Method for manufacturing a container for holding edible material, method for providing a packaged edible product, blank of paper or paperboard for forming a side wall of a container and container for holding edible material

Abstract

The present invention concerns a method for manufacturing a container (1) for holding edible material, in particular yogurt, the container (1) including a sidewall (2) and a bottom (3) and having a top filling opening (6), which is configured to be closed by joining together opposing regions of the side wall (2), in particular after filling the container (1) via the top filling opening (6), the method comprising the following method steps: ̶ providing a blank (100) of paper or paperboard for forming a side wall (2) of the container (1) by cutting the blank (100) from a sheet of paper or paperboard; ̶ providing a tear line (110) in the blank (100), or in an area of the sheet (99) intended to form the blank (100) after cutting, respectively; ̶ applying a barrier material on the tear line (110); ̶ forming the side wall (2) of the container (1) from the blank (100); and ̶ providing the bottom (3) and joining the bottom (3) with the side wall (2) to form a container (1) having the top filling opening (6).

Description

[0001] Method for manufacturing a container for holding edible material, method for providing a packaged edible product, blank of paper or paperboard for forming a side wall of a container and container for holding edible material

[0002] The invention concerns a method for manufacturing a container for holding edible material, in particular yogurt, the container including a sidewall, a bottom and a top opening. Further, the invention concerns a method for providing a packaged edible product. The invention further concerns a blank of paper or paperboard for forming a side wall of a container. Additionally, the invention concerns a container for holding edible material comprising a sidewall, a bottom and a top opening.

[0003] The invention can be applied in the field of the food packaging, in particular in the field of packaging of edible substances like yogurt.

[0004] Yogurt is typically packaged in containers comprising a cup having a side wall and a bottom connected to the side wall, e.g., the cup being made from plastics. The cup usually comprises a top opening via which the yogurt is filled. Said top opening may be surrounded by a flangelike rim. After filling the yogurt into the cup, the container may be closed by connecting a lid to the side wall of the cup, for example to the flange-like rim surrounding the top opening. Thereby, the top opening is closed to protect the yogurt from external influences and avoid product leakage during transport. The lid material is typically thin and not resistant to unintended perforation. Thus, there is a risk of unintended opening of the container during transport. Additionally, the cup and the lid are often made from different materials which comes with the disadvantage that the cup and the lid need to be recycled in different processes.

[0005] Against this background, the problem underlying the invention is to provide a container for holding edible material which is resistant to unintended opening and leakage and can be recycled with less effort.

[0006] According to an aspect of the i n v e n t i o n , there is provided a method for manufacturing a container for holding edible material, in particular yogurt, the container including a sidewall and a bottom and having a top filling opening, which is configured to be closed by joining together opposing regions of the side wall, in particular after filling the container via the top filling opening, the method comprising the following method steps:

[0007] - providing a blank of paper or paperboard for forming a side wall of the container by cutting the blank from a sheet of paper or paperboard;

[0008] - providing a tear line in the blank, or in an area of the sheet intended to form the blank after cutting, respectively;

[0009] - applying a barrier material on the tear line;

[0010] - forming the side wall of the container from the blank; and

[0011] - providing the bottom and joining the bottom with the side wall to form a container having the top filling opening.

[0012] The inventive method allows manufacturing the container using a single paper or paperboard material. Using said method there is no need to provide a lid and connect the lid to the rest of the container after filling the container with the edible material. Instead, the edible material may be filled into the open container comprising the bottom and the side wall joined to the bottom, and then the container may be closed by joining together opposing regions of the side wall. To access the edible material inside the container, the side wall may be torn along the tear line thereby opening the container. The barrier material applied to the tear line avoids soaking of the side wall by the edible material and avoids leakage of the edible material through the side wall. Thus, the inventive method provides a container for holding edible material which is resistant to unintended opening and leakage and can be recycled with less effort.

[0013] In the context of this application, the tear line is considered a contiguous area wherein the paper or paperboard material is weakened, e.g., such that the paper or paperboard material is more likely to tear along the tear line than in another area. For example, the tear line may allow the paper or paperboard material to be torn along the tear line when applying a force in the range of 4 to 25 N, whereas the material in another area of the paper or paperboard material can only be torn when applying a force above 30 N, e.g., a force in the range of 30 to 80 N.

[0014] In the context of this application, the barrier material is considered a barrier material that increases the resistance of a substrate it is applied to against the influence of liquids, e.g., water and / or oil. When applying the barrier material to the tear line, the barrier material serves to repair the damage to the inherent barrier of the paper or paperboard material due to the provision of the tear line. The inherent barrier of the paper or paperboard material may include a barrier layer, e.g., a polymer barrier layer like a polyethylene (PE) barrier layer or a varnish barrier layer. Applying the barrier material to the tear line preferably includes applying the barrier material on the tear line and a surrounding of the tear line having a width in the range of 1 mm to 5 mm on both sides of the tear line. Applying the barrier material preferably comprises applying the barrier material such that the barrier material increases the paper weight of the paper or paperboard material by a value in the range of 3 gsm to 20 gsm. Applying the barrier material preferably comprises applying the barrier material in a layer having a thickness in the range of 10 to 40 microns. The barrier material preferably modifies the paper or paperboard material such that it has a COBB water value and / or COBB oil value below 50 g / m2, more preferably below 20 g / m2. The barrier material preferably modifies the paper or paperboard material such that it has a WVTR value below 50 g / m2 / day, more preferably below 20 g / m2 / day.

[0015] The paper or paperboard is preferably coated paper or coated paperboard. The coated paper or coated paperboard is preferably coated only on one side of the paper or paperboard. Alternatively, the coated paper or coated paperboard may be coated on both sides. The coated paper or coated paperboard may comprise a polymer coating, e.g., a polyethylene, PE, coating.

[0016] Preferably, the bottom is provided by cutting from a sheet of paper or paperboard, in particular the same paper or paperboard that is used for providing the blank for forming the side wall.

[0017] Cutting the blank and / or cutting the bottom from the sheet of paper or paperboard may be implemented using die cutting and / or laser cutting. Alternatively, other cutting methods can be used.

[0018] The bottom may have a circular shape. Alternatively, the bottom may have oval or rectangular shape. The side wall may be connected to the bottom such that the side wall runs around the bottom, in particular runs around the circumference of the bottom.

[0019] According to a preferred embodiment of the invention, the tear line is provided in the blank or sheet, respectively, such that after forming the container the tear line is arranged in a region between the bottom of the container and the top opening of the container. After the opening of the container has been closed by joining together opposing regions of the side wall, the container may be opened along the tear line, thereby creating a product access opening in the container. The product access opening is arranged closer to the bottom than the initially available top filling opening of the container which is used for filling the product into the container. According to a preferred embodiment of the invention, the tear line is provided in the blank or sheet, respectively, such that after forming the container the tear line is arranged circumferentially around the side wall. Such embodiment allows to separate the side wall completely along the tear line. For example, a top part of the side wall, e.g. a part forming a cover of the container, may be completely removed from the rest of the side wall, above the tear line from the part below the tear line. Thereby, a product access opening may be provided which is arranged at a top of the container, thereby providing a cup-like appearance of the opened container.

[0020] According to a preferred embodiment of the invention, applying a barrier material on the tear line includes applying the barrier material on a surface of the blank or sheet, respectively, that is intended to form the inside of the side wall of the container. By providing the tear line in the side wall, the side wall is vulnerable to being soaked by moisture or to being penetrated by moisture at the tear line. Applying the barrier material on the interior side of side wall along the tear line, therefore, restores the resistance of the paper or paperboard material against moisture influence at the tear line on the surface of the side wall that is more likely to be influenced by moisture.

[0021] According to a preferred embodiment of the invention, the tear line comprises a scoring line. More preferably, the tear line is a scoring line. Along the scoring line the paper or paperboard material may have a reduced material thickness as compared to another area of the paper or paperboard material. Thus, the paper or paperboard material is weakened along the scoring line but still provides a continuous surface, e.g., a surface without through holes. Preferably the thickness of the paper or paperboard material along the scoring line is reduced to a value below 70% of the thickness of the paper or paperboard material in another area, preferably to a value in the range of 60% to 70% of the ness of the paper or paperboard material in another area.

[0022] According to a preferred embodiment of the invention, the tear line comprises a perforation line. More preferably, the tear line is a perforation line. Along the perforation line the paper or paperboard material may have multiple through holes. Thus, the paper or paperboard material is weakened along the perforation line and does provide a discontinuous surface, e.g., a surface with through holes.

[0023] According to a preferred embodiment of the invention, the tear line is provided using a laser. The tear line may be provided as a scoring line using a laser, wherein a laser beam cuts a groove in the paper or paperboard material and / or a laser beam reduces the thickness of the paper or paperboard material along the tear line. The tear line may be provided as a perforation line using a laser, wherein a laser beam cuts through holes in the paper or paperboard material along the tear line.

[0024] According to a preferred embodiment of the invention, the tear line is provided using compression forces, in particular ultrasonic or mechanical compression forces. The tear line may be provided as a scoring line using compression forces which compress the paper or paperboard material along the tear line, thereby reducing the thickness of the paper or paperboard material. The tear line may be provided as a perforation line using compressing forces that shear the paper or paperboard material thereby generating through holes. For example, the perforation line may be generated by using pins or needles, e.g., pins or needles on a roller, or by using a die and punch combination.

[0025] According to a preferred embodiment of the invention, applying the barrier material comprises spraying the barrier material on the tear line. Spaying the barrier material allows for reliable application of the barrier material. Preferably, the barrier material used for spraying has a viscosity below 2000 mPa s.

[0026] According to a preferred embodiment of the invention, applying the barrier material comprises printing the barrier material on the tear line. Preferably, the barrier material used for printing has a viscosity below 2000 mPa s.

[0027] According to a preferred embodiment of the invention, joining the bottom with the side wall comprises folding a bottom part of the side wall around a peripheral region of the bottom. Joining may include applying heat for bonding the side wall and the bottom and / or applying an adhesive.

[0028] According to a preferred embodiment of the invention, after joining the bottom with the side wall an additional barrier material is applied on an inside connection region of the side wall and the bottom. Applying the additional barrier material may prevent moisture and contaminations to reach the area between the bottom and the side wall folded around the peripheral region of the bottom. Thereby, disinfecting the interior of the container, in particular before filling the container with edible material, may be facilitated. The additional barrier material ma be the same barrier material as applied to the tear line. The additional barrier material may be apply using the same techniques as the for applying the barrier material to the tear line, e.g., spraying. According to a further aspect of the i n v e n t i o n , a method is provided for providing a packaged edible product, comprising the following method steps:

[0029] - manufacturing a container for holding edible material using a method according to any of the preceding claims;

[0030] - filling the container with edible material, in particular with yogurt, via the top filling opening; and

[0031] - joining together opposing regions of the side wall thereby closing the top filling opening and forming a top cover of the container.

[0032] The inventive method provides a container for holding edible material which is resistant to unintended opening and leakage and can be recycled with less effort.

[0033] According to a further aspect of the i n v e n t i o n , a blank of paper or paperboard for forming a side wall of a container is provided, having a tear line, which is coated with a barrier material at least on one surface of the blank.

[0034] The inventive blank allows to provide a container for holding edible material which is resistant to unintended opening and leakage and can be recycled with less effort.

[0035] According to a further aspect of the i n v e n t i o n , a container for holding edible material is provided, comprising a side wall, a bottom, and a top filling opening, wherein the top filling opening is configured to be closed by joining together opposing regions of the side wall, in particular after filling the container via the top filling opening, wherein the side wall comprises a tear line, which is coated with a barrier material on an interior surface of the container.

[0036] The inventive container is resistant to unintended opening and leakage and can be recycled with less effort.

[0037] The preferred embodiments and optional features elucidated with respect to the method of for manufacturing a container for holding edible material and / or the method for providing a packaged edible product may - alone or in combination - be employed with the inventive blank and / or the inventive container.

[0038] Further details and advantages of the invention will be elucidated in the following with reference to the embodiments shown in the figures.

[0039] Fig. 1 depicts a blank according to an exemplary embodiment of the present invention; Fig. 2 depicts a container according to an exemplary embodiment of the present invention with a top filling opening in a perspective view;

[0040] Fig. 3 depicts different views of a container according to an exemplary embodiment of the present invention after having closed the filling opening by joining opposing regions of the side wall;

[0041] Fig. 4 depicts different views of a container according to an exemplary embodiment of the present invention after having partly opened the container along the tear line; and

[0042] Fig. 5 depicts different views of a container according to an exemplary embodiment of the present invention after having opened the container even further along the tear line.

[0043] Fig. 1 depicts a blank 100 of paper or paperboard for forming a side wall 2 of a container 1. The container 1 is preferably a container for holding edible material, like yogurt. The blank 100 has an outline 101 represented by a solid line. Further solid lines 102 are shown within the outline 101 and represent lines along which the material may be folded during use as a side wall 2 of a container 1.

[0044] The blank 100 includes multiple tear lines 110, which are contiguous areas wherein the paper or paperboard material is weakened, e.g., such that the paper or paperboard material is more likely to tear along the tear lines than in other areas. The tear lines may be provided as scoring lines and / or as perforation lines. To avoid soaking of the side wall 2 by the edible material and / or avoid leakage of the edible material through the side wall 2, the tear lines 110 are coated with a barrier material at least on the surface of the blank which is intended to be the inside of the side wall 2.

[0045] The blank 100 may be provided by cutting the blank 100 from a sheet of paper or paperboard. The tear line 110 may be provided either in the blank 100, or in an area of the sheet intended to form the blank 100 after cutting, respectively. The barrier material is applied on the tear line 110 either before cutting the blank 100 from the sheet, so that the tear line 110 is part of the sheet, or after cutting the blank 100 from the sheet, so that the tear line 110 is part of the blank 100. The barrier material may be applied by spraying and / or printing the barrier material on the tear line 110. Preferably, the barrier material in only applied to the surface of the sheet or blank along a small region on both sides of the tear line 110. For example, the region wherein the barrier material is applied nay have a width of in the range of 1 mm to 5 mm on both sides of the tear line 110.

[0046] Fig. 2 depicts a schematic perspective view of a container 1 for holding edible material comprising a side wall 2, a bottom 3, and a top filling opening 6, wherein the top filling opening 6 is configured to be closed by joining together opposing regions 2.1 , 2.2 of the side wall 2, in particular after filling the container 1 via the top filling opening 6. The side wall 2 may be manufactured from a blank as depicted in Fig. 1 , the blank comprising a tear line 110 which is coated with a barrier material on the surface intended to form the interior surface of the container 1. Thus, the resulting side wall 2 comprises the tear line 110.

[0047] Fig. 3 depicts different views of a packaged edible product including a container 1 for holding edible material. Whereas view a) is a top view, views b) and c) are side views showing the container 1 from different sides and view d) is a bottom view. The container 1 comprises a side wall 2 and a bottom 3. A top filling opening of the container 1 is closed, wherein opposing regions of the side wall 2 are joined together, thereby providing a top cover 5.

[0048] For manufacturing the container 1, a blank, e.g., a blank 100 as shown in Fig. 1 , has been provided and the side wall 1 of the container 2 has been formed from the blank 100. For this to happen, two side regions of the blank 100 may be joined along a side seam. A bottom 3, in particular a bottom blank, may be provided separately from the blank 100 for forming the side wall 2. Both, the bottom 3 and the side wall 2 may be joined to form a cup-like container with a top opening. The edible material, e.g., yogurt, may be filled into the cup-like container through the top opening. After filling, the top opening is closed by joining together opposing regions of the side wall 2 thereby closing the top filling opening and forming the top cover 5 of the container 1.

[0049] View b) contains a partial sectional view of the connection region of the bottom 3 and the side wall 2 of the cup. Here, it is apparent that a bottom part of the side wall 2 is folded around a peripheral region of the bottom 3, namely a peripheral region of the bottom 3 that is folded downwards. Joining the bottom 3 and the side wall 2 may include applying heat for bonding the side wall 2 and the bottom 3 and / or applying an adhesive between the adjacent regions of the side wall 2 and the bottom 3.

[0050] After joining the bottom 3 with the side wall 2 an additional barrier material may be applied on an inside connection region of the side wall 2 and the bottom 3. Thus, a channel formed at the joint between the bottom 3 and the side wall 2 may be closed by the additional barrier material.

[0051] Fig. 4 depicts the packaged edible product including the container 1 according to Fig. 3 wherein the tear line 110 is partly opened. Views a) and b) are side views showing the container 1 from different sides.

[0052] Fig. 5 depicts the packaged edible product including the container 1 according to Fig. 3 wherein the tear line 110 is even further opened. Views a) and b) are side views showing the container 1 from different sides.

[0053] Reference Signs:

[0054] 1 container

[0055] 2 side wall

[0056] 2.1 , 2.2 opposing sides

[0057] 3 bottom

[0058] 4 side seam

[0059] 5 top cover

[0060] 6 top filling opening

[0061] 100 blank

[0062] 101 outline

[0063] 110 tear line

Claims

Patent Claims:

1. Method for manufacturing a container (1) for holding edible material, in particular yogurt, the container (1) including a sidewall (2) and a bottom (3) and having a top filling opening (6), which is configured to be closed by joining together opposing regions of the side wall (2), in particular after filling the container (1) via the top filling opening (6), the method comprising the following method steps:- providing a blank (100) of paper or paperboard for forming a side wall (2) of the container (1) by cutting the blank (100) from a sheet of paper or paperboard;- providing a tear line (110) in the blank (100), or in an area of the sheet intended to form the blank (100) after cutting, respectively;- applying a barrier material on the tear line (110);- forming the side wall (2) of the container (1) from the blank (100); and- providing the bottom (3) and joining the bottom (3) with the side wall (2) to form a container (1) having the top filling opening (6).

2. Method according to claim 1 , wherein the tear line (11) is provided in the blank (100) or sheet, respectively, such that after forming the container (1) the tear line (110) is arranged in a region between the bottom (3) of the container and the top opening (6) of the container (1).

3. Method according to any of the preceding claims, wherein the tear line (11) is provided in the blank (100) or sheet, respectively, such that after forming the container (1) the tear line (110) is arranged circumferentially around the side wall (2).

4. Method according to any of the preceding claims, wherein applying a barrier material on the tear line includes applying the barrier material on a surface of the blank (100) or sheet, respectively, that is intended to form the inside of the side wall (2) of the container (1).

5. Method according to any of the preceding claims, wherein the tear line comprises a scoring line.

6. Method according to any of the preceding claims, wherein the tear line comprises a perforation line.

7. Method according to any of the preceding claims, wherein the tear line is provided using a laser.

8. Method according to any of the preceding claims, wherein the tear line is provided using compression forces, in particular ultrasonic or mechanical compression forces.

9. Method according to any of the preceding claims, wherein applying the barrier material comprises spraying the barrier material on the tear line.

10. Method according to any of the preceding claims, wherein applying the barrier material comprises printing the barrier material on the tear line.

11. Method according to any of the preceding claims, wherein joining the bottom (3) with the side wall (2) comprises folding a bottom part of the side wall (2) around a peripheral region of the bottom (3).

12. Method according to any of the preceding claims, wherein after joining the bottom (3) with the side wall (2) an additional barrier material is applied on an inside connection region of the side wall (2) and the bottom (3).

13. Method for providing a packaged edible product, comprising the following method steps:- manufacturing a container (1) for holding edible material using a method according to any of the preceding claims;- filling the container (1) with edible material via the top filling opening (6); and- joining together opposing regions of the side wall (2) thereby closing the top filling opening (6) and forming a top cover (5) of the container (1).

14. Blank (100) of paper or paperboard for forming a side wall (2) of a container (1), characterized by a tear line (110), which is coated with a barrier material at least on one surface of the blank (100).

15. Container (1) for holding edible material, comprising a side wall (2), a bottom (3) and a top filling opening (6), characterized in that the top filling opening (6) is configured to be closed by joining together opposing regions of the side wall (2), in particular after filling the container (1)via the top filling opening (6), wherein the side wall (2) comprises a tear line (110), which is coated with a barrier material on an interior surface of the container (1).

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