maintain the freshness of food products. Packaging films are widely used to provide low cost, light-weight and durable packaging. Many packaging films are made from plastics materials, and / or may be mono-layer or multi-layer (also known as laminate) films. Typically, a film is wrapped around one or more food products, and joined to itself, e.g. by welding or with adhesives. In a horizontal flow-wrap packaging system (also known as form-fill-seal horizontal bagging), products are placed on a sheet of film which has been formed into a tube-shaped arrangement, and the film is closed at each end by end seals and along the length of the packaging between the ends by a fin seal or a lap seal. Fin seals are also known as A-A seals, or inside-inside seals, because the inside face of one edge of the film joins to the inside face of the opposed second edge. Lap seals are also known as A-B seals, or inside, outside seals, because the inside face of one edge of the film joins to the outside face of the opposed second edge. In form-fill-seal vertical bagging systems, a bag is formed from a sheet of film similar to the package formed by a form-fill-seal horizontal bagging system, except that the packaging is oriented so that the open end faces upwards rather than sideways, and products are dropped into the packaging from above. Once the packaging is filled, the open end is closed by an end seal.

[0004] Traditionally, such film-based packaging has been arranged to be torn open by the user. Some films are provided by points of weakness and / or slits to make the film readily tearable, and some are provided with reinforcing strips to help guide tear formation. Such tear-open packaging, while relatively inexpensive and straightforward to manufacture and use to wrap food items, does not allow the package to be re-sealed. Unless a consumer wishes to consume the entire contents of a pack upon opening, they are often left to choose between either finding a new container for the product, or allowing food items to spoil and / or spill out of the torn packaging.

[0005] Cold-seal horizontal form-fill-seal flow wrap packaging is described in UK Patent No. GB2349862B (Dairy Crest Ltd.), incorporated herein by reference.

[0006] Various types of re-sealable packaging have been devised. European Patent Application Publication No, EP1477425A1 (Amcor Flexibles Europe A / S) discloses tearable resalable packaging utilising cold seal adhesives. While the tear location is said to be better controlled than previously known packs, it appears that care is still required to ensure correct usage. U.S. Pat. No. 5,945,145A (Kraft General Foods), incorporated herein by reference, discloses recloseable packaging for sliced food products-the packaging comprises a flap, which may be pre-cut or defined by end seals having permanent and resealable sections. The flap and seal arrangement is relatively complex and requires specialist film manufacturing and / or packaging equipment. The flap is openable at its end and sides to facilitate removal of slices without undue distortion. International (PCT) Publication No. WO2014067673A1 (Amcor), incorporated herein by reference, discloses a recloseable flow pack for a single, tablet-shaped food product. All seals on pack are openable and recloseable, allowing the packaging film to be fully peeled back and opened to access the tablet inside. It is disclosed that a particular adhesive pattern aids reseal. The pack is suited to tablet products that can be conveniently held in place during opening and reclosing of the packaging. A similar packaging system for a tablet food product is disclosed in US Patent Application Publication No. US2011 / 0266180A1 (Robert Bosch), incorporated herein by reference.

[0007] Some recloseable packaging utilises multi-layer laminate films having an internal adhesive layer. For example, US Patent Application Publication No. US2012082764A1 (Kraft Foods Global Brands), incorporated herein by reference, discloses a film structure with an internal pressure sensitive adhesive layer. Outer layers are heat sealed together to form a lap seal, and when packaging is opened the film delaminates to expose the internal adhesive layer. Such laminates are comparatively expensive to produce, and there is often a requirement for the packaging film to be provided with cuts / predefined points of weakness to control delamination, adding to the complexity of manufacture and use.

[0008] There remains a need for recloseable packaging that is cost effective to manufacture and use, and which allow convenient sharing of packaged food items. The present invention seeks to mitigate the above-mentioned problems. Alternatively or additionally, the present invention seeks to provide improved packaging for food items, such as confectionery items, especially baked items such as biscuits and cookies.SUMMARY OF THE INVENTION

[0009] The present invention provides, according to a first aspect, packaging for a plurality of food items, the packaging having a sealed cavity for containing the plurality of food items and comprising a continuous sheet of packaging material that wraps around and defines the cavity and which is sealed at a first end of the cavity by a first end seal, at a second opposed end of the cavity by a second end seal, and along the cavity by a longitudinal seal that extends from the first end seal to the second end seal. The first end seal and the longitudinal seal are each permanent seals, and the second end seal is an openable and recloseable seal. An openable and recloseable seal allows the packaging to be opened to access the cavity without damaging the packaging film, and allows the packaging to be reclosed by the consumer to seal the cavity after opening without requiring specialist equipment or any additional materials. For example, an openable and recloseable seal can be opened and reclosed by hand. Thus, it will be understood that an openable and recloseable seal is a resealable seal. Resealing the packaging to reclose the cavity allows the consumer to preserve food item freshness without needing to transfer the items to a separate container (e.g. a biscuit tin). It has been found that such packaging, having permanently closed first end seal and fin seal, and an openable / recloseable second end seal provides particularly cost-effective and convenient to use packaging. For the consumer, the packaging is convenient because the openable / recloseable seal is readily accessible, and consumers are used to opening the end. In particular, it has been found that consumers typically open one end of conventional packaging, i.e. packaging having permanent seals at both ends and along a fin. Furthermore, the permanently sealed longitudinal seal (e.g. fin) helps to control opening, so that the pack does not accidentally split along its entire length (which may result in the contents falling out). Yet further, it has been found that consumers find a recloseable end seal to be particularly straightforward to re-seal, both because of its positioning and because of its relatively small size. Yet further, it has been found that the packaging can be produced from low-cost, convenient to manufacture packaging sheets converted on conventional packaging machinery with little modification. More particularly, there is no requirement for specialised tools for cutting or shaping the packaging materials. Furthermore, the packaging of the present invention may be assembled using conventional machinery. Taking for example a conventional flow-wrap assembly line—permanently sealed end seals and permanently sealed fin seals are often formed by pressing layers of film together between heated rollers. The first end seal and the longitudinal seal of the packaging of the present invention may, for example, be formed in the same manner, while the second end seal may be formed by pressing together layers of film having a pressure sensitive adhesive disposed between them. In that case, it may be that the only machinery modification required is to replace jaws used for forming the end seals.

[0010] It will be understood that the continuous sheet of packaging material is a single sheet of material, for example having first and second opposed side edges and first and second opposed end edges. The sheet may have an inner surface (i.e. arranged to face the cavity / the interior of the packaging) and an opposed outer surface. It will be appreciated that the longitudinal seal may be a fin seal or a lap seal, optionally a fin seal. It will be understood that a longitudinal fin seal is an A-A seal, for example wherein the sheet of packaging material is arranged with the inner surface of a first side edge abutting the inner surface of a second side edge along the longitudinal seal. It will be understood that a longitudinal lap seal is an A-B seal, for example wherein the sheet of packaging material is arranged with the inner surface of a first side edge abutting the outer surface of a second side edge along the longitudinal seal. It will be understood that each end seal is an A-A seal, for example wherein the sheet of packaging material is arranged with the inner surface of each end edge folded onto itself. Optionally, the sheet has a plurality of sealing portions that seal together at the end and longitudinal seals to close the cavity. For example, the sheet may have a first side edge portion that abuts and joins a second side edge portion along the longitudinal seal, and / or a first and second end edge portions that each fold over and joins to itself along the first and second end seals, respectively. Additionally or alternatively, the sheet may have a first side sealing portion at or adjacent a first side edge that seals to a second side sealing portion at or adjacent a second side edge. Optionally, the end seals each join a portion of the inner surface of the sheet to another portion of the inner surface of the sheet. It will be understood that a sealing portion may, for example, be a portion of the sheet designated for permanent (welded) sealing (such as a portion at the first end and along the sides designated for heat sealing) or a portion coated with an adhesive (such as a portion at the second end coated with a cold-seal adhesive).

[0011] It will be appreciated that the terms ‘permanent seal’ and ‘openable / recloseable seal’ are familiar in the art. For example, it will be understood that a permanent seal does not allow a sealed join to be opened without damaging the packaging material and / or which cannot be resealed once opened by a consumer. In contrast, openable seals / recloseable seals will be understood to refer to sealed joins that can be opened by a consumer to access the interior of the packaging and subsequently reclosed by the consumer to reseal the packaging. Preferably, the permanent seals are welded seals. Optionally, the packaging comprises a plastic film packaging (e.g. the packaging is plastic film packaging), which may for example be subjected to thermal welding by application of pressure and heat or ultrasonic welding by exposure to pressure and high frequency vibrational energy. Additionally or alternatively, the permanent seals are closed by a heat sealing permanent adhesive, for example an adhesive that once set cannot be released and resealed. Typically, openable / recloseable seals used in packaging materials utilise cold-seal adhesives (e.g. pressure-sensitive adhesives). As used herein, and unless stated otherwise, the terms ‘inner’ and ‘outer’ are relative to the cavity.

[0012] Preferably, the packaging is form-fill-seal packaging. Typically, in form-fill-seal packaging, a wrapper is first formed into a shape such as a tube, cylinder or bag, then filled with one or more food products, and then sealed to form the packaged food item. Examples of form-fill-seal packaging include horizontal form-fill-seal packaging (sometimes referred to as horizontal flow-wrap packaging) and vertical form-fill-seal packaging (sometimes referred to as vertical bagging). It will be appreciated that the equipment and processing steps for form-fill-seal packaging systems is substantially the same for horizontal and vertical bagging, a key difference being the orientation of the packaging during filling. The fill methodology used often depends on the nature of the food product. Products that can be stacked or otherwise arranged in a block (such as biscuits) tend to be more suited to horizontal form-fill-seal packaging because they can be pushed into the packaging as a block. Products that are more disordered (such as small snacks) tend to be more suited to vertical form-fill-seal packaging because they can be poured into the packaging from above.

[0013] Optionally, the sheet of packaging material comprises a polymeric material, for example wherein the sheet comprises or consists of a plastic film. Optionally, the sheet comprises a paper-based material layer, for example a paper-based material layer coated with or otherwise adhered to a layer of polymeric material. Optionally, when the sheet comprises a paper-based material layer and a polymeric material layer, the polymeric material layer is positioned inside the paper-based material layer, for example lining the cavity when the packaging is formed. Optionally the sheet is a recyclable material and / or comprises recycled material. Examples of suitable materials include polyolefins, such as polypropylene, and polyesters. It will be appreciated that the film may be a multi-layer (e.g. laminate) film, or a monolayer film, optionally a monolayer film. Optionally, the packaging is openable without delamination of the multi-layer laminate packaging material. Optionally, the film comprises OPP (oriented polypropylene, e.g. biaxally oriented polypropylene, BOPP) film and / or PET (polyethylene terephthalate film, also known as a polyester film, e.g. oriented polyester film, such as biaxally oriented polyester film), preferably OPP. Optionally, the film is a monolayer OPP or PET, preferably OPP, film. Optionally, the film is a bilayer OPP / OPP film, OPP / PET film, or PET / PET film, such as bilayer OPP / OPP film or OPP / PET film, for example bilayer OPP / OPP film. Optionally, at least one layer, such as the inner layer, of the film has a heat-sealable surface on the inner face of the film. It will be understood that a heat-sealable surface is, for example, a surface weldable to itself when portions of the film are pressed together between heated jaws or rollers. Optionally, the film a thickness of at least 20 microns, such as at least 40 microns, for example 20-60 microns, e.g. 30-50 microns. Optionally, when the packaging is horizontal form-fill-seal packaging, the film thickness is 20-60 microns, e.g. 30-50 microns. Optionally, when the packaging is vertical form-fill-seal packaging, the film thickness is 30-80 microns, e.g. 40-70 microns. Optionally, the film is a monolayer film, such as an OPP monolayer film, having a thickness of at least 20 microns, such as at least 40 microns, for example 20-60 microns, e.g. 30-50 microns. Optionally, the film has at least two layers (such as at least two OPP layers and / or at least an OPP layer and a PET layer, preferably at least two OPP layers), for example the film is a bilayer film, wherein each layer has a thickness of at least 10 microns, preferably wherein the two layers have a combined thickness of at least 20 microns, such as a combined thickness of at least 30 microns, for example wherein the two layers have a combined thickness of 20-60 microns, e.g. 30-50 microns. Optionally, each layer of the film has the same or different thicknesses. Preferably, the film has an oxygen transmission rate (23° C.-0%R.H.) of no more than 2000 cc / m2 d atm (measured according to ASTM D3985) and / or a water vapour transmission rate (38° C.-100% R.H.) or no more than 8 g / m2 d) (measured according to ASTM F1249). Examples of suitable OPP and PET films include those available from Vibac®, Polibak® (e.g. PL1, PWE), Jindal Films® (e.g. Bicor™, Innovia (e.g. Propafilm™), Super Film Packaging Films®, and Polinas® (e.g. Polipet®). Optionally, the sheet is a multi-layer material comprising a paper-based material layer and an OPP or PET (preferably OPP) layer.

[0014] Optionally, the cavity is sealed to reduce water vapour and / or oxygen transmission between the cavity and the surroundings of the packaging. It will be appreciated that the tightness of the seal will vary according to the nature of the products contained in the packaging.

[0015] Optionally, the end seals and the longitudinal seal are the only seals that close the cavity, for example are the only seals formed between portions of the sheet of material. Additionally or alternatively, the packaging consists of the sheet of material and optionally one or more adhesives forming the second end seal that closes the cavity. Optionally, the first end seal and the longitudinal seal are substantially free from any adhesive, such as a pressure sensitive adhesive. It will be appreciated that a seal is substantially free from adhesive when the seal is primarily formed without adhesive, for example when the sealing area comprises a minor amount of adhesive, By way of example, a seal may be substantially free from adhesive when 95% or more of the sealing area, e.g. 98% or more, is entirely free from adhesive. Optionally, any seal described as free, or substantially free, from adhesive may be entirely free from adhesive. Optionally, the permanent first end seal is the only seal at the first end of the cavity, and / or the permanent longitudinal seal is the only seal along the side of the cavity. Additionally or alternatively, the openable / recloseable second end seal is the only seal at the second end of the cavity. Optionally, the first end seal and / or the second end seal extend across the entire width of the cavity (for example from a first side of the cavity to an opposed second side of the cavity), and / or the longitudinal seal extends along the entire length of the cavity (for example from the first end of the cavity to the opposed second end of the cavity).

[0016] Optionally, the sheet is folded twice at each end seal, for example so that the sheet folds back upon itself along each end seal and so that the opposed side edges of the sheet meet at the longitudinal seal.

[0017] Preferably, the first end seal and the longitudinal seal are both heat-sealed. Optionally, the first end seal and the longitudinal seal are both welded (for example by thermal or ultrasonic welding). For example, at each of the first end seal and the longitudinal seal the edge of the sheet is welded to itself, e.g. the inner surface of the first end edge to another part of the inner surface of the first end edge, and the inner surface of one side edge to the inner surface of the other side edge. Optionally, the first end seal is spaced inwards from the outer first end edge of the sheet of packaging material, for example so that the end tip of the sheet is not held closed. Optionally the longitudinal seal is positioned at the outer side edges of the sheet of packaging material, for example so that side tips of the sheet are sealed closed. Optionally, the end edges of the sheet are straight-cut. It will be appreciated that straight-cut ends form a straight linear edge, as opposed to serrated-cut ends which may have a zig-zag shaped or jagged edge. It may be that a straight cut edge helps to avoid damage to, or accidental misuse of, the packaging. For example, serrated cut edges can make packaging film more susceptible to tearing, for example during handling, and / or can encourage consumers to tear the packaging open at the ends rather than use the openable / recloseable end seal. Optionally, the side edges of the sheet are straight-cut. It will be appreciated that straight-cut sides form a straight linear sedge, as opposed to other side shape profiles which may, for example, require more complex sheet cutting methods.

[0018] Optionally, the packaging is openable without tearing the sheet of packaging material. For example, the packaging is openable by drawing apart the overlaid portions of the sheet of packaging material at the openable / recloseable end seal, and / or the openable / recloseable end / seal is configured to be opened without tearing the packaging material. Optionally, the packaging is free from perforations and / or weakening cut-outs configured to promote tearing of the packaging material.

[0019] Optionally, the side edges of the sheet are straight-cut. It will be appreciated that straight-cut sides form a straight linear sedge, as opposed to other side shape profiles which may, for example, require more complex sheet cutting methods.

[0020] Optionally, the second end seal is cold-sealed. Typically, a cold seal adhesive is a material that has good adhesion to itself at ambient temperatures, a property that is often referred to as “self-adhesion”, “auto adhesion”, or “autohesion”. Optionally, the cold seal adhesive is a natural rubber latex adhesive, or a natural rubber latex-free adhesive. Preferably, the cold seal adhesive is applied to both surfaces that are to be sealed together. Optionally, the second end seal comprises a cold-seal adhesive that adheres a portion of the second end edge of the sheet to another portion of the second end edge of the sheet (e.g. portions of the inner surface of the second end are sealed to each other). Preferably, the cold-seal adhesive is a pressure sensitive adhesive. Suitable cold seal adhesives include those available from Valpac® (e.g. CH260 series adhesives), Dyna-Tech Adhesives ® (e.g. CoStick®), Dow® (e.g. COSEAL™ adhesives) and van Asperen Fleestoffen B.V.® (e.g. Liofol® adhesives). It will be appreciated that adhesives may, for example, be chosen depending on the seal strength and resealability (e.g. number of reseals) desired.

[0021] Optionally, the packaging comprises an opening tab element adjacent the second end seal, for example a tab element arranged to be gripped by the user to aid opening of the second end seal. Preferably, the tab element is a part of the sheet of packaging material. For example, the tab element is part of the second end edge of the sheet. Optionally, the packaging comprises a plurality of tab elements. Preferably, the tab elements are symmetrical. It will be appreciated that symmetrical tab elements may, for example, be particularly convenient to shape when the end of the packaging is cut after sealing in a form-fill-seal process. Optionally, the or each tab element comprises a portion of the inner surface of the sheet, for example configured to be gripped by a consumer. Optionally, the or each tab element comprises a portion of the inner surface of the sheet having a surface area of at least 1 cm2 (100mm2), for example at least 2 cm2 (200 mm2). Optionally, the or each tab element is free from adhesive, for example the or each tab element comprises a portion of the inner surface of the sheet free from adhesive. For example, it may be that the or each tab element is a part of the sheet positioned outwards of the second end sealing zone. Optionally, the packaging comprises a first tab element overlying an opposed second tab element, wherein the first tab element and the second tab element each protrude outwards from the second end sealing zone. It will be appreciated that such an arrangement may conveniently allow a user to grip the opposed tab elements, and draw them apart to open the second end seal. Optionally, the packaging comprises at least two overlaid opening tab elements along the second end seal, wherein each opening tab element is arranged to be gripped by a user to aid opening of the second end seal, and wherein the opening tab elements are arranged so that portions of packaging sealed together at the second end seal are pulled apart when the tab elements are pulled away from each other. For example, the opening tab elements and the second end seal are arranged so that the second end seal is opened when the tab elements are pulled away from each other without any other seal being opened or damaged, and without delamination and / or tearing of the packaging material. Optionally, the tab elements have matching edge profiles. For example, it may be that the tab elements have a domed edge profile. It will be appreciated that such tab elements may, for example, be conveniently cut simultaneously from a sheet of packaging material folded onto itself to form the second end seal. Optionally, the first and second ends of the packaging have corresponding edge profiles, for example so that the outer edge of the first end of a wrapped food product nests with the outer edge of the second end of another corresponding wrapped food product. Optionally, the packaging has a first end comprising the first end seal, and a second end comprising the second end seal, wherein the first end of the packaging comprises a plurality of cut-outs corresponding in size, shape and arrangement to the at least two opening tab elements at the second end of the packaging. It will be appreciated that such corresponding profiles may arise, for example, when a packaging film is provided as a continuous web which is cut into lengths during a flow-wrap packaging process, for example so that a first length provides the wrapper for a first wrapped food product and a subsequent length provides the wrapper for a second wrapped food product. Optionally, the first end edge of the packaging comprises a cut-out having a shape corresponding to the shape of tab elements formed on the second end edge of the packaging. Optionally, the first end seal is spaced apart from the first end edge of the packaging, for example so that the cut-out is accommodated in a portion of the first end outward of the first end seal (for example outward of the first end sealing zone).

[0022] Optionally, the second end seal comprises an adhesive (e.g. a cold-seal adhesive such as a pressure-sensitive adhesive) arranged along the end seal at or adjacent to the second end edge of the sheet. Optionally, said adhesive extends along the entire length of the second end seal. Optionally, the second end seal comprises a sealing zone extending across the width of the packaging from a first side to a second side, for example being the area of the second end where a first portion of the second end of the sheet contacts a second portion, for example to form a continuous seal along the length of the second end seal. Preferably, the first end seal and the longitudinal seal zones are substantially free from, for example entirely free from, adhesive, such as pressure sensitive adhesive. Optionally, the adhesive covers and / or defines a sealing zone. Optionally, the second end comprises a sealing zone spaced apart from the second end edge of the sheet by a first distance (optionally along at least 25%, such as the whole, length of the second end edge). Optionally, the first distance is in the range of about 0.3 cm (3 mm) to about 2.0 cm (20 mm), such as about 0.5 cm (5 mm) to about 1.0 cm (10 mm). It will be appreciated that when the sealing zone is spaced apart from an edge, said edge may provide an area of the sheet that extends outwards from the seal and which can be gripped by a consumer to aid opening of the packaging. Optionally, the second end comprises a plurality of sealing zones, such as a first sealing zone spaced apart from a second sealing zone, for example wherein a first sealing zone is positioned at or adjacent the second end edge of the sheet and a second sealing zone is positioned adjacent the cavity. Optionally, the second end comprises a sealing zone shaped to define one or more tab elements, optionally wherein overlaid portions of the second end edge have matching and optionally aligned edge profiles and / or sealing zone shapes. It will be understood that the outer edge of the sealing zone is the distal edge relative to the cavity. Optionally, the outer edge profile of the sealing zone is shaped to provide at least one, such as a plurality of, tab element areas along the second end that are free from adhesive. Preferably, the or each tab element area extends about 0.3 cm (3 mm) to about 2.0 cm (20 mm), such as about 0.5 cm (5 mm) to about 1.0 cm (10 mm), from the outer edge of the sheet towards the cavity. It will be appreciated that each tab element area may have any suitable shape, such as an angled (e.g. square or triangular) or curved shape. It will be understood that in such arrangements the shape of a tab element corresponds to the shape of the sealing zone edge profile that bounds the tab area.

[0023] The present invention provides, according to a second aspect, a wrapped food product, the product comprising a plurality of food items packaged in packaging according to the first aspect of the invention. Optionally, the food items are confectionery items, such as baked confectionery items, for example biscuits and / or cookies. Optionally, the cavity of the packaging is free from any container, such as a tray, for holding the food items. For example, the cavity contains only the food items, such as wherein the wrapped food product consists of the packaging and the food items. Optionally, the wrapped food product comprises at least 6 food products, for example at least 10 food products, such as at least 20 food products. Optionally, the food products are stacked in the packaging. Optionally, each of the food items is a planar food item (for example having a general disc shape), and when the food items are stacked they are arranged coplanar with each other. Optionally, when the food products are stacked, a first food item is positioned at the first end of the packaging, a second food item is positioned at the second end of the packaging, and a plurality of additional food items are positioned in a row between the first and second food items. Optionally, when the food products are stacked, they are arranged so that each item abuts the wrapper at its side edge, optionally wherein each item has at least one end face abutting the end face of an adjacent item. when items are substantially disc-shaped, for example, it may be that the side edge is the curved peripheral edge, and the end faces are the opposed generally planar faces. Such an arrangement may be referred to as edge stacked, for example. Alternatively, the food items are stacked in the packaging in a so-called ‘penny stack’ arrangement. Optionally, the food products are stacked in the packaging, wherein a first plurality of items are stacked at the first end of the packaging in a first stack, and a second plurality of items are stacked at the second end of the packaging in a second stack parallel to the first stack. Optionally, further parallel stacks are arranged in a row between the first and second stacks. Optionally, a further row of parallel stacks is arranged alongside said row. It will be appreciated that items may, for example, be stacked towards the longitudinal seal, or across the longitudinal seal.

[0024] The present invention also provides, according to a third aspect, sealing jaws for sealing together two or more overlaid layers of packaging film, for example sealing jaws sized and configured to press together two or more overlaid layers of a packaging film to form a first permanent seal between the layers and a second openable and recloseable seal between the layers. Optionally, the sealing jaws are sealing jaws for flow wrap packaging apparatus (e.g. form-fill-seal wrapping apparatus). Preferably, the first permanent seal is spaced apart from the second openable and recloseable seal. Preferably, the seals each extend across the entire width of the layers of packaging film. Preferably, the seals are end seals as described herein. For example, the sealing jaws are configured to form first and second end seals of packaging according to the first aspect of the invention, and / or a wrapped food product according to the second aspect of the invention. Preferably, the jaws comprise: a first set of opposed sealing surfaces for pressing the layers together to form a first permanent seal between the layers, a second set of opposed sealing surfaces for pressing the layers together to form a second openable and recloseable seal between the layers, and a film cutter (e.g. a knife) for cutting the packaging film between the first and second seals. In use, operation of the film cutter may detach a first portion of the film comprising the first seal from a second portion comprising the second seal. Preferably, the cutter is sized and configured to cut across the entire width of the layers of packaging film. Optionally, the first and second set of sealing surfaces each comprises an upper sealing surface and a lower sealing surface. It will be appreciated that, in operation, the respective upper and lower sealing surfaces may be brought together by any suitable mechanism. For example, the sealing surfaces may be actuated by sliding or rotating mechanisms. Optionally, the sealing jaws are configured to weld overlaid layers of packaging film at the permanent seal, for example by thermal welding or by ultrasonic welding. For example, at least one of the upper and / or lower sealing surfaces of the first set of sealing surfaces is configured for thermal or ultrasonic welding. Preferably, the jaws comprise a thermal or ultrasonic welder for heating the overlaid layers of packaging film at the permanent seal, such as to a temperature of at least 100° C. (e.g. to a temperature of 100-200° C.). Optionally, the sealing jaws comprise an ultrasonic welder configured for ultrasonic welding of packaging material pressed between the first set of sealing surfaces. Optionally, at least one of the upper and / or lower sealing surfaces of the first set of sealing surfaces is a heated sealing surface, and both the upper and lower sealing surfaces of the second set of sealing surfaces are not welding sealing surfaces (e.g. are not configured for ultrasonic welding and / or are unheated sealing surfaces). For example, it may be that the jaws comprise a heater for heating one or both of the upper and lower sealing surfaces of the first set of sealing surfaces, such as to a temperature of at least 100° C. (e.g. to a temperature of 100-200° C.). It will be appreciated that any suitable heater may be used, such as an electrical heating element. Optionally, there is no second heater for heating either the upper or lower sealing surfaces of the second set of sealing surfaces. Alternatively, the jaws may comprise a second heater provided that the second heater can be disabled so that neither of the second set of sealing surfaces are heated. Optionally, at least one of the upper and / or lower sealing surfaces of the first set of sealing surfaces is an ultrasonic welding sealing surface, and both the upper and lower sealing surfaces of the second set of sealing surfaces are not welding sealing surfaces (e.g. are not configured for ultrasonic welding and / or are unheated sealing surfaces). For example, it may be that the jaws comprise an ultrasonic welder at one or both of the upper and lower sealing surfaces of the first set of sealing surfaces, for example configured to heat packaging material to a temperature of at least 100° C. (e.g. to a temperature of 100-200° C.). It will be appreciated that any suitable ultrasonic welder may be used. Optionally, there is no second ultrasonic welder for heating packaging at either the upper or lower sealing surfaces of the second set of sealing surfaces. Alternatively, the jaws may comprise an ultrasonic welder provided that the second ultrasonic welder can be disabled so that packaging is not heated at the second set of sealing surfaces. Optionally, the first set of sealing surfaces are crimping sealing surfaces, for example being operable to crimp the packaging film at the first permanent seal. Optionally, at least one, preferably both, of the first and second sealing surfaces of the first set of sealing surfaces has a ridged profile, for example so that the overlaid layers of film adopt a ridged shape when sealed together. It will be understood that a ridged shape may also be referred to as a corrugated shape, for example formed when film is crimped. Optionally, the first and second sealing surfaces of the second set of sealing surfaces are smooth (e.g. not ridged), for example so that the overlaid layers of film adopt a flat profile when sealed together. Optionally, the sealing jaws comprise one or more temperature deflectors positioned between the sets of sealing surfaces, for example one or more blocks of thermally insulating materials for forming a thermal barrier between the first and second set of sealing surfaces. Optionally, the temperature deflector is sized and configured so that the second set of sealing surfaces remain at a temperature of no more than 50° C. during use, for example when one or both of the upper or lower sealing surfaces of the first set of sealing surfaces is heated to their operating temperature, such as a temperature of at least 100° C. (e.g. 100-200° C.). Optionally, the sealing jaws are configured to form the first and second end seals of packaging according to the invention. It will be appreciated that, in operation, the jaws may simultaneously form the first end seal of a first item of packaging and the second end seal of a second item of packaging. Optionally, the jaws comprise an upper jaw and a lower jaw. Optionally the upper jaw comprises upper sealing surfaces of the first and second sets of sealing surfaces, optionally a temperature deflector (e.g. if the upper sealing surface of the first set of sealing surfaces is heated), and / or optionally a cutter blade (such as a knife). Optionally, the lower jaw comprises lower sealing surfaces of the first and second sets of sealing surfaces, optionally a temperature deflector (e.g. if the lower sealing surface of the first set of sealing surfaces is heated), and / or optionally a cutter anvil (e.g. providing a surface for a cutter blade to cut against).

[0025] The present invention proves, according to a fourth aspect, packaging apparatus for wrapping a food product, the apparatus comprising a fin or lap sealer for forming a longitudinal seal along the length of a food wrapper, and an end sealer for forming first and second end seals of a food wrapper, wherein the end sealer comprises sealing jaws according to the third aspect of the invention. Optionally, the apparatus is flow wrap packaging apparatus. Optionally, the fin or lap sealer comprises rollers or jaws sized and configured to press together two or more overlaid layers of a packaging film to form a permanent longitudinal seal between the layers. Optionally, the fin or lap sealer comprises one or more heated rollers or jaws. Preferably, the apparatus is configured to form packaging according to the first aspect of the invention an / or to produce a wrapped food product according to the second aspect of the invention. Optionally, the apparatus comprises one or more of: a former for folding packaging film into shape prior to forming the longitudinal seal and the end seals; one or more dispensing rollers for dispensing film from a roll; and, one or more conveyors for transporting food items and / or wrapped food products. Optionally, the apparatus is oriented for horizontal filling, for example wherein items to be packaged are moved laterally into a tube of packaging material formed by the forming box during the packaging process. Alternatively, the apparatus is oriented for vertical bagging, for example wherein items to be packaged are dropped vertically into a tube of packaging material formed by the forming box during the packaging process. Optionally, when the apparatus is oriented for horizontal filling, the former is a forming box, such as a forming box for folding a packaging sheet around food items to be wrapped. Optionally, when the apparatus is oriented for vertical filling, the former is a forming shoulder, such as a forming shoulder for shaping a packaging sheet into a tube into which food items can be dropped.

[0026] The present invention provides, according to a fifth aspect, a method of packaging a plurality of food items, the method comprising the steps of: forming a sheet of packaging material into a tube closed along its side and at one end so that a surface of the sheet forms an inner surface and an opposed surface of the sheet forms an outer surface of the packaging, wherein the tube is closed along its side by a permanent longitudinal seal and at the one end by a permanent first end seal, placing food items to be wrapped in the tube, and closing the tube at a second opposed end with a second openable and recloseable seal to define a cavity containing the food items. It will be appreciated that the sheet is sealed to itself at each of the longitudinal and end seals, and that the longitudinal seal extends along the packaging from the first end to the second end thereby joining a first side edge of the sheet to a second side edge of the sheet. Optionally, the tube is arranged horizontally and the food items are moved into the tube laterally (horizontal form-fill-seal), or the tube is arranged vertically and the food items are dropped into the tube from above (vertical form-fill-seal). Optionally, the method provides a packaged food product according to the second aspect of the invention. It will be appreciated that the steps may optionally be carried out in a different order to that set out above. For example, the longitudinal seal may be formed before, after or simultaneously with the first and / or second end seal. Similarly, the first end seal may optionally be formed before, after or simultaneously with the second end seal. Furthermore, the food items may optionally be placed into the tube of packaging material at any stage in the process, provided that they are placed in the tube before the final seal is formed. For example, one or more seals may optionally be formed before the food items are placed in the tube.

[0027] Optionally, the first end seal and / or the longitudinal seal is welded (e.g. thermally or ultrasonically welded). Optionally, the portions of the sheet joined together to form each of the first end seal and / or the longitudinal seal are pressed together between jaws or rollers, such as heated jaws or rollers. For example, a heat-sealed welded join may be achieved by use of sealing jaws or rollers that apply heat and pressure, thereby melting an inner surface (or layer) of the film permanently welding films together. Additionally or alternatively, the portions of the sheet joined together to form each of the first end seal and / or the longitudinal seal are pressed together between ultrasonic welding jaws. For example, a heat-sealed welded join may be achieved by use of sealing jaws or rollers that apply pressure and cause heating of the sheet, thereby melting an inner surface (or layer) of the film permanently welding films together. Optionally, the second end seal is cold sealed (e.g. using a cold seal adhesive). Optionally, the portions of the sheet joined together to form the second end seal are pressed together between jaws or rollers, such as unheated jaws or rollers. Optionally, the second end seal is formed by pressing second end seal portions of the sheet together between unheated jaws, and the first end seal is formed by pressing end seal portions together between heated jaws, and the longitudinal seal is formed by pressing side seal portions together between heated jaws or rollers. Optionally, each sheet of packing material is cut from a continuous web of packaging material, for example before, during or after forming the packaged food product.

[0028] Optionally, the method of the fifth aspect of the invention comprises using the sealing jaws of the third aspect of the invention to form the first and second end seals, and / or using the apparatus of the fourth aspect of the invention to wrap the food items.

[0029] The present invention provides, according to a sixth aspect, a sheet of packaging material configured to form the packaging of the first aspect of the invention. Optionally, the sheet of packaging material has an inner surface and an opposed outer surface, first and second opposed ends and first and second opposed sides. Optionally, the sheet comprises first and second end seal portions on the inner surface at the first and second ends, respectively, and first and second side seal portions on the inner surface at or adjacent to the first and second sides, respectively. Optionally, the first end seal portion and the first and second side seal portions are designated heat-seal, e.g. configured to be welded when pressed together between heated jaws or rollers. Preferably, the first end seal portions and the first and second side seal portions are free from cold-seal adhesive. Optionally, the second end seal portion is coated with a cold sealing adhesive. It will be understood that the sheet is configured so that it can be folded to form various configurations, for example with end seals formed by each end seal portion sealing to itself, and a longitudinal seal formed by bringing together the side seal portions. It will be appreciated that the sheet may be part of a web of packaging material. Optionally, the sheet comprises tab elements as described in relation to the packaging of the first aspect of the invention.

[0030] It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the packaging of the invention and vice versa.DESCRIPTION OF THE DRAWINGS

[0031] Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which:

[0032] FIG. 1 shows a perspective view of packaging according to a first embodiment of the invention prior to opening;

[0033] FIG. 2 shows perspective view of the packaging of FIG. 1 with the second end seal open;

[0034] FIG. 3 shows perspective view of the packaging of FIG. 1 during closing and re-sealing of second end seal;

[0035] FIG. 4 shows a front view of the packaging of FIG. 1 prior to opening;

[0036] FIG. 5 shows a perspective view of the packaging of FIG. 1 prior to opening;

[0037] FIG. 6 shows a back view of the packaging of FIG. 1 prior to opening;

[0038] FIG. 7 shows a cross-sectional view of the packaging of FIG. 1 prior to opening, cut along the length of the packaging;

[0039] FIG. 7a shows an enlarged view of part of FIG. 7, showing the second end seal;

[0040] FIG. 8 shows a cross-sectional view of the packaging of FIG. 1 prior to opening, cut across the length of the packaging;

[0041] FIG. 9 shows a cross-sectional view of packaging according to a second embodiment of the invention prior to opening, cut along the length of the packaging;

[0042] FIG. 9a shows a cross-sectional view of the packaging of FIG. 9 prior to opening, cut across the length of the packaging;

[0043] FIG. 9b shows a cross-sectional view of packaging according to a third embodiment of the invention prior to opening, cut across the length of the packaging;

[0044] FIGS. 10a and 10b show side and cross-sectional schematic views of a cold-seal adhesive arrangement in an end seal suitable for the packaging of the invention;

[0045] FIG. 11 shows a top plan view of a sheet of packaging material according to the invention;

[0046] FIGS. 12a, 12b, 13a and 13b show side and cross-sectional schematic views of various cold-seal adhesive arrangements in end seals suitable for the packaging of the invention;

[0047] FIG. 14a shows a schematic perspective view of horizontal form-fill-seal wrapping apparatus according to an embodiment of the invention;

[0048] FIG. 14b shows a schematic perspective view of vertical form-fill-seal wrapping apparatus according to an embodiment of the invention;

[0049] FIG. 15 shows a plan view of the upper jaw of sealing jaws according to an embodiment of the invention;

[0050] FIG. 16a shows a cross-sectional view of sealing jaws comprising the upper jaw of FIG. 15, cut along line A-A;

[0051] FIG. 16b shows a cross-sectional view of sealing jaws comprising the upper jaw of FIG. 15, cut along line B-B; and,

[0052] FIG. 16c shows another cross-sectional view of the sealing jaw shown in FIG. 16a, with the sealing jaw in the closed position.DETAILED DESCRIPTION

[0053] FIG. 1 shows a perspective view of packaging according to a first embodiment of the invention prior to opening, held by a consumer 1002. The packaging 1001 shown is a pack of biscuits, flow-wrapped in a sheet of plastic film 1003. The packaging has a heat-sealed first end 1004a and a cold-sealed second end 1004b. A heat-sealed longitudinal fin seal 1006 (not shown in FIG. 1—see FIG. 6) extends along the rear of the packaging from the first end 1004a to the second end 1004b. The heat sealed first end 1004a and heat sealed fin 1006 provide permanent (welded) seals. The cold-sealed second end 1004b is an openable / recloseable cold-sealed join. The seal is provided by a pressure sensitive adhesive. In this condition, the packaging protects the contents from moisture, sealing the biscuits inside the internal cavity formed by the packaging and thereby extending product shelf life. While the packaging 1001 is shown with a longitudinal fin seal, it will be appreciated that a longitudinal lap seal could be used instead.

[0054] FIG. 2 shows a perspective view of the packaging 1001 of FIG. 1 while opened. To open the second end 1004b, the consumer grips the opening tabs 1007a, 1007b of the first and second end edges and pulls them apart. The cold-seal adhesive allows the package to be opened without tearing the sheet of film. Once the second end 1004b is open, the consumer 1002 can remove a biscuit 1090 from the packaging.

[0055] FIG. 3 shows a perspective view of the packaging 1001 of FIG. 1 during closing and re-sealing of second end 1004b. To re-close the second end 1004b, the consumer presses together the packaging across the width of the packaging. The cold-seal adhesive allows the package to be re-closed.

[0056] FIGS. 4-6 show a front, perspective and back views of the packaging of FIG. 1 prior to opening. As shown in FIGS. 4-6, the film is crimped at the seal at the first end 1004a, and the seal is positioned inwards of the outer end edges of the packaging. The film is smooth at the seal at the second end 1004b, and opening tabs 1007a, 1007b protrude outwards beyond the seal at the second end 1004b. The opening tabs 1007a, 1007b are free from adhesive, allowing the user to convenient grip both sides of the film forming the tab and pull the layers of film apart to open the second end seal 1004b. The opening tables 1007a, 1007b have a domed shape that corresponds to the domed cut-outs from the first end 1004a. The end edges of the film each side of the opening tabs 1007a, 1007b are shown with zig-zag cut ends, but could be given straight cut ends to help deter consumers from tearing the pack instead of unpeeling the seal at the second end 1004b. The fin seal 1006 extends along opening tab 1007b. A cut-out 1008 at the first end 1004a has a shape corresponding to the shape of the opening tabs 1007a, 1007b—it will be appreciated that the cut-line that separates the film forming one pack from the film forming another adjacent pack on the packging line forms the opening tabs 1007a, 1007b and the cut-out 1008.

[0057] FIG. 7 shows a cross-sectional view of the packaging 1001 of FIG. 1, cut along its length. The film 1003 forming the wrapper is a bilayer film (layer thicknesses are exaggerated in FIG. 7 for the purposes of illustration, the actual thickness of each layer is about 20 microns) having an outer OPP layer 1003a and an inner OPP layer 1003b, the inner surface of the inner layer 1003b being heat-sealable. A crimped permanent end seal 1005a is formed at the first end 1004a, and an openable / recloseable seal 1005b is formed at the second end 1004b. The permanent seal 1005a is formed by heating the first end 1004a under pressure in heated jaws. The biscuits 1010 contained in the cavity 1009 are shown inside the packaging 1001.

[0058] FIG. 7a shows an enlarged section of the drawing of FIG. 7, labelled with the same reference numerals. The section shown in FIG. 7a includes the second end 1004b of the packaging 1001.

[0059] FIG. 8 shows a cross-sectional view of the packaging 1001 of FIG. 1, cut across its length. The cross section is taken through the middle of the pack, showing one of the biscuits 1010 contained in the cavity 1009. At the fin seal 1006, a portion of the inside of the inner layer 1003b of the film 1003 is joined to another potion of the inside of the inner layer 1003b of the film 1003, providing an A-A seal along the length of the longitudinal fin 1006.

[0060] FIG. 9 shows a cross-sectional view of packaging 1101 of a second embodiment of the invention, cut along its length. The packaging is substantially identical to that of the first embodiment, except that the biscuits 1110 are ‘penny stacked’ in four stacks arranged parallel and side by side through the length of the packaging, and the longitudinal seal 1106 (not shown in FIG. 9) is a longitudinal lap seal. The same reference numerals are used to identify the parts of the packaging as in FIG. 7, except that the prefix ‘11’ is used rather than ‘10’.

[0061] FIG. 9a shows a cross-sectional view of the packaging 1101 of FIG. 9, cut across its length. The cross section is taken through the middle of the pack, showing one of the stacks of biscuits 1110 contained in the cavity 1109. As shown in FIG. 5A, the biscuits 1110 are stacked towards the longitudinal seal 1106. At the longitudinal lap seal 1106, a portion of the inside of the inner layer 1103b of the film 1103 is joined to a potion of the outside of the outer layer 1103a of the film 1103, providing an A-B seal along the length of the longitudinal lap seal 1106. The same reference numerals are used to identify the parts of the packaging as in FIG. 8, except that the prefix ‘11’ is used rather than ‘10’.

[0062] FIG. 9b shows a cross-sectional view of packaging 1201 of a third embodiment of the invention, cut across its length. The packaging is substantially identical to that of the second embodiment, with the only difference being that the penny stacked biscuits 1210 are stacked across the longitudinal lap seal 1206. The same reference numerals are used to identify the parts of the packaging as in FIG. 9a, except that the prefix ‘12’ is used rather than ‘11’.

[0063] FIG. 10a shows a cut-away schematic side view of a second end seal 2001 suitable for use in the packaging according to the invention, and FIG. 6b shows a schematic cross-sectional view of the second end seal 2001 along A-A. The seal 2001 joins a first portion of an end 2002a of a sheet 2002 to a second portion of an end 2002b using a pressure sensitive adhesive 2003 (represented by a diamond pattern in FIGS. 10a and 10b). Only the second end of the sheet 2002 is shown in the cut-away views of FIGS. 10a and 10b. The sealing zone 2004 is positioned at the second end edge portions 2005a, 2005b. As shown in the schematic view of FIG. 10a, the sealing zone extends along the whole length of the second end seal 2001.

[0064] FIG. 11 shows a top plan view of a sheet of packaging 8010 according to the invention. The sheet of packaging shown may be a sheet ready to be folded into packaging according to the invention, or a representation of a section of a continuous sheet web. Only the inner surface of the sheet 8010 is visible in FIG. 11. The sheet 8010 has first and second opposed ends 8011a, 8011b and first and second opposed sides 8012a, 8012b. The comprises first and second end seal zones on the inner surface at the first and second ends, respectively, and first and second side seal zones on the inner surface at or adjacent to the first and second sides, respectively. The first end seal zone, and the first and second side seal zones, are each areas designated for heat sealing by welding, and are thus free from cold-seal adhesive, and are marked by a chequerboard pattern in FIG. 11. The second end seal zone is coated with a cold sealing adhesive marked by a diamond pattern in FIG. 11. The sheet is configured so that it can be folded at least twice, firstly along A-A and secondly along line B-B.

[0065] When folded along lines A-A and B-B, end seals are formed as the first end seal zone seals to itself and the second end seal zone seals to itself. The first and second side seal zones are brought together to seal to each other to form a longitudinal fin seal, which may be folded flat along line C-C. It will be appreciated that other folds may be made to provide packaging of different shapes and sizes. It will also be appreciated that the packaging could be folded to form a longitudinal lap seal rather than a fin seal, in which case there would be no additional fold along line C-C. As shown in FIG. 11, opening tabs 8007a, 8007b are formed by portions of the second end 8011b of the sheet 8010 the protrude outwards from the second end seal zone, opening tab 8007b being formed by overlapped portions of the sheet and an end section of the fin seal. Cut-outs 8500a, 8500b each having a shape corresponding to that of the opening tabs 8007a, 8007b are shown at the first end 8011a of the sheet 8010.

[0066] FIG. 12a shows a cut-away schematic side view of another second end seal 4001 suitable for use in the packaging according to the invention, FIG. 12b shows a schematic cross-sectional view of the second end seal 4001 along A-A. Features the same as those of second end seal 2001 in FIGS. 10a and 10b are labelled with the same reference numerals, except that the prefix ‘2’ is used in place of ‘2’. The sealing zone 4004 is spaced apart from the end edges 4005a, 4005b by equal amounts, providing equally sized opening tab elements 4006a, 4006b free from adhesive along the length of the seal 4001.

[0067] FIG. 13a shows a cut-away schematic side view of another second end seal 7001 suitable for use in the packaging according to the invention, FIG. 13b shows a schematic cross-sectional view of the second end seal 7001 along A-A. It will be appreciated that the cross-sectional view along B-B for fin seal 7001 would be substantially identical to the view of seal 2001 shown in FIG. 10b. Features the same as those of seal 2001 in FIGS. 10a and 10b are labelled with the same reference numerals, except that the prefix ‘7’ is used in place of ‘2’. The sealing zone 7004 is positioned at end edge portions 7005a, 7005b, however the edge profile shape of the sealing zone 7004 does not match the edge profile of the end edge portions 7005a, 7005b so that there are three areas along the edge portions 7005a, 7005b free from adhesive providing opening tab elements. Opening tab elements 7006a, 7006b are visible in the cross-sectional view along A-B shown in FIG. 13b.

[0068] FIG. 14a shows a schematic perspective view of horizontal form-fill-seal wrapping apparatus according to an embodiment of the invention. The apparatus comprises: sealing jaws 1401 (comprising upper sealing jaw 1401a and lower sealing jaw 1401b) for forming first and second end seals and cutting the film 1410 to provide separate packaged products 1420; rollers 1402 for forming longitudinal fin seals; a forming box 1403 for folding the packaging film 1410 around items 1411 to be packaged; dispensing rollers 1404 for dispensing film from film roll 1412; and conveyor 1405. For simplicity, items 1411 to be packaged are shown as a single block in FIG. 14. It will be appreciated that in the apparatus according to the invention multiple items (e.g. stacked food items) may be packaged together.

[0069] FIG. 14b shows a schematic perspective view of vertical form-fill-seal apparatus according to an embodiment of the invention. The apparatus comprises: sealing jaws 1451 (comprising left sealing jaw 1451a and right sealing jaw 1451b) for forming first and second end seals and cutting the film 1460 to provide separate packaged products 1470; rollers 1452 for forming longitudinal fin seals; a forming shoulder 1453 for folding the packaging film 1460 around items to be packaged; feeding funnel 1465 for dropping items to be packed into packaging; and dispensing rollers 1454 for dispensing film from film roll 1462.

[0070] FIG. 15 shows a plan view of the upper jaw 1500a of sealing jaws according to an embodiment of the invention. The upper jaw comprises a heated sealing surface 1501a provided with crimping ridges 1502a, thermal deflector 1503a (an a further optional thermal deflector 1504a), and non-heated sealing surface 1505a. The upper jaw further comprises a cutting blade (knife) 1506 accommodated in recess 1507a. It will be appreciated that while the sealing jaw is shown with a heated sealing surface 1501a, an ultrasonic welder could be used instead.

[0071] FIG. 16a shows a cross-sectional view of sealing jaws 1500 comprising the upper jaw 1500a of FIG. 15, cut along line A-A. Features corresponding to those shown in FIG. 15 are labelled with the same reference numerals. Features of the lower jaw 1500b are labelled with the suffix ‘b’ in place of ‘a’. Also shown in FIG. 16a is anvil 1508 accommodated in recess 1507b, against which the cutting blade 1506 acts. FIG. 16b shows another cross-sectional view of sealing jaws 1500 comprising the upper jaw 1500a of FIG. 14, cut along line B-B. Features are labelled with the same reference numerals as used in FIG. 16a. FIG. 16c shows another cross-sectional view of the sealing jaw 1500 shown in FIG. 16a, with the sealing jaw in the closed position. For the sake of clarity, no film is shown in FIG. 16c. It will be appreciated that the film would be held in gap 1520 during operation of the jaws 1500 to seal and cut the film.

[0072] Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein.

[0073] Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.

Claims

1. Packaging for a plurality of food items, the packaging having a sealed cavity for containing the plurality of food items, wherein the packaging comprises a continuous sheet of packaging material that wraps around and defines the cavity and which is sealed at a first end of the cavity by a first end seal, at a second opposed end of the cavity by a second end seal, and along the cavity by a longitudinal seal, the longitudinal seal extending from the first end seal to the second end seal, the sheet of packaging material having an inner surface and an opposed outer surface,wherein the first end seal and the longitudinal seal are each permanent seals free from pressure sensitive adhesive,wherein the end seals each join a portion of the inner surface of the sheet to another portion of the inner surface of the sheet,wherein the second end seal is an openable and recloseable seal cold sealed with a pressure sensitive adhesive,wherein the first and second ends have corresponding edge profiles, and wherein the packaging comprises at least two overlaid opening tab elements along the second end seal, wherein each opening tab element is arranged to be gripped by a user to aid opening of the second end seal, and wherein the opening tab elements are arranged so that portions of packaging sealed together at the second end seal are pulled apart when the tab elements are pulled away from each other.

2. Packaging according to claim 1, wherein the sheet of packaging material is a monolayer or multilayer plastic film, and wherein the packaging is form-fill-seal flow-wrap packaging.

3. Packaging according to claim 1 or claim 2, wherein the openable and recloseable second end seal is the only seal at the second end of the cavity.

4. Packaging according to any preceding claim, wherein the first and second end seals and the longitudinal seal are the only seals that close the cavity.

5. Packaging according to any preceding claim, wherein the first and second end seals and the longitudinal seal are the only seals formed between portions of the sheet of material.

6. Packaging according to any preceding claim, wherein the first end seal and the longitudinal seal are each heat-sealed.

7. Packaging according to any preceding claim, wherein the first end seal and the longitudinal seal are each substantially free from adhesive, such as pressure-sensitive adhesive.

8. Packaging according to any preceding claim, wherein the packaging is openable without tearing the sheet of packaging material.

9. Packaging according to any preceding claim, wherein the sheet of packaging material is a multi-layer laminate packaging material, and wherein the packaging is openable without delamination of the multi-layer laminate packaging material.

10. Packaging according to any preceding claim, wherein the packaging has a first end comprising the first end seal, and a second end comprising the second end seal, wherein the first end of the packaging comprises a plurality of cut-outs corresponding in size, shape and arrangement to the at least two opening tab elements at the second end of the packaging.

11. A packaged food product comprising a plurality of food items packaged in packaging according to any one of claims 1 to 10.

12. The packaged food product of claim 11, wherein the food items are baked confectionery items, such as biscuits and / or cookies.

13. Flow wrap packaging sealing jaws configured to form first and second end seals of the packaging according to any one of claims 1 to 10, or of a packaged food product according to claim 11 or claim 12;wherein the jaws comprise: a first set of opposed sealing surfaces for pressing layers of packaging film together to form the first end seal, a second set of opposed sealing surfaces for pressing layers of packaging film together to form the second end seal, and a film cutter for cutting the packaging film between the first and second seals;and wherein the first set of sealing surfaces are configured to form the first end seal as a permanent end seal, and the second set of sealing surfaces are configured to form the second end seal as an openable and recloseable seal.

14. Sealing jaws according to claim 13, wherein the first set of sealing surfaces are heated sealing surfaces, and the second set of sealing surfaces are unheated sealing surfaces, optionally wherein the sealing jaws comprise a thermally insulating temperature deflector disposed between the first set of sealing surfaces and the second set of sealing surfaces.

15. Sealing jaws according to claim 13, comprising an ultrasonic welder configured for ultrasonic welding of packaging material pressed between the first set of sealing surfaces.

16. Flow wrap packaging apparatus for forming packaging according to any one of claims 1-10, or for providing a packaged food product according to claim 11 or claim 12,wherein the apparatus comprises: sealing jaws according to any one or claims 13 to 15, and rollers or further sealing jaws for forming the longitudinal seal of the packaging.

17. A method of packaging food items, the method comprising the steps of:forming a sheet of packaging material into a tube closed along its side and at one end so that a surface of the sheet forms an inner surface and an opposed surface of the sheet forms an outer surface of the packaging, wherein the tube is closed along its side by a permanent longitudinal seal and at the one end by a permanent first end seal,placing food items to be wrapped in the tube, andclosing the tube at a second opposed end with a second openable and recloseable seal to define a cavity containing the food items;wherein the sheet is sealed to itself at each of the longitudinal and end seals;and wherein the method provides a packaged food product according to claim 11 or claim 12.

18. The method of claim 17, wherein portions of the sheet joined together to form the first end seal and / or the longitudinal seal are pressed together between heated rollers and / or heated jaws.

19. The method of claim 17 or claim 18, wherein portions of the sheet joined together to form the first end seal and / or the second end seal are pressed together and welded, optionally by thermal or ultrasonic welding.

20. The method of any one of claims 17 to 19, wherein portions of the sheet joined together to form the second end seal are pressed together between unheated rollers and / or jaws.

21. The method of any one of claims 17 to 20, comprising using the sealing jaws of any one of claims 13 to 15 to form the first and second end seals, and / or comprising using the apparatus of claim 16 to package the food items.

22. The method of claim 21, wherein the method comprises heating the first set of sealing surfaces to heat-seal the first end seal, or operating the ultrasonic welder (if present) to ultrasonically weld the first end seal.

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