Field of the invention
[0001] The invention relates to an array of packs comprising compressed flexible articles
encased in flexible bags which are covered by a flexible paper covering to form a
package and to a process for wrapping the flexible paper covering under tension around
the array of packs.
Background to the invention
[0002] It is widely known in the art to pack an array of packs comprising compressed flexible
articles encased in flexible bags in cardboard cases for ease of handling, storage
and transport. Cardboard, however, is heavy, requires space and has less flexibility
for storage since it is rigid and in use continues to occupy the same amount of space
even when nearly empty. The space inside these cardboard cases cannot be fully utilised
because of the variations in the pack dimensions resulting from the production processes
and the tolerances imposed by the usual automatic mechanical packaging systems. The
problem of utilisation of space is becoming more and more important with the increasingly
widespread use of pallets of standard dimensions resulting from the demands of large
manufacturing, distribution and sales organisations. Furthermore, due to the deviations
in the pack dimensions resulting from the packing of compressible flexible articles
into flexible bags, the cardboard cases need to be over-dimensioned. As a consequence
of this over-dimensioning, arrays of packs on the bottom of pallets are incapable
of supporting the imposed loads when pallets of products are stacked or grouped three
pallets high. Therefore, the cardboard cases must be designed to support the extra
loads.
[0003] Prior art developments include WO 94/00362 which discloses a plurality of flexible
packs placed side by side and held together by means of detachable adhesive tapes.
The configuration avoids the use of corrugated cardboard boxes, but offers little
in terms of support, stability and protection for the plurality of packs. Consequently,
damage can occur quite easily.
[0004] EP 0 313 721 B1 discloses a process for erecting packaging on rigid cubic material.
The method uses a set of constructional elements produced from packaging cardboard
blanks fitted with adhesive flaps and results in the formation of at least one flat
basal frame structure constructed without a packaging base. A reduction in the level
of packaging material occurs and improved stability results, but the main aim of the
invention is to use packaging cardboard and not paper as a packaging material.
[0005] EP 0 477 487 B1 discloses a process for producing a package consisting of a dimensionally
stable framework with at least one open frame section which supports the material
to be packed at the base. In particular, a strip of stiff, stretchfree packaging material
is pulled off a supply roll, placed tightly with its edge projecting against the material
to be packed, closed to form a surrounding strap and folded angled inwards into the
basal plane of the material to be packed. Similarly, a reduction in the level of packaging
material results. Nevertheless, the main aim of this invention is to produce a stable
framework supporting the material to be packed without using constructional elements.
Cardboard is the only example given as a packaging material.
[0006] EP 0 675 042 A1 claims a process leading to a rigid package comprising two spaced
apart surrounding straps at the top and the bottom of the material to be packed, namely
a tray-forming packaging material strip and a top hoop packaging material strip. The
end product comprising separated strips is in contrast to the integral wrapping system
of the present invention.
[0007] Arrays of packs of flexible articles can also be wrapped in plastic foil. The plastic
foil can comprise relatively inexpensive materials such as polymeric films or thermoplastic
films. Nevertheless, problems exist concerning the severity of the disposal problem
from an environmental standpoint both with respect to the amount of wrapping material
required and the disposability/degradability of the particular wrapping material.
Paper offers an attractive alternative by being fully biodegradable and recyclable.
[0008] The prior art therefore does not teach an integral wrapping system which eliminates
the need for cardboard and plastic foil as a packaging material, which is independent
of fixed dimensioned cases and which exploits the compressibility of an array of packs
to form a stable unit.
Object and summary of the invention
[0009] The object of the present invention is to provide a package for compressed flexible
articles such as disposable absorbent diapers, sanitary articles, incontinent pads
or briefs, bandages and the like comprising a flexible paper covering, which functions
as a strong, stable and protective outer casing for the array of packs of flexible
articles. In another aspect of the invention, a process for wrapping a paper covering
under tension around the array of packs of compressed flexible articles is described.
[0010] The present invention eliminates cardboard and plastic foil as a packaging material
by making use of a flexible paper covering, which is wrapped under tension around
a substantial part of an array of packs of compressed flexible articles. This subsequently
leads to several benefits namely, the creation of a strong and protective outer casing
for the array of packs of flexible articles; a reduction in the overall weight of
the packages to be handled, stored and transported; a decrease in the level of waste
packaging material; an increase in the level of recyclable material and an improved
and optimised pallet fit during handling, storage and transport operations.
[0011] In accordance with the object of the invention, a package comprising an array of
at least two substantially parallelepipedal packs comprising compressed flexible articles
is provided. The package has a top and a bottom panel and four side panels. The package
also comprises a flexible paper covering, which is disposed adjacent to the whole
of the bottom panel and a substantial part of the side panels corresponding to at
least 30 percent of the height H of the array. The paper covering on the bottom panel
can comprise either four diagonal fold lines and an attachment means or a completely
uninterrupted panel. For the paper covering on the bottom panel comprising four diagonal
fold lines, one of the side panels comprises a seam and an attachment means and for
the paper covering on the bottom panel comprising the completely uninterrupted panel,
each of the side panels perpendicular to the direction of compression comprise two
fold lines and an attachment means. The paper covering is held under tension around
the array so as to create a strong and protective outer casing for the array and the
paper covering is preferably of a basis weight of less than 200 grams per square metre.
The package may comprise a least one unobstructed opening feature in the side panels.
For stability purposes, when stacking packages on top of each other to form a unit
in such a manner that the top panel of the flexible bags of the arrays of the packs
are placed in contact with the paper covering of the bottom panel of the arrays of
packs, adhesive or adhesive sheets can be used.
[0012] The underlying principle of the wrapping process is described and it can be modified
to encompass the different wrapping embodiments.
[0013] According to the present invention, the objects are achieved by a package and a process
having the characteristics specified in the claims.
Brief description of the drawings
[0014] The invention will be described hereinafter with reference to the following drawings:
Figure 1 shows a pack comprising compressed flexible articles encased in a flexible
bag;
Figure 2 is a perspective view of an array of five packs and a flexible paper covering
with folding occurring on the bottom panel;
Figure 3 is a perspective side view of an alternative configuration of an array of
five packs and a flexible paper covering with folding occurring on the side panels;
Figure 4 details a perspective view of the process for the package described in figure
2.
Detailed description of the invention
[0015] Figure 1 shows a pack
12 comprising compressed flexible articles
14 encased in a flexible bag
13. The substantially parallelipedal packs
12 are arranged in an up-on-base configuration. Other configurations such as flat-on-face
and up-on-side are also possible. The compressed flexible articles
14 may comprise disposable absorbent diapers, sanitary articles, incontinent pads or
briefs, bandages and the like. The flexible articles
14 are compressed to between 20 and 70 percent of their uncompressed volume in a direction
of compression
C. In particular, figure
1 shows a diaper pack
12 comprising between eight to fifty disposable absorbent diapers
14 and a plastic bag
13 with a thickness ranging from 30 to 120 micrometres. A method for the compression
packing of disposable absorbent diapers into flexible bags has been described in detail
in the following patents US 4,934,535, US 4,966,286, US 5,022,216, US 5,050,742 and
US 5,150,561.
[0016] As is displayed in figure 2, the packs
12 are arranged in the form of an array
11 before transport and storage. An array
11 usually comprises at least two substantially parallelipedal packs
12. More specifically, figure 2 shows a perspective view of a substantially covered
array
11 comprising five substantially parallelepipedal packs
12 of the type shown in figure 1. The substantially covered array forms the package
10. For the purposes of transport and storage, a number of packages
10 can be stacked or grouped in a plurality of configurations to form a unit on a pallet
such that a load
L is applied to a top panel or to a side panel of the unit with the direction of the
load
L being perpendicular to the direction of compression
C, which is around the circumference of the unit. The packages are less compressible
in directions perpendicular to the direction of compression
C.
[0017] In figure 2, the package
10 comprises a top panel
15, a bottom panel
16 and side panels
17,
18,
19,
20. The package
10 also comprises a paper covering
21, which is wrapped around the side panels
17,
18,
19,
20 of the array
11 of height
H and maintained in a fixed configuration by a seam
22 on one of the side panels
17,
18,
19,
20. The paper covering can be selected from, for example, kraft, virgin kraft or recycled
paper and can have a basis weight of less than 200 grams per square metre and more
preferably in the range from 80 to 130 grams per square metre. The paper covering
21 does not extend more than 5 percent and preferably not more than 0.5 percent in length
when being wrapped around the array
11 of packs
12.
[0018] The paper covering
21 has a height which corresponds to at least 30 percent of the height
H of the array
11. This percentage can vary depending on how the packs are configured in the array
11 whether flat-on-face, up-on-base or up-on-side. For the first configuration, a height
H of 65 percent is possible, but 70 percent is preferred. For the remaining two configurations,
a height
H of 30 percent is possible, but 70 percent is preferred. By tightly wrapping the paper
covering under tension around the array
11 of packs
12 such that a reduction in the circumference occurs in the range from 3-5 percent,
the stability of the array
11 is improved without resulting in a deterioration of the substantially parallelepipedal
shape of the array
11. Furthermore, a strong and protective outer casing for the array
11 is created, which guarantees stability.
[0019] The paper covering
21, as shown in figure 2, comprises a section
23 that extends beyond the bottom panel
16 of the array
11. The section
23 of the paper covering
21 comprises four subsections
24,
25,
26,
27 bounded by corner fold lines
28. The subsections
24 and
26 comprise two diagonal fold lines
29,
30 extending from the corner fold line
28 to a free edge
31. The subsections
25,
27 are folded along the fold line
32, which coincides with the lower peripheral edge of the array
11. The subsections
24,
26 are folded along the fold line
32 and along the diagonal fold lines
29,
30 to form an overlapping section on the bottom panel
16. The fold lines of the subsections
24,
26 are maintained in a fixed configuration by an attachment means
33. The attachment means
33 may comprise any variety of means such as stapling, welding, adhesion, bonding, gluing
or mechanical fastening. For example, adhesive strips, beads or patches of adhesive
comprising a hot melt adhesive are suitable.
[0020] Figure 3 shows a perspective side view of a different embodiment with regard to the
paper covering
21 of a substantially covered array
11 comprising five substantially parallelepipedal packs
12 of the type shown in figure 1. A paper covering
21 is wrapped around the bottom panel
16 and folded along the fold lines
32 to form a completely uninterrupted bottom panel
16. The fold lines
32 coincide with the lower peripheral edge of the array
11. The paper covering
21 is of an area approximately 30 percent greater than the area of the bottom panel
16 to be covered. The subsections
34,
35 are subsequently wrapped against the side panels
19,
20 of the array
11 of the package
10; the subsections
34 and
35 having a height which comprises at least 30 percent, preferably 70 percent of the
height
H of the array. This is also applicable to the up-on-side configuration. For the flat-on-face
configuration, 65 percent is possible, but 70 percent is preferred. The subsections
36,
37 comprise diagonal fold lines
38,
39 extending from the corner of the free edge
41 to the fold line
32. The subsections
36 and
37 are folded along the fold line
32 and along the diagonal lines to cover a substantial part of the height of the side
panels
17,
18. In addition, the subsections
36,
37 can also be folded onto the side panels
19,
20 and tucked underneath the subsections
34,
35. Furthermore, the direction of the folds at each corner of the free edge
41 can all be oriented in one direction or in different directions. The fold lines of
the subsections
36,
37 are maintained in a fixed configuration by an attachment means
33.
[0021] The paper covering
21 may also comprise the optional feature of an unobstructed opening feature
42, which is readily located and which can be easily and reliably opened in order to
gain easy access to the packs
12 within the array
11 of the package
10 for price marking and display purposes. The paper covering
21 comprises at least one unobstructed opening feature
42, which may comprise a predetermined tear portion in the form of a line of weakness.
Lines of weakness can be formed by many means well known in the art and typically
comprise, for example, perforations. In addition, the unobstructed opening feature
42 may comprise a plastic thread in conjunction with a tear tab, which is located on
the surface of the paper covering
21. The combination of the plastic thread and the tear tab does not result in any weakening
of the paper covering
21. The unobstructed opening features are preferably positioned on the paper covering
21 in a substantially spaced relation to each other and are generally in the form of
a thumb shape though other shapes are possible. Typical dimensions for the diameter
range from 20-60 millimetres. In addition, graphical indicia may be provided on the
paper covering
21 to highlight the location of the opening feature
42.
[0022] According to the other aspect of the invention, a process for wrapping the array
11 of packs
12 with a paper covering
21 to form the package
10 encompassing the embodiments described above is provided. In general, the process
involves the following steps:
a) supplying the array 11 of packs 12 on a feed conveyor 50 to a packaging station 51;
b) pulling a paper covering 21 from a supply roll 52;
c) feeding the paper covering 21 to the packaging station 51;
d) moving the array 11 along the packaging station 51 transverse to the paper covering 21 onto a discharge conveyor 53 in such a manner that the bottom 16 and side panels 17, 18, 19, 20 are surrounded with the paper covering 21;
e) applying the attachment means 33 in the appropriate manner to form the package 10.
[0023] More particularly, the array
11 to be wrapped is moved along the packaging station
51 towards the paper covering
21 (consider, for example, that the side panel
18 faces the paper covering
21), which is transverse to the path of movement of the array
11. A pusher clamp is used to hold the array
11 in place. The paper covering
21 is wrapped around the array
11 in a U-shape and pulled by means of a pull force
F such that the two edges of the side panel
17 of the array
11 are deformed. A pusher plate pushes on the upper panel
15 of the array
11 to prevent the paper covering
21 from slipping backwards. The third edge of the side panel
18 is deformed with a metal plate. The action of the metal plate results in the formation
of round edges and produces the same effect as the paper covering
21 does by means of the pull force
F. The pusher clamp retreats. The fourth edge of the side panel
18 is deformed with a roller. The circumference of the array
11 is reduced by at least 3 percent depending on the product and the size of the array
11. The paper covering
21 is cut perpendicular to the direction of the paper feed and the final step involves
the application of an attachment means
33 with the aid of a roller. The pusher plate retreats. At least three edges of the
array
11 have to be deformed before the application of the attachment means
33. The deformed edges act like springs and keep the paper covering
21 under tension and thus, ensure the stability of the package
10.
[0024] This represents the underlying principle of the wrapping process and can be modified
to take account of the different wrapping configurations described herein. Furthermore,
the process can be used both to completely wrap an array of packs to form a package
and a stack or grouping of packages to form a unit.
[0025] For ease of handling, transport and storage, the packages
10, wrapped according to the present invention, are stacked in a plurality of configurations
to form a unit disposed on a pallet. Glue or adhesive coated sheets can be employed
to stabilise the unit. In particular, pressure sensitive glue, as supplied by Actio-pack®
of Germany, is sprayed on the top panel
15 of the flexible plastic bags
13 of the arrays
11 of packs
12 and placed in contact with the paper covering
21 of the bottom panel
16 of the arrays
11 of packs
12. In order to minimise the quantity of glue on the plastic bags
13 and to maintain sufficient unit stability, glue beads of approximately 3 centimetres
diameter located close to the corners of the package
10 are employed. Alternatively, adhesive coated palletisation insert sheets Stop Gliss®,
as supplied by ENDUPACK of France, are disposed between the packages to ensure stability.
The same anti-slip compound can be coated on both sides of the palletisation insert
sheets or different anti-slip compounds can be coated on each side to meet the frictional/stabilising
requirements of each material.
Glossary
[0026]
- 10
- package
- 11
- array
- 12
- pack
- 13
- flexible bag
- 14
- compressed articles
- 15
- top panel
- 16
- bottom panel
- 17, 18, 19, 20
- side panels
- 21
- paper covering
- 22
- seam
- 23
- section
- 24, 25, 26, 27
- subsections
- 28
- corner fold line
- 29, 30
- diagonal fold lines for 26, 27
- 31, 41
- free edges
- 32
- fold line
- 33
- attachment means
- 34, 35, 36, 37
- subsections
- 38, 39
- diagonal fold lines for 36, 37
- 42
- unobstructed opening feature
- 50
- feed conveyor
- 51
- packaging station
- 52
- supply roll
- 53
- discharge conveyor
1. A package (10) comprising an array (11) of at least two substantially parallelepipedal
packs (12), said packs (12) comprising compressed flexible articles (14) encased in
a flexible bag (13), said compressed flexible articles (14) having been compressed
to between 20 percent and 70 percent of their uncompressed volume in a direction of
compression C, said array (11) comprising a top panel (15), a bottom panel (16) and
four side panels (17, 18, 19, 20),
characterised in that
a flexible paper covering (21) is disposed adjacent whole of said bottom panel (16)
and a substantial part of said side panels (17, 18, 19, 20) corresponding to at least
30 percent of height H of said array, said paper covering (21) being held under tension
around said array (11) so as to create a strong and protective outer casing for said
array (11).
2. A package (10) according to claim 1 wherein said bottom panel (16) comprises four
diagonal fold lines and an attachment means to maintain said diagonal lines in a fixed
configuration.
3. A package (10) according to claim 2 wherein one of said side panels (17, 18, 19, 20)
comprises a seam (22) and an attachment means to maintain said seam (22) in a fixed
configuration.
4. A package (10) according to claim 1 wherein said bottom panel (16) comprises a completely
uninterrupted panel.
5. A package (10) according to claim 4 wherein each of said side panels (17, 18) perpendicular
to the direction of compression C comprises two fold lines and an attachment means
to maintain said fold lines in a fixed configuration.
6. A package (10) according to any of the previous claims wherein said paper covering
(21) comprises paper of a basis weight of less than 200 grams per square metre.
7. A package according to any of the previous claims, wherein said paper covering (21)
comprises at least one unobstructed opening feature (42) in said side panels (17,
18, 19, 20) in a substantially spaced relation to each other.
8. A package according to any of the previous claims, wherein said compressed flexible
articles (14) are disposable absorbent diapers, sanitary articles, incontinent pads
or briefs, bandages and the like.
9. A package according to any of the previous claims, wherein said package (10) is stacked
with other packages (10) to form a unit in such a manner that said top panel (15)
of said flexible bags (13) of said arrays (11) of said packs (12) are placed in contact
with said paper covering (21) of said bottom panel (16) of said arrays (11) of said
packs (12) by means of an adhesive or an adhesive sheet.
10. A process for producing a package (10) according to claims 1 to 9 comprising the following
steps:
a) said array (11) of said packs (14) to be packed is supplied on a feed conveyor
(50) to a packaging station (51);
b) said paper covering (21) is pulled off a supply roll (52);
c) said paper covering (21) is fed to said packaging station (51);
d) said array (11) is moved along said packaging station (51) transverse to said paper
covering (21) and onto a discharge conveyor (53) in such a manner that said bottom
panel (16) and said side panels (17, 18, 19, 20) of said array (11) are surrounded
with said paper covering (21);
e) said attachment means (33) is applied.
11. A process according to claims 10, 1, 2 and 3 wherein at least three edges of said
array (11) are deformed before said attachment means (33) are applied.
12. A process according to claim 11 wherein circumference of said array (11) is reduced
by at least 3 percent.