Splittable Retail Package With Segmented Lid And Base Tray
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Solution Overview
Problem
Current retail ready packaging systems face challenges in efficiently transitioning from shipping to display, maintaining product integrity during distribution, and minimizing handling, while also requiring flexible adaptation to different article sizes and batches, which leads to complications in simultaneous processing and increased downtime for line conversions.
Innovation Solution
The development of a novel article processing method and system that forms split or splittable article packs by encoding and perfing panels to create a line-of-weakness, allowing for in-line splitting into sub-packs, and utilizing tandem tray blanks to form trays with adjustable sidewalls, enabling efficient formation and display of article packs with minimal handling and reduced processing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional carton enclosures or film wrapping are used for bundling articles, then shipping and display needs are met, but handling time and processing complexity increase during retail display transitions
Solution Approach 1:
The packaging system is segmented into modular components: a base tray that remains with the articles and a separate lid that can be removed or retained. This segmentation allows the package to be easily opened at the point of sale without requiring complex tools or procedures, while maintaining shipping integrity. The base tray and lid can be independently handled, reducing overall processing complexity during retail display transitions.
Solution Approach 2:
The lid is designed with dynamic characteristics, allowing it to transition between a closed shipping position and an open display position. The lid can be completely removed, partially opened, or left attached depending on retail needs. This dynamic design enables flexible handling at different stages of the supply chain, reducing handling time while maintaining simple package structure.
2Area of stationary object
If display packages are downsized to meet retail display needs, then shelf space competition is addressed, but palletization integrity during distribution is compromised
Solution Approach 1:
The packaging system divides the original large display package into multiple smaller sub-units using the removable lid concept. Each sub-unit consists of a base tray with articles and an associated lid portion. These modular sub-units can be efficiently palletized while maintaining integrity, and then easily separated at the retail level to create appropriate display package sizes without compromising distribution reliability.
Solution Approach 2:
The packaging system is pre-configured with separation features (weakened lines, perforations, or adhesive bonds) that allow easy division into smaller units. This preliminary preparation enables the package to maintain its integrity during palletization and distribution, while being ready for quick downsizing at the retail level to meet various display space requirements.
3Adaptability or versatility
If multi-bundle packs with multiple discrete trays are used, then retail display flexibility is improved, but processing time and handling complexity increase
Solution Approach 1:
The lid is designed as a single dynamic component that can serve multiple functions: it can be completely removed to expose all articles, partially opened to reveal specific sections, or left attached for shipping. This dynamic design provides the same display flexibility as multiple discrete trays but reduces processing time by eliminating the need to handle and position multiple separate tray components.
Solution Approach 2:
The packaging system merges multiple tray functions into a single integrated structure with one lid that covers the entire article array. This consolidation maintains the ability to access and display articles flexibly while significantly reducing the number of handling operations required compared to managing multiple separate trays, thereby reducing processing time and handling complexity.
4Ease of operation
If packaged articles are made readily accessible to consumers, then consumer convenience is improved, but package security and product protection during transport are reduced
Solution Approach 1:
The package is segmented into a secure base tray and a removable lid. During transport, the lid remains closed and attached, providing full package security and product protection. At the point of sale, the lid can be easily removed or opened to provide consumer access to articles. This segmentation allows the package to maintain strength and security during distribution while enabling convenient access when needed.
Solution Approach 2:
The packaging system incorporates pre-designed access features such as weakened lines, perforations, or magnetic closures in the lid that allow easy removal or opening. These preliminary preparations enable the package to maintain full security during transport while requiring minimal effort for consumer access at the retail level, effectively resolving the contradiction between protection and accessibility.
Data Source
AI summary
An article processing method is generally provided, namely, a method in furtherance of the formation of a split or splittable article pack. Spaced apart article groups are formed from a stream of articles. Each panel of panels of a supply of panels is passed through a processing station for execution of a processing step so as to establish a stream of processed panels. A processed panel of the stream of processed panels is associated with an article group of the spaced apart article groups so as to form a splittable article pack. The splittable article pack may be bundled for subsequent splitting, or split via in-line processing and discrete sub-packs having origins in the split splittable article pack bundled.