Package product, package set comprising at least two package products, method for manufacturing such package products

Abstract

The package product (1) comprises a container (2) and a packaging (10) The container (2) comprises: - a container body (2.0) defining a cavity (6), - a food component (4) in the cavity (6), - a membrane (9) closing the cavity (6). The packaging (10) comprises: - a protection sheet (12) covering the container body (2.0), and - a closure sheet (14) covering the membrane (9) and part of the protection sheet (12) to enclose the container (2) between the protection sheet (12) and the closure sheet (14). The closure sheet (14) and the protection sheet (12) are attached along a sheet attaching section (20) extending around the membrane (9). A line of weakness (22) extends around the membrane (9) to allow separation of a lid (24) from the closure sheet (14) under a manual force (F) for the container (2) to be released.

Description

[0001] PACKAGE PRODUCT, PACKAGE SET COMPRISING AT LEAST TWO PACKAGE PRODUCTS, METHOD

[0002] FOR MANUFACTURING SUCH PACKAGE PRODUCTS

[0003] 1. Field of the invention The present invention is directed to a package product comprising a container for a food component and a packaging enclosing the container. The invention is further directed to a package set comprising a plurality of such package products. The present invention is also directed to a method for manufacturing such package products. 2. Technical background

[0004] In the field of packaging, doses of food component, like ground coffee, are usually enclosed in a container, for example a coffee capsule, made of a packaging that is substantially impervious to oxygen, water vapor and / or ultraviolet light in order to preserve the quality of the food component. Such containers are commonly made of plastics or plastic laminates. The dose of food component may interact with water for preparing a food product, for example a beverage like coffee or tea, when placed in a food or beverage preparation machine during a preparation process. After processing of the food component, the resulting food product, e.g. the beverage, can be discharged out of the package product and dispensed in a cup, from which the user may ingest the food or beverage. Once the package product has been used for preparing a food product, for example a beverage like coffee, the used package product must be disposed of along with food component sticking to it.

[0005] However, the used package product, for example a used coffee capsule, cannot be easily recycled or composted as the impervious container is not made of recyclable, biodegradable and / or compostable material. As a result, a certain amount of waste can be produced. Yet, there is a general effort to reduce waste and to increase the disposability, compostability and / or recyclability of used package products.

[0006] 3. Summary It is thus an object of the present invention to provide a package product comprising a container and a packaging: wherein the container comprises:

[0007] - a container body defining a cavity and an opening of the cavity,

[0008] - a dose of food component contained within the cavity, the dose of food component being suitable for interacting with a fluid introduced into the cavity so as to prepare a food product, and

[0009] - a membrane attached to the container body so as to close the cavity, wherein the packaging comprises:

[0010] - a protection sheet arranged to cover an outer side of the container body, and - a closure sheet arranged to cover the membrane and at least part of the protection sheet, such that the container is enclosed between the protection sheet and the closure sheet, wherein the closure sheet and the protection sheet are attached to each other along a sheet attaching section, the sheet attaching section extending around the membrane, and wherein the closure sheet has a line of weakness extending near or around part or all of the membrane, the line of weakness being configured such that it allows at least partial separation of a lid portion from the rest of the closure sheet under a manual force exerted on the protection sheet to press the container against the closure sheet such that the line of weakness tears partly or totally open and defines a release opening in the closure sheet for the container to be released from the protection sheet. As the protection sheet covers and protects the container during storage of the package product, the container can be made of materials that are not completely impervious to oxygen and humidity. This is especially the case when the container is sealed close between the closure and protection sheets that are impervious to air and water vapor.

[0011] As a result, the container can be made of various materials, in particular biodegradable and / or compostable materials like cellulose-based materials, which reduces the quantity of waste that is not easily recyclable. Besides, the quantity of materials necessary for manufacturing the package product can be reduced as no additional box is necessary for protecting all packaging products.

[0012] Besides, a user can easily detach the container by pushing it, via the protection sheet, to tear open the line of weakness and thus form the release opening to get the container out of the packaging. In particular, the container body may have an inner side defining the cavity and an outer side extending opposite the cavity, the protection sheet being arranged to cover the outer side of the container body.

[0013] Preferably, the closure sheet and the container body may be sealed tight to each other along the body attaching section. In particular, the protection sheet may be arranged to tightly cover an outer surface of the container body. Thus, air and vapor cannot ingress between the protection sheet and the container body, not even during manufacturing of the package product.

[0014] The membrane may be attached directly, preferably sealed, to the container body, preferably to the flange, for example by means of a thermic weld, a laser weld, a compression weld, a friction weld, a glue weld or a ultrasonic weld and / or any combination thereof.

[0015] Preferably, the closure sheet may be fastened directly to the container body, for example by means of a thermic weld, a laser weld, a laser weld, a glue weld, a compression weld, a friction weld, a glue weld or an ultrasonic weld and / or any combination thereof. Preferably, the protection sheet may be thermoformed on the container body.

[0016] Preferably, the closure sheet and the protection sheet may be sealed to each other along the sheet attaching section. Thus, air and vapor cannot ingress between the protection sheet and the container body.

[0017] In some implementations, the line of weakness may extend along part or all of the sheet attaching section.

[0018] In some implementations, the line of weakness may be configured such that the manual force to be exerted may be lower than 50 N, preferably be lower than 20 , more preferably lower than 10 N. The manual force may substantially be oriented from the outer side of the protection sheet toward the membrane. In some implementations, the container body may substantially have a shape with a symmetry of revolution, for example a frustoconical shape, and wherein, preferably, the opening has substantially a circular perimeter. Likewise, the membrane may substantially have a shape with a symmetry of revolution, for example a circular shape.

[0019] Thus, a substantially round container can facilitate its manufacturing and packaging, while providing a relatively light container, hence reducing the quantity of material to be biodegraded, composted, recycled or disposed of. In the present disclosure, the term "container" may be understood as designating any container that contains a dose of food component(s), for example a rigid capsule or cartridge or a semirigid pod. The container may be symmetrical or asymmetrical, frustoconical, spheroidal, etc. Such dose of food component(s) may be suitable for preparing one beverage (single-serve), two or a few beverages.

[0020] The food component may be a beverage component selected within the list of: roast and ground coffee, a soluble ingredient such as milk-based, chocolate, soup, infusion or herbal tea ingredients as well as nutritional soluble compositions, and more generally any liquid edible composition for human or animal consumption, and / or mixtures thereof. During preparation of a food product, the food component may be made to interact with a fluid, for example water or milk, injected into the container by a preparation machine in order to produce an ingestible substance, for example coffee, tea, milk, cream, soup, puree, medication, etc.

[0021] In some implementations, the body attaching section and the sheet attaching section may be joined to or integral with one another. Conversely, the body attaching section and the sheet attaching section may be distant from one another.

[0022] According to an embodiment, the line of weakness may extend around part or all of the sheet attaching section, preferably along part or all of the sheet attaching section, so as to define a release opening in the closure sheet to allow release of the container from the protection sheet. In some implementations, the line of weakness may extend on a portion of the closure sheet facing the membrane and may take any appropriate geometry defining a release opening in the closure sheet to allow release of the container from the protection sheet. It may be, for example, be in the form of a cross.

[0023] Thus, a user can easily detach the container and release it from the protection sheet through the release opening.

[0024] According to an embodiment, the line of weakness may be made of a perforation line, a score line or a combination thereof, the line of weakness being preferably formed mechanically or by laser.

[0025] Thus, the line of weakness can easily be made and can provide a consistent mechanical resistance among a series of package products. A score line may extend only partly through the closure sheet, which can maintain a certain tightness across the closure sheet. A perforation line may extend all the way through the closure sheet, which can make it very easy for a user to tear the line of weakness.

[0026] The line of weakness can be made before or after attaching, resp. sealing, sealing of the closure sheet.

[0027] In some implementations, the container body may comprise a flange extending around the opening, the flange having substantially an annular shape, preferably a planar ring shape, the membrane extending along the flange, and the protection sheet extending preferably around the flange. Thus, the flange can provide a support for the membrane on the container body.

[0028] The flange may preferably be integral, more preferably one-piece, with the container body. Alternatively, the protection sheet may extend on and around the flange. In some implementations, the flange may substantially have an annular shape, for example the shape of a circular ring. According to an embodiment, the protection sheet is thermoformed to fit on the container body, the protection sheet being formed directly on the container body, or the protection sheet being first formed on a mold shaped substantially like the container body, and the protection sheet being then attached to the container body, a maximal gap between the container body and the protection sheet being preferably less than 3 mm, preferably less than 1 mm, more preferably less than 0,25 mm, still more preferably 0 mm, the protection sheet being preferably thermoformed on the container body.

[0029] As the gap is small, no or very few air can be present in the packaging, which helps preserve the quality of the food component, e.g. aroma, and lengthens the shelf life of the package product.

[0030] Alternatively to thermoforming, the protection sheet to fit on the container body, blown forming or vacuum forming may also be used.

[0031] According to an embodiment, the container body may comprise: a fiber-based material or derivates or coproducts thereof, said fiber-based being selected from the group consisting of: hemp, flax, bamboo, sisal, kenaf, miscanthus, nettle, wood derivates (MFC, NFC, CNC), a cellulose-based material selected from the group consisting of: paper, wood, bamboo in form of paper, cardboard or pulp-molded parts, a bio-polymer selected from the group consisting of: PLA, PBAT, PCL, PBS, PBSL, PBSA, PBST, PGA, PHA in films (molded, formed) or injected part, and / or - any combination thereof.

[0032] According to an embodiment, the sheet attaching section may be formed by a thermic weld, a laser weld, a glue weld, a compression weld, a friction weld, a ultrasonic weld, and / or any combination thereof.

[0033] Thus, such a weld can provide a seal that is substantially impervious, which can prevent delamination of the respective attaching due to a pressure difference, as well as ingress of dust, humidity and / or air, which in turn lengthens the shelf life of the package product.

[0034] According to an embodiment, the container body may further comprise a flange extending around the opening, the membrane being attached to the flange so as to close the cavity.

[0035] Thus, the membrane can be easily attached to the container body. In some implementations, the body attaching section and the sheet attaching section may extend about the same plane substantially parallel to the opening, the body attaching section being preferably integral, for example one-piece, with the sheet attaching section, or a maximal distance between the flange and the sheet attaching section may being preferably comprised between 1 mm and 20 mm.

[0036] Thus, as the body attaching section and the sheet attaching section may extend substantially at the same level, the package product can be relatively compact, which reduces the quantity of material to be biodegraded, composted, recycled or disposed of.

[0037] Due to the maximal distance the sealing can be strong enough to avoid that the release of a container unseals the neighboring container.

[0038] In some implementations, the closure sheet may be substantially flat. In particular, the closure sheet may extend near the opening.

[0039] In some implementations, the largest dimension of the membrane portion, for example its diameter, is ranging from 15 mm to 150 mm, preferably from 10 mm to 100 mm, more preferably from 12 mm to 70 mm. According to an embodiment, at least one, preferably each one, of the protection sheet and the closure sheet may have an Oxygen Transmission Rate of less than 1 cm3 / m2 / day / bar [cubic centimeter per square meter per day per bar] and a Water Vapor Transmission Rate of less than 1 g / m2 / day / bar [gram per square meter per day per bar] at 23°C [Celsius] and 50% [percent] of Relative Humidity.

[0040] Thus, the protection sheet and / or the closure sheet can form a reliable barrier to oxygen and humidity, which helps preserve the quality, e.g. aroma, of the food component, and lengthens the shelf life of the package product.

[0041] According to an embodiment, at least one of the protection sheet and the closure sheet has an average thickness comprised between 0.1 mm and 10 mm, the closure sheet being possibly planar.

[0042] Thus, the protection sheet and / or the closure sheet can form a reliable barrier to oxygen and humidity, which helps preserve the quality, e.g. aroma, of the food component, and lengthens the shelf life of the package product. According to an embodiment, at least one of the protection sheet and the closure sheet may be made of a material selected from the group consisting of: a biodegradable or compostable material comprising: o a biopolymer-based material with one or more layers selected from the group consisting of: poly(butylene adipate-co-terephthalate) (PBAT), poly(butylene succinate-co-adipate) (PBSA), poly(butylene succinatecolactide) (PBSL), poly(butylene succinate-co-terephthalate) (PBST), poly(butylene succinate) (PBS), lactic acid derived polymers (PLA), polycaprolactones (PCL), polyesteramines (PEA), polyglycolide (PGA), poly(methylene adipate-co-terephthalate) (PTMAT), polyvinyl alcohol, polyhydroxyalkanoate (PHA) or a mixture thereof; and / or o a fiber-based material with one or more layers selected from the group consisting of: cellulose, paper, pulp, wood, wood derivates MFC, NFC and CNC), bamboo, hemp, flax, sisal, kenaf, miscanthus, and nettle and any combination thereof, said fiber-based material having received a chemical pre-treatement or not; said biodegradable or compostable material being provided with at least one barrier layer, the barrier layer being preferably selected from the group consisting of: ethylene vinyl alcohol (EVOH), poly(vinyl alcohol) (PVOH), butenediol vinyl alcohol copolymer (BVOH), polyglycolide (PGA), and a metallization layer preferably made of aluminum, and any combination thereof; a recyclable material comprising: a polymer-based material selected from the group consisting of: polyethylene (PE), polypropylene (PP), polyethylene terephthalate) (PET), polyamid (PA), and polyethylene furanoate) (PEF); preferably, said recyclable material being provided with at least one barrier layer, the barrier layer being preferably selected from the group consisting of: ethylene vinyl alcohol

[0043] (EVOH), poly(vinyl alcohol) (PVOH), butenediol vinyl alcohol copolymer (BVOH), polyglycolide (PGA), and a metallization layer preferably made of aluminum, and any combination thereof.

[0044] Thus, the container body, the membrane and the food component can be biodegradable or compostable or recyclable, while the packaging can protect the food product from air and humidity, thus preserving its quality and lengthening the shelf life of the package product.

[0045] At least one of or each one of the protection and the closure sheet can be made of at least two layers. Besides, the container body can partly or fully be biodegradable and / or compostable.

[0046] The fiber-based material can increase the mechanical resistance of the closure sheet and / or the protection sheet. The biopolymer-based material may be implemented as a laminate, a film, an injected part, or a dispersion coating.

[0047] The, or each barrier layer can help stop or minimize transmission of oxygen (OTR) and / or of water vapor (WVTR). The, or each barrier layer may be applied by thermoforming, dipping, or spray coating. Some of the afore-listed materials can provide the following technical effects:

[0048] - Polyethylene (PE) is a very common plastic available in the field of packaging; PE offers good sealing properties.

[0049] - Polypropylene (PP) is a thermoplastic polymer that can be processed via extrusion and molding, with injection molding being a common shaping technique. PP is recyclable. - Polyethylene terephthalate (PET) can provide a relatively good gas and moisture barrier. PET is recyclable.

[0050] - Polyhydroxyalkanoates (PHAs) are biodegradable polyesters. They can be thermoplastic with melting points ranging from 40 to 180°C. In industrial production, PHAs are produced by microbial fermentation of sugar or glucose and extracted and purified from the bacteria. PHAs can be mainly processed via injection molding, extrusion and extrusion bubbles into films and hollow bodies. One of the simplest and most commonly occurring form of PH A is polyhydroxybutyrate (PHB). Thus, PHB is a bio-derived and biodegradable plastic. PHB is non-toxic and biocompatible and is suitable for medical applications. Further, PHB is a relatively good oxygen barrier. Furthermore, it can provide a dimensionally stable body, since it is biodegradable and biocompostable.

[0051] - Polybutylene terephthalate (PBT) is a thermoplastic polyester, which is usually (semi- )crystalline and resistant to solvents. PBT shrinks very little during forming and it is mechanically strong and heat-resistant up to about 150 °C.

[0052] - Polylactic acid or polylactide (PLA) can be obtained from renewable resources, such as corn starch or sugarcane. PLA is available both as a single enantiomer polymer, i.e. as poly-L- lactide (PLLA) or poly-D-lactide (PDLA), or as a mixture of the two enantiomers. PLA can be processed by extrusion, injection molding, film and sheet casting, as well as spinning. PLA can be recycled to the monomer by thermal depolymerizaton or hydrolysis. When purified, said monomer can be used for the manufacture of virgin PLA with no loss of original properties. - Polyvinyl alcohol (PVOH) is a water-soluble synthetic polymer having excellent film forming, emulsifying and high tensile strength and adhesive properties. It can exhibit a high flexibility, as well as high oxygen and aroma barrier properties. PVOH is preferably used in combination with a suitable stabilizer, such as a PET film, and can be cross-linked to stabilize against moisture. - Ethylene vinyl alcohol (EVOH) is commonly used in food applications. Its primary purpose is to provide barrier properties, primarily as an oxygen barrier for improved food packaging shelf life and as a hydrocarbon barrier. EVOH is typically co-extruded or laminated as a thin layer between cardboard, foil, or other plastics.

[0053] - Polyglycolide or polyglycolic acid (PGA) is a biodegradable, thermoplastic polymer. PGA can be a tough fiber-forming polymer. It has a relatively high hydrolytic stability, which allows the use of PGA in rigid packaging applications without direct food contact. By combining, blending or laminating films or resins of PGA with PET, PLA or PHB, it can be sufficiently stabilized to serve as a barrier material for food packaging.

[0054] In some implementations, mineral fillers like talk or calcium carbonate may be added to the protection sheet and / or to the closure sheet.

[0055] In some implementations, the container body can be made of at least two layers, each layer being made of a material as listed above. It is another object of the present invention to provide a package set comprising a plurality of package products, each package product being in accordance with any one of the preceding object, embodiments or implementations, wherein part or all of the package products are arranged in a row or in a lattice, and wherein the protection sheets of the package products form a first integral sheet and wherein the closure sheets of the package products form a second integral sheet.

[0056] As the packagings are joined by integral protection sheets and closure sheets, the protection sheets on the one hand and the closure sheets on the other hand form a sort of continuum enclosing all package products of the package set. In other words the package products share a common protection sheet and a common closure sheet. Thus, several package products can be manipulated and transported conveniently. Besides, it is easier to recycle the larger common protection and closure sheets than foils of individual portions.

[0057] Thus, the package products can form a regular pattern, which helps the user count the containers left in the package set. According to an embodiment, the package set may include:

[0058] - a first subset of package products arranged at least in a first row or in a first lattice, and

[0059] - a second subset of package products arranged at least in a second row or in a second lattice, wherein, in an assembled state, the package products of the first subset fully or partly mesh with the package products of the second subset such that: i) several package products of the first subset extend fully or partly in interspaces respectively present between two consecutive package products of the second subset, and ii) several package products of the second subset extend fully or partly in interspaces respectively present between consecutive package products of the first subset. Thus, the package set can provide a compact arrangement of the package products, which in turn reduces the storage space thereof or the size of a secondary cover as the case may be.

[0060] As the package products of the first subset fully mesh with the package products of the second subset, there can be a complete overlap in a height dimension of the package products, e.g. the capsules, of the first and second subsets, in which case the package set can be more compact in a height dimension.

[0061] As the package products of the first subset mesh only partially with the package products of the second subset, there can be a partial overlap in the height dimension of the package products, e.g. the capsules, of the first and second subsets, in which case the package set should be less compact in a height dimension but it can be more compact in a width and / or length dimension(s) depending on the shape of each package product.

[0062] It is yet another object of the present invention to provide a method for manufacturing a package product, the method comprising:

[0063] - providing a container comprising a container body defining a cavity and an opening of the cavity,

[0064] - introducing a dose of food component within the cavity, the dose of food component being suitable for interacting with a fluid introduced into the cavity so as to prepare a food product, and

[0065] - forming a packaging by:

[0066] • arranging a protection sheet to cover the container body and to not cover the opening, and

[0067] • arranging a closure sheet to cover the opening and at least part of the protection sheet such that the container is enclosed between the protection sheet and the closure sheet,

[0068] • attaching the protection sheet to the closure sheet along a sheet attaching section, the sheet attaching section extending around the membrane, and.

[0069] - providing the closure sheet with a line of weakness extending around part or all of the membrane, preferably along part or all of the sheet attaching section, such that the closure sheet defines a lid portion, the line of weakness being configured such that it allows at least partial separation of the lid portion from the rest of the closure sheet so as to define a release opening in the closure sheet for the container to be released from the protection sheet.

[0070] Said operations of prodiving a container body, introducing a dose of food component, and forming a packaging can be put in various orders. These operations can be consecutive or there may be some intermediate operation performed in between.

[0071] In some implementations, the protection sheet is arranged to tightly cover an outer side of the container body.

[0072] In some implementations, the protection sheet may be thermoformed around an outer side of the container body. Alternatively, the method may further comprise preforming the protection sheet to have a shape corresponding to an outer side of the container body.

[0073] According to an embodiment, the arranging of the protection sheet may comprise one of thermoforming, blown forming or vacuum forming the protection sheet to fit on the container body by: forming the protection sheet directly on the container body, or first forming the protection sheet on a mold shaped substantially like the container body and then attaching the protection sheet to the container body, wherein a maximal gap between the container body and the protection sheet is being preferably less than 3 mm, preferably less than 1 mm, more preferably less than 0,25 mm, still more preferably 0 mm, the protection sheet being preferably thermoformed on the container body.

[0074] When the protection sheet is formed directly on the container body (online technique), the method can require less operations for manufacturing the package product(s). When the protection sheet is first formed on the container body and then attached to it (offline technique), some method operations can be easier to carry out for manufacturing the package product(s).

[0075] The words "comprise", "include", "have" and their derivatives are to be interpreted inclusively rather than exclusively. The term "and / or" used in the context of "X and / or Y" should be interpreted as "X," or "Y," or "X and Y."

[0076] Brief description of drawings

[0077] Further features, details and advantages of the present invention are described hereinafter, in particular in relation to the appended figures, which illustrate some of the afore-described aspects, embodiments and implementations thereof, and in which:

[0078] Fig.l shows a schematic cross-sectional view of a package product according to an embodiment;

[0079] Fig.2 shows a flowchart of a method for manufacturing the package product of Fig.l;

[0080] Fig.3 shows a view of a package product similar to Fig.l in a stage where a user exerts a force to release the container from the packaging;

[0081] Fig.4 shows a view similar to Fig.l of the package product of Fig.3 in a stage where the container is being released from the packaging;

[0082] Figs.5A, 5B and 5C show a schematic cross-sectional view of a package set according to another embodiment at three stages of a manufacturing method according to an embodiment; Figs.6A, 6B and 6C show views similar to Figs.5A, 5B, 5C of a package set according to another embodiment; Figs.7A, 7B and 7C show views similar to Figs.5A, 5B, 5C of a package set according to yet another embodiment;

[0083] Figs.8A, 8B and 8C show views similar to Figs.5A, 5B, 5C of a package set according to still another embodiment; Fig.9 shows a schematic cross-sectional view of a package set according to yet another embodiment in an unfolded state;

[0084] Fig.10 shows the package set of Fig.9 in a folded state;

[0085] Fig.ll shows a schematic perspective view of the package set of Fig.10. Detailed description

[0086] Fig.l shows a package product 1 comprising a container 2 and a packaging 10. The container 2 comprises a container body 2.0, a dose of food component 4, and a membrane 9. The container body 2.0 defines a cavity 6, in which the dose of food component 4 is contained. The cavity 6 has an opening 8 that is defined by the container body 2.0. The container body 2.0 may have an inner side 2.1, which may form the cavity 6, and an outer side 2.2, which may extend opposite the cavity 6. The container body 2.0 may substantially have a frustoconical shape, hence with a symmetry of revolution. The membrane 9 may substantially have a circular shape, hence with a symmetry of revolution. The cavity 6 may also have a frustoconical shape. Further, the container body 2.0 may comprise a flange 2.3 extending around the opening 8. The flange 2.3 may be one-piece with the container body 2.0. The flange 2.3 may substantially be in the shape of a planar circular ring. The dose of food component 4 is suitable for interacting with a fluid introduced into the cavity 6 so as to prepare a food product. The food component 4 may be ground coffee. In the example of Figs.l and 2 the container 2 is a rigid capsule, and the dose of ground coffee is suitable for preparing a single- serve beverage. When the container 2 is being processed in a not shown preparation machine, hot water, may be injected into the cavity 6 where it can interact with the food component 4 in order to prepare a coffee beverage as the food product to be dispensed by the preparation machine.

[0087] The package product 1 further comprises a packaging 10. The packaging 10 comprises a protection sheet 12, which is arranged to cover the outer side 2.2 of the container body 2.0 and to not cover the opening 8 (nor the top of flange 2.3). The packaging 10 further comprises a closure sheet 14, which is arranged to cover the membrane 9 and the protection sheet 12 around the flange 2.3, such that the container 2 is sealed close between the protection sheet 12 and the closure sheet 14. The closure sheet 14 may be planar in the example of Fig.l. The closure sheet 14 and the protection sheet 12 may be airtight and watertight. The closure sheet 14 and / or the protection sheet 12 may be a multilayered sheet(s). The closure sheet 14 and / or the protection sheet 12 may for example comprise an inner layer of ethylene vinyl alcohol (EVOH) arranged between two outer layers of polypropylene (claim).

[0088] Each one of the protection sheet 12 and the closure sheet 14 may have an average thickness of about 0,5 mm. Each one of the protection sheet 12 and the closure sheet 14 may have an Oxygen

[0089] Transmission Rate of less than 1 cm3 / m2 / day / bar and a Water Vapor Transmission Rate of less than 1 g / m2 / day / bar at 23°C and 50% of Relative Humidity. The protection sheet 12 and the closure sheet 14 can form barriers to dust, oxygen and humidity.

[0090] The container 2 may be sealed close by the impervious closure and protection sheets 14 and 12. The protection sheet 12 may be arranged to tightly cover the outer side 2.2 of the container body 2.0. The protection sheet 12 may be thermoformed on the container body 2.0. The closure sheet 14 and the protection sheet 12 may be sealed to each other along the sheet attaching section 20, which may substantially have an annular shape.

[0091] A maximal gap between the container body 2.0 and the protection sheet 14 may be less than 0,25 mm and preferably 0 mm. The quality of the food component 4 can be well preserved as air and vapor cannot ingress between protection sheet 12 and container body 2.0 and / or as no or very few air can be present in the packaging 10.

[0092] The membrane 9 and the container body 2.0 are attached to each other so as to close the cavity 6. The membrane 9 extends around the opening 8 such that the closure sheet 14 defines a membrane 9 that seals the cavity 6. The membrane 9 may be glued directly to the container body 2.0, preferably to the flange 2.3. The membrane 9 may have a diameter of about 30 mm.

[0093] The closure sheet 14 and the protection sheet 12 are attached to each other along a sheet attaching section 20. The sheet attaching section 20 extends around the membrane 9 and the flange 2.3. A maximal distance between the sheet attaching section 20 and a section where the membrane 9 is attached to the container body 2.0 may be about 5 mm and may be substantially constant.

[0094] The protection sheet 12 may extend around and outside the flange 2.3. The peripheral portion of the membrane 9 may extend along the flange 2.3. The flange 2.3 can provide a support for the membrane 9 on the container body 2.0. As the membrane 9 may have a circular perimeter, the sheet attaching section 20 may also have a circular perimeter of a larger diameter.

[0095] The body attaching section 16 and the sheet attaching section 20 may extend about the same plane, which may be defined by a top face of the flange 2.3 and which may be substantially parallel to the opening 8. In the example of Fig.l, the body attaching section 16 and the sheet attaching section 20 may be slightly distant from one another.

[0096] In the example of Figs.l and 2, a weld may be formed at the sheet attaching section 16. This weld can provide a seal that is substantially impervious to dust, humidity and air, which helps preserve the quality of the food component 4. Most or all of the container 2, in particular the container body 2.0 and the membrane 9, can be biodegradable and / or compostable. The container body 2.0 may be made of one or more layers of pulp material and / or cellulose-based material having preferably more than 80%, of cellulose fibers. The container body 2.0 may a bio-polymer like polylactic acid (PLA). During storage of the package product 1 the container body 2.0 may be protected from outside oxygen and humidity by the protection sheet 12 covering it.

[0097] The closure sheet 14 has a line of weakness 22, which extends all around the membrane 9 and in particular along the sheet attaching section 20, so as to define a lid portion 24. The line of weakness 22 is configured such that it allows a partial or full separation of the lid portion 24 from the rest of the closure sheet 14 under a manual force F of say 20 N exerted on the protection sheet 12 to press the container 2 against the closure sheet 14 such that the line of weakness 22 tears partly or totally open and define a release opening in the closure sheet 14 for the container 2 to be released from the protection sheet 12.

[0098] The line of weakness 22 may extend along the sheet attaching section 20, so as to define the release opening in the closure sheet 14 to allow release of the container 2 from the protection sheet 12. The line of weakness 22 may be made by mechanical stamping or indenting. The line of weakness 22 may be a score line, which extends only partly through the closure sheet 14, hence not through the whole thickness of the closure sheet 14, thus enhancing the water- and airtightness of the package product 1.

[0099] The line of weakness 22 may also be separated from the attaching section 20 and extend on the portion of the closure sheet 14 facing the membrane 9. The line of weakness 22 may also be of any geometry allowing opening of the closure sheet 14. It may be for example in the form of a cross on the surface of the closure sheet 14. A user can easily detach the assembly of the container 2 by pushing the container body 2.0 with the force F so as to tear open the line of weakness 22, and then release the container through the opening 8. The container 2, which includes the container body 2.0, the food component 4 and the membrane 9, can be safely manipulated and processed in a not shown beverage preparation machine.

[0100] Fig.2 shows a method 100 for manufacturing the package product 1. The method 100 comprises:

[0101] - 102) providing the container 2 comprising the container body 2.0 defining i) the cavity 6 and ii) the opening 8 of the cavity 6,

[0102] - 104) introducing the dose of food component 4 within the cavity 6, - 106) attaching the membrane 9 to the container body 2.0 so as to close the cavity 6, and

[0103] - 106) forming the packaging 10 by:

[0104] • 108) arranging the protection sheet 12 to cover the container body 2.0, and

[0105] • 110) arranging the closure sheet 14 to cover the membrane 9 and at least part of the protection sheet 12 such that the container 2 is enclosed, preferably sealed close, between the protection sheet 12 and the closure sheet 14,

[0106] • 112) attaching the protection sheet 12 to the closure sheet 14 along the sheet attaching section 10, the sheet attaching section 10 extending around the membrane 9.

[0107] Further, the method 100 may comprise, either before or after placing the food component 4 within the cavity 6, 114) thermoforming the protection sheet 12 around the outer side 2.3 of the container body 2.0, hence directly on the container body 2.

[0108] Alternatively to thermoforming, other methods for applying the protection sheet 12 around the outer side 2.3 of the container body 2.0 may be used like blown forming or vacuum forming.

[0109] Figs.3-4 show a package product 1 comprising a container 2 and a packaging 10, which are similar to the ones depicted in relation to Fig.l, apart from the following main differences. Like in the embodiment of Fig.l the container 2 comprises i) a container body 2.0, ii) a cavity 6 containing a food component, and iii) a membrane 9 closing the cavity 4. The container 2 may be a rigid single-serve capsule of ground coffee. Like in the embodiment of Fig.l the packaging 10 of Fig.3 comprises a protection sheet 12 and a closure sheet 14.

[0110] The line of weakness 22 in Fig.3 may substantially have a linear design instead of the circular design in Fig.l. The line of weakness 22 in Fig.3 extends near the membrane 9. The closure sheet

[0111] 14 in Fig.4 may be include a paper or cardboard layer in addition to the plastic film of the embodiment of Fig.l. A user can exert a manual force F on the protection sheet 12 to press the container 2 against the closure sheet 14. As shown in Fig.4 and like in the embodiment of Fig.l, the line of weakness 22 allows, under the force F, separation of a lid portion 24 from the rest of the closure sheet 14 such that the line of weakness 22 tears open and defines a release opening 26 in the closure sheet 14 for the container 2 to be released from the protection sheet 12. As the line of weakness 22 has a linear design in Fig.3, there is only a partial separation of the lid portion 24 from the rest of the closure sheet 14, but the release opening 26 resulting from this partial separation is large enough for the container 2 to be released from the protection sheet 12.

[0112] Figs.5A-5C show a package set 201 in a manufacturing step. The package set 201 comprises a plurality of package products 1. Each of the two illustrated package products 1 is substantially as described above in relation to Fig.l. The package products 1 are arranged in a row. Their protection sheets 12 form a first integral sheet 212 and their closure sheets 14 form a second integral sheet 214.

[0113] As the packagings 10 are joined side-by-side by the protection sheets 12 and closure sheets 14, the protection sheets 12 on the one hand and the closure sheets 14 on the other hand form a sort of continuum enclosing all package products 1 of the package set 201. In other words the package products 1 share i) a common protection sheet, i.e. the first integral sheet 212, and ii) a common closure sheet, i.e. the second integral sheet 214. The package products 1 can be manipulated and transported conveniently. As visible in the sequence of Figs.5A and 5B, the common protection sheet 212 may be provided and thermoformed, in a mold M, onto the container bodies 2.0 of the package products 1.

[0114] In a non-illustrated alternative, the protection sheets could be first formed on a mold shaped substantially like the container body and then attached, preferably sealed, to the container body. So the operations 102 to 112 may be performed in various orders. For example, the container bodies 2.0 may first be provided empty. Then the protection sheets

[0115] 212 may be attached, preferably sealed to the container bodies 2.0. After that, the cavities 6 may be filled in with food component 4. Then the cavities 6 may be sealed closed by gluing the membranes 7 to the flanges 2.3. Finally, the closure sheets 14 may be attached to respective protection sheets 12 by welding the second integral sheet 214 to the first integral sheet 212 at the sheet attaching sections 20.

[0116] Accordingly, the arranging of the protection sheet 12 to fit on the container body 2 may comprise: first forming the protection sheet 12 on a mold shaped substantially like the container body 2 and then attaching the protection sheet 12 to the container body 2. After the thermoforming stage of Fig.5 B, the common protection sheet 212 (first integral sheet) and the common closure sheet 214 (second integral sheet) and may be attached, e.g. by laser welding between two consecutive containers 2.

[0117] Figs.6A-6C show a package set 201 similar to the one depicted in relation to Fig.5A-5C, apart from the following main differences. Unlike in the embodiment of Figs.5A-5C, each container 2 may have a container body 2.0 and a membrane 9 that are substantially symmetrical to one another.

[0118] Unlike in the embodiment of Figs.5A-5C, the containers 2 may be formed by first providing, in Fig.6A, a common container body 202.0, which is formed by an integral sheet that is common to at least two containers 2. In Fig.6B a laser beam may be used to cut a layer that spans the container bodies 202.0 such that each container body 202.0 is individualized. Then, the food component 4 may be placed in the container body 2.0, and a common membrane 9 may be arranged to enclose the food component 4 and complete the containers 2.

[0119] As a particular feature of the embodiment of Figs.6A-6C the common protection and closure sheets 212 and 214 may be pre-formed before filling in the containers 2.

[0120] The operations illustrated in Fig.6A-6C may be carried out in a different order. For example, a preliminary operation may comprise producing a flat laminate of at least two layers including the protection sheet and a body sheet (e.g. paper-based), and then mold the laminate into the shape of containers to form the cavities. Figs.7A-7C show a package set 201 similar to the one depicted in relation to Fig.6A-6C, apart from the following main differences. Unlike in the embodiment of Figs.6A-6C, the containers 2 -i.e. bodies, food components and membranes- may be provided in one piece instead of being assembled piecewise. Unlike in the embodiment of Figs.6A-6C, the common protection and closure sheets 212 and 214 may be thermoformed tightly around the containers 2 instead of being pre-formed. Figs.8A-8C show a package set 201 similar to the one depicted in relation to Fig.6A-6C, apart from the following main differences. Unlike in the embodiment of Figs.6A-6C, the containers 2 -i.e. bodies, food components and membranes- may be provided in one piece like in Fig.8B, instead of being assembled piecewise. Unlike in the embodiment of Figs.6A-6C, the common protection sheet 212 may be held and formed by vacuum represented by all the arrows in Figs.8A and 8B, before putting the containers 2. Then the common closure sheet 214 of Fig.8B may be thermoformed like in Figs.7A-7C.

[0121] Figs.9, 10, 11 show a package set 201 similar to the one shown in Figs.5A-5C and which may include a first subset 201.1 of package products 1, which are arranged in a first row of say 5 package products, and a second subset 201.2 of package products 1, which are arranged in a second row of say 5 package products.

[0122] In an assembled state (Fig.10), the package products 1 of the first subset 201.1 mesh almost fully with the package products 1 of the second subset 201.2 such that each the package product 1 of the first subset 201.1 extend almost fully in an interspace 230 present between two consecutive package products 1 of the second subset 201.2.

[0123] In the assembled state (Fig.10), the package products 1 of the second subset 201.2 mesh almost fully with the package products 1 of the first subset 201.1 such that each package product 1 of the second subset 201.2 extend almost fully in an interspace 230 present between two consecutive package products 1 of the first subset 201.1.

[0124] The package set 201 may further comprise a foldable portion 222, which links the first subset 201.1 with the second subset 201.2. By means of the foldable portion 222, the package set 201 may be in an unfolded state in Fig.9 and in an folded state in Fig.10. The foldable portion 222 may preferably include respective portions of the closure sheet 14 and of the protection sheet 12. The package set 201 can provide a compact arrangement of the package products 1, which in turn reduces the storage space thereof or the size of an optional secondary cover 240.

[0125] As shown in Fig.11, to release a container from the first subset 201.1 or the second subset 201.2, a user can tear open the secondary cover 240 and then exert a manual force F to push the container 2 upwards to press it against the lid portion 24 until the line of weakness 22 tears open and the container 1 can be released through the release opening.

[0126] The invention defined in the appended claims is not limited to the afore-described objects, aspects, embodiments and implementations, most of which may be combined.

Claims

Claims1. Package product (1) comprising a container (2) and a packaging (10): wherein the container (2) comprises: - a container body (2.0) defining a cavity (6) and an opening (8) of the cavity (6), a dose of food component (4) contained within the cavity (6), the dose of food component (4) being suitable for interacting with a fluid introduced into the cavity (6) so as to prepare a food product, and a membrane (9) attached to the container body (2.0) so as to close the cavity (6), wherein the packaging (10) comprises: a protection sheet (12) arranged to cover an outer side (2.2) of the container body (2.0), and a closure sheet (14) arranged to cover the membrane (9) and at least part of the protection sheet (12), such that the container (2) is enclosed between the protection sheet (12) and the closure sheet (14), wherein the closure sheet (14) and the protection sheet (12) are attached to each other along a sheet attaching section (20), the sheet attaching section (20) extending around the membrane (9), and wherein the closure sheet (14) has a line of weakness (22) extending near or around part or all of the membrane (9), the line of weakness (22) being configured such that it allows at least partial separation of a lid portion (24) from the rest of the closure sheet (14) under a manual force (F) exerted on the protection sheet (12) to press the container (2) against the closure sheet (14) such that the line of weakness (22) tears partly or totally open and defines a release opening (26) in the closure sheet (14) for the container (2) to be released from the protection sheet (12).

2. Package product (1) according to claim 1, wherein the line of weakness (22) extends around part or all of the sheet attaching section (20), preferably along part or all of the sheet attaching section (20), so as to define a release opening in the closure sheet (14) allowing release of the container (2) from the protection sheet (12).

3. Package product (1) according to any one of the preceding claims, wherein the line of weakness (22) is made of a perforation line, a score line or a combination thereof, the line of weakness (22) being preferably formed mechanically or by laser.

4. Package product (1) according to any one of the preceding claims, wherein the protection sheet (12) is thermoformed, blown formed or vacuum formed to fit on the container body (2-0), the protection sheet (12) being formed directly on the container body (2), or the protection sheet (12) being first formed on a mold shaped substantially like the container body (2), and the protection sheet (12) being then attached to the container body (2), a maximal gap between the container body (2.0) and the protection sheet (12) being preferably less than 3 mm, preferably less than 1 mm, more preferably less than 0,25 mm, still more preferably 0 mm, the protection sheet (12) being preferably thermoformed on the container body (2.0).

5. Package product (1) according to any one of the preceding claims, wherein the container body (2.0) comprises: a fiber-based material or derivates or coproducts thereof, said fiber-based being selected from the group consisting of: hemp, flax, bamboo, sisal, kenaf, miscanthus, nettle, wood derivates (MFC, NFC, CNC), a cellulose-based material selected from the group consisting of: paper, wood, bamboo in form of paper, cardboard or pulp-molded parts, a bio-polymer selected from the group consisting of: PLA, PBAT, PCL, PBS, PBSL, PBSA, PBST, PGA, PHA in films (molded, formed) or injected part, and / or any combination thereof.

6. Package product (1) according to any one of the preceding claims, wherein the sheet attaching section (20) is formed by a thermic weld, a laser weld, a glue weld, a compression weld, a friction weld, a ultrasonic weld, and / or any combination thereof.

7. Package product (1) according to any one of the preceding claims, wherein the container body (2.0) further comprises a flange (2.0) extending around the opening (8), the membrane (9) being attached to the flange (2.3) so as to close the cavity (6).

8. Package product (1) according to claim 7 , wherein a maximal distance between the flange (2.3) and the sheet attaching section (20) is comprised between 1 mm and 20 mm.

9. Package product (1) according to any one of the preceding claims, wherein at least one, preferably each one, of the protection sheet (12) and the closure sheet (14) has an Oxygen Transmission Rate of less than 1 cm3 / m2 / day / bar and a Water VaporTransmission Rate of less than 1 g / m2 / day / bar at 23°C and 50% of Relative Humidity.

10. Package product (1) according to any one of the preceding claims, wherein at least one of the protection sheet (12) and the closure sheet (14) has an average thickness comprised between 0.1 mm and 10 mm, the closure sheet (14) being possibly planar.

11. Package product (1) according to any one of the preceding claims, wherein at least one of the protection sheet (12) and the closure sheet (14) is made of a material selected from the group consisting of: - a biodegradable or compostable material comprising: o a biopolymer-based material with one or more layers selected from the group consisting of: poly(butylene adipate-co-terephthalate) (PBAT), poly(butylene succinate-co-adipate) (PBSA), poly(butylene succinatecolactide) (PBSL), poly(butylene succinate-co-terephthalate) (PBST), poly(butylene succinate) (PBS), lactic acid derived polymers (PLA), polycaprolactones (PCL), polyesteramines (PEA), polyglycolide (PGA), poly(methylene adipate-co-terephthalate) (PTMAT), polyvinyl alcohol, polyhydroxyalkanoate (PHA) or a mixture thereof; and / or o a fiber-based material with one or more layers selected from the group consisting of: cellulose, paper, pulp, wood, wood derivates MFC, NFC and CNC), bamboo, hemp, flax, sisal, kenaf, miscanthus, and nettle and any combination thereof, said fiber-based material having received a chemical pre-treatement or not;said biodegradable or compostable material being provided with at least one barrier layer, the barrier layer being preferably selected from the group consisting of: ethylene vinyl alcohol (EVOH), poly(vinyl alcohol) (PVOH), butenediol vinyl alcohol copolymer (BVOH), polyglycolide (PGA), and a metallization layer preferably made of aluminum, and any combination thereof; a recyclable material comprising: a polymer-based material selected from the group consisting of: polyethylene (PE), polypropylene (PP), polyethylene terephthalate) (PET), polyamide (PA), and poly(ethylene furanoate) (PEF); preferably, said recyclable material being provided with at least one barrier layer, the barrier layer being preferably selected from the group consisting of: ethylene vinyl alcohol(EVOH), poly(vinyl alcohol) (PVOH), butenediol vinyl alcohol copolymer (BVOH), polyglycolide (PGA), and a metallization layer preferably made of aluminum, and any combination thereof.

12. Package set (201) comprising a plurality of package products (1), each package product (1) being in accordance with any one of the preceding claims, wherein part or all of the package products (1) are arranged in a row or in a lattice, and wherein the protection sheets (12) of the package products (1) form a first integral sheet (212) and wherein the closure sheets (14) of the package products (1) form a second integral sheet (214).

13. Package set (1) according to claim 12, further including: a first subset (201.1) of package products (1) arranged at least in a first row or in a first lattice, and a second subset (201.2) of package products (1) arranged at least in a second row or in a second lattice, wherein, in an assembled state, the package products (1) of the first subset (201.1) fully or partly mesh with the package products (1) of the second subset (201.2) such that: i) several package products (1) of the first subset (201.1) extend fully or partly in interspaces (230) respectively present between consecutive package products (1) of the second subset (201.2), andii) several package products (1) of the second subset (201.2) extend fully or partly in interspaces respectively present between consecutive package products (1) of the first subset (201.1).

14. Method (100) for manufacturing a package product (1), the method (100) comprising:102) providing a container (2) comprising a container body (2.0) defining i) a cavity (6) and ii) an opening of the cavity (6),104) introducing a dose of food component (4) within the cavity (6), the dose of food component (4) being suitable for interacting with a fluid introduced into the cavity (6) so as to prepare a food product,106) attaching a membrane (9) to the container body (2.0) so as to close the cavity (6), and 108) forming a packaging (10) by:• arranging a protection sheet (12) to cover the container body (2.0), and• arranging a closure sheet (14) to cover the membrane (9) and at least part of the protection sheet (12) such that the container (2) is enclosed between the protection sheet (12) and the closure sheet (14),• attaching the protection sheet (12) to the closure sheet (14) along a sheet attaching section (20), the sheet attaching section (20) extending around the membrane (9), and110) providing the closure sheet (14) with a line of weakness (22) extending around part or all of the membrane (9), preferably along part or all of the sheet attaching section (20), such that the closure sheet (14) defines a lid portion (24), the line of weakness (22) being configured such that it allows at least partial separation of the lid portion (24) from the rest of the closure sheet (14) so as to define a release opening in the closure sheet (14) for the container (2) to be released from the protection sheet (12).

15. Method according to claim 14, wherein the arranging of the protection sheet (12) comprises one of thermoforming, blown forming or vacuum forming the protection sheet (12) to fit on the container body (2) by: forming the protection sheet (12) directly on the container body (2), or - first forming the protection sheet (12) on a mold shaped substantially like the container body (2) and then attaching the protection sheet (12) to the container body (2),wherein a maximal gap between the container body (2.0) and the protection sheet (12) is being preferably less than 3 mm, preferably less than 1 mm, more preferably less than 0,25 mm, still more preferably 0 mm, the protection sheet (12) being preferably thermoformed on the container body (2.0).

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