NL2036021B1

NL2036021B1 - Packaging products in envelopes

Info

Publication number: NL2036021B1
Application number: NL2036021A
Authority: NL
Inventors: Maria Mous Fransiscus
Original assignee: Buhrs Packaging Solutions B V
Priority date: 2023-10-12
Filing date: 2023-10-12
Publication date: 2025-04-30
Also published as: WO2025080141A3; WO2025080141A2

Abstract

Title: Packaging products in envelopes Abstract A method of packaging a product in an envelope. The method comprises steps of feeding a web of packaging material through a packaging system, at a preparation station of the packaging system, preparing the web of packaging material by one or more preparations, at a product positioning station, downstream of the preparation station, positioning the product onto the web of packaging material, and at an envelope forming station, forming the envelope with the product inside the envelope by folding packaging material around the product and separating the envelope from the web of packaging material.

Description

P135418NL00

Title: Packaging products in envelopes

TECHNICAL FIELD

The aspects and embodiments thereof relate to the field of automatically packaging products, such as mail items, into envelopes.

BACKGROUND

Mail items are often packaged in an envelope. Manually inserting mail items in envelopes 1s a cumbersome process. As such, it has been an object to automate the process of packaging mail items in envelops.

In a known automatic system for packaging mail items in envelops, pre-formed envelops are used. By automatically opening up the envelope by moving a front pane away from a back pane, the mail item can be inserted into the envelope. Subsequently, the envelope can be closed and sealed.

SUMMARY

It is an object of the present disclosure to provide an improved method and system for packaging products in envelopes. The product to be putin an envelope will typically be a mail item, although it is also envisioned that the product is or comprises any other, typically flat, product, such as a plastic card. A mail item may comprise one or more printed documents, such as a letter or a magazine. Improvements may be found in packaging speed, an ability to form differently sized envelopes, reduced changeover time for a system, and/or in any other property of a packaging system and/or method.

A first aspect of the present disclosure provides a method of packaging a product in an envelope. The method comprises steps of feeding a web of packaging material through a packaging system, at a preparation station of the packaging system, preparing the web of packaging material by one or more preparations, at a product positioning station, typically downstream of the preparation station, positioning the product onto the web of packaging material, and at an envelope forming station, forming the envelope with the product inside the envelope by folding packaging material around the product and separating the envelope from the web of packaging material.

The preparations may be one or more or all of: - forming one or more folding lines in the web of packaging material; - forming one or more embossments in the web of packaging material; - forming one or more openings in the web of packaging material; - applying adhesive to the web of packaging material; - connecting a viewing window onto the web of packaging material; and - printing one or more graphical images, for example letters or a logo, onto the web of packaging material.

By virtue of being able to prepare the packaging material to be formed into an envelope and also to form the envelope from the same web of packaging material allows for a fast and convenient method of packaging products into envelops. Furthermore, as a preferred option, it allows differently sized envelopes to be formed without having to stop the process of packaging products into envelopes.

At the envelope forming station, typically a tube is formed from the web of packaging material, for example by folding the packaging material over itself. The envelope forming station comprises a separation substation at which material is separated from the web to form an individual envelop.

As option, the separation can take place before or after the tube has been formed.

Typically, but not necessarily, an envelope comprises a flap which is folded back onto the envelope, for example onto a rear pane of the envelop, and the flap is adhered to the rear pane, for example using adhesive. Folding the flap back onto the envelope may take place downstream or upstream of the separation substation.

The packaging material preferably consists of or comprises paper.

Paper in the context of the present disclosure may be defined as a sheet material comprising or consisting of cellulose fibres typically derived from a natural source, such as wood, rags, grasses, or any other plant or vegetable source.

The packaging material may be free of images printed thereon, any may thus have a constant colour over the entire web. Alternatively, one or more images may be provided on the packaging material, prior to the packaging material entering the preparation station, for example when the packaging material is on a roll. Such images may for example be one or more registration markings which may be used by a controller of a packaging system for controlling where one or more preparations have to be formed into the packaging material. Any packaging system disclosed herein may comprise one or more cameras, scanners, or other sensor for providing location data on the location of one or more markings on the packaging material to the controller. The location data can be used by the controller for controlling one or more preparation substations.

For any method and system of the present disclosure, prior to entering the preparation station, the packaging material is preferably free of folding lines and/or free of adhesive and/or free of embossments and/or free of openings, in any combination.

Any folding line may be a crease or a score. When it 1s an aim to crease the packaging material to form a folding line, a preparation substation for forming a folding line may comprise a folding line unit comprising a set of rollers, which set may comprise a first roller with a protrusion as a raised surface — also referred to as male disc - and a second roller with a corresponding indentation — also referred to as a female disc. Preferably, but not necessarily, the male disc is positioned on the inside of the packaging material, i.e. the side on which the product is placed. Alternatively, the second roller may comprise a resilient surface into which the male disc can be forced, thereby temporarily forming an indentation into the second roller.

Generally, it 1s envisioned that one product is packaged into one envelop. However, conceivably, multiple products can be packaged into a single envelop. Depending on the size of the envelops, and the length of packaging material available, any number of envelops may be formed from the web of packaging material, without having to interrupt the packaging method.

A second aspect of the present disclosure provides a method of packaging two products each in an envelope, the method comprising packaging a first of the products in a first envelope in a method according to the first aspect and packaging a second of the products in a second envelope in a method according to the first aspect. The first and second envelopes are formed from adjacent sections of packaging material of the same web of packaging material, and a length of the second envelope in the transport direction is larger than a length of the first envelope. As an option, a length of the product packaged into the second envelope may be larger than a length of the product packaged into the first envelope.

A controller, for example an electronic controller with an electronic processing unit, may receive data related to a length of a product to be packaged and/or data related to a length of an envelope to be formed. Based on this data, the controller can control a timing with which at least one of the preparations is or are formed in the web. As such, the controller can control the process of forming different envelopes from adjacent sections of packaging material from the same web of packaging material.

A third aspect of the present disclosure provides a preparation station for preparing packaging material in a web of packaging material to be formed into envelopes.

In general, any combination of one, more, or all preparation substations disclosed herein may be comprise by a preparation station according to the third aspect. The preparation substations may be positioned in any order upstream and downstream relative to each other. Any one or more preparation substations may be positioned upstream of the product positioning station, although it is also envisioned that one or more preparation substations may be positioned downstream of the product positioning station.

Any preparation station may be positioned in-line in a packaging 5 system. The transport direction of the web of packaging material through the preparation station may be constant, or may change. For example, at least through part of the preparation station, the web may be oriented horizontally, vertically, at any other angle, in any combination thereof.

A fourth aspect of the present disclosure provides a system for packaging products into envelopes, which comprises a preparation station according to the second aspect. Any system according to the third aspect may be arranged for performing one, more, or all steps of any method according to the first aspect and second aspect.

Any system for packaging products in envelopes — also referred to as packaging system — may comprise a controller for controlling a timing with which at least one preparation is formed in the web of packaging material at the preparation station, based on data related to a length of a product to be packaged and/or data related to a length of an envelope to be formed and/or data related to a desired location and/or area on the web of packaging material of any preparation, such as a folding line, embossment, opening, cut- out, or area of adhesive.

In use, for any system according to the fourth aspect, a continuous web of packaging material can extend from the supply to the separation substation, via the preparation station.

BRIEF DESCRIPTION OF THE FIGURES

In the figures,

Fig. 1A schematically shows different steps which may be applied to a web of packaging material;

Figs. 1B and 1C schematically show an envelope;

Fig. 2 schematically shows a packaging system;

Fig. 3 shows another example of a packaging system; and

Figs. 4A-4C schematically show a side view of a preparation station.

It will be appreciated that for legibility of the figures, not each element is always provided with a reference number. Furthermore, figures may not be drawn to scale.

DETAILED DESCRIPTION OF THE FIGURES

Fig. 1A schematically shows a roll of paper 100, as an example of a supply of packaging material. A web 102 of packaging material is unwound from the roll 100. Fig. 1A shows different steps which may be applied to the web 102 of packaging material, to prepare the web 102 of packaging material to have individual envelopes formed from the web 102. Any one, more, or all of the steps may be applied to web 102 in any order by a preparation station 300 of a packaging system 200.

In general, the web 102 of packaging material is transported in a transport direction T. In general, in any packaging system 200, the transport direction T may have the same orientation for the entire web 102. However, it is also envisioned that the transport direction T changes orientation when passing through different sections of the packaging system 200 or even through different sections of the preparation system 300, for example to achieve a more compact packaging system. A change in orientation may for example be from horizontal to vertical, vertical to horizontal, a clock-wise rotation or anti-clock-wise rotation about any rotation axis, for example a vertical rotation axis. The transport direction is in general parallel to the length of the web of packaging material.

At a first preparation substation 301, one or more folding lines which are generally parallel to the transport direction T can be formed. For example, a bottom folding line 104 is formed in the web 102. The bottom folding line 104 may be a crease or score, and may be formed by passing the web 102 through two rollers positioned on opposite sides of the web 102. One or both rollers may comprise one or more protrusions and/or indentations to form the bottom folding line 104 into the web 102. The bottom folding line 104 can be a continuous folding line in the web 102. Additionally, or alternatively, a flap folding line 105 can be formed at the first preparation substation 301.

At a second preparation substation 302, one or more embossments 106 are formed in the web 102 of packaging material. An embossment may be formed using two dies positioned on opposite sides of the web 102 of packaging material, one die having a partially raised surface and the other die have a partially recessed surface shaped generally correspondingly to the raised surface. The dies may be formed as rollers. Instead of using a die with a rigid partially recessed surface, a die with a resiliently deformable surface may be used into which the partially raised surface of the other die may be pressed to form a temporary recessed surface. It is envisioned that for any roller, the raised surface may be interchangeable.

An embossment may for example be positioned at one or more both sides of the envelope, to for example locally change a thickness of the envelop.

In a particular example, embossments are formed at both sides of the envelope to mimic the look of a conventional envelop in which the sides are folded back onto the rear pane. Alternatively, an embossment may be used to emboss a logo or other graphical information into the packaging material.

At a third preparation substation 303, one or more openings 108 are formed in the web 102 of packaging material, in particular at a distance from each side of the web 102 of packaging material. An example of an opening which may be formed is a viewing opening through which part of the product inside the envelope is visible from outside the envelop. For example when the product is a mail item, address information on the mail item may be visible through an opening 108 formed at the third preparation substation 303. In general, an opening or cut-out may be formed using a die-cutting process, for example using a roller with a sharp raised surface for cutting through the packaging material.

At a fourth preparation substation 304, one or more circumferential cut-outs 110 are formed in the web 102 of packaging material. One or more circumferential cut-outs may be formed at one or both sides of the packaging material. The one or more circumferential cut-outs may be used to form the outer shape of the packaging material forming the envelope, at least prior to forming the envelope at an envelope forming station.

At a fifth preparation substation 305, adhesive is applied to one or more areas on the web 102 of packaging system. For example, adhesive may be applied for adhering a front pane and rear pane of the envelope together and/or for adhering a flap to the rear pane. Adhesive may be hot melt adhesive, or cold adhesive. In general, adhesive may be applied to the packaging material using by first applying adhesive to a stamp, and subsequently transferring the adhesive from the stamp onto the packaging material. The stamp may be provided on a roller, of which a rotational speed may be controllable by a controller 800. Alternatively, adhesive may be jetted onto the packaging material. Timing of the jetting may be controlled by the controller 800. It will thus be appreciated that adhesive may be applied to the packaging material in a contactless manner, for example using jetting, and alternatively in a contacting manner for example using a stamp or with a beam contacting the packaging material, which beam comprises apertures through which adhesive can be transported onto the packaging material. The beam may alternatively beam suspended above the packaging material.

At a sixth preparation substation 306, a viewing window 112 is applied onto the web 102 of packaging material, for example aligned with an opening 108 in the web 102. The sixth preparation substation 306 is thus preferably positioned downstream of the third preparation substation 303.

The viewing window may be connected to the web 120 of packaging material for example using an adhesive, which adhesive may have been previously applied to the viewing window and/or to the web 102 of packaging material, for example at the fifth preparation substation. A viewing window may for example be formed by a transparent sheet, for example a plastic foil.

Further preparation substations are also envisioned. For example, a printing substation 307 may be used to print one or more graphical images, for example letters, a logo, or any other image, onto the web 102 of packaging material. Printing may be performed on an outer side, inner side, or both sides, of the web 102 of packaging material. Printing may be inkjet printing, laser printing, offset printing, or any other method of applying ink to the web 102 of packaging material.

As general options depicted in Fig. 1A, any preparation substation may comprise one or more rollers. For example, a set or rollers with rollers positioned on opposite sides of the web 102 may be comprised by any preparation substation. Using a roller or set of rollers, preparations may be made to the packaging material, which preparation may include at least one of a folding line, an embossment, an opening, application of an adhesive, and connection of a viewing window to the web of packaging material.

Any roller may span a particular width, with the width defined in a direction D perpendicular to the transport direction T. The width of any roller may correspond to a width of the packaging material, may be larger than a width of the packaging material, but preferably the width of any roller is smaller than a width of the packaging material in the web 102 of packaging material. In particular, any roller which is positioned above the web 102 of packaging material may have a width smaller than a width of the packaging material in the web 102 of packaging material.

A reduced width of any roller may be used to reduce the mass of the roller and/or the mass moment of inertia of the roller. This in turn allows for more dynamic controlling of the rotational speed of the roller, for example by a controller 800 of a packaging system 200. Controlling the rotational speed of the roller allows for the rotational speed to be temporarily increased or decreased, for example to change a spacing between adjacent preparations — as will be elaborated in conjunction with Figs. 4A-4C — while the web 102 is moving in the transport direction T.

For any preparation substation, a position of at least part of the preparation substation, such a roller, a printer, or any other part, may be controllable in the width direction D. As such, the width position of any preparation may become controllable, for example by virtue of the controller 800. As such, the controller 800 may change the position in the width direction D of one or more folding lines, one or more embossments, one or more openings, one or more areas on which adhesive is applied on the packaging material, and the position of one or more viewing windows connected to the packaging material. The width position may be controlled by the controller 800 based on product data of the products to be packaged into the envelopes by the packaging system 200. It will thus be appreciated that any preparation substation may comprise one or more actuators for moving a roller, a printer, or any other part in the width direction D.

Product data may in general be indicative of one or more of: 5 - a length of a product to be packaged; - a desired length of an envelop into which a particular product is to be packaged; - a width of a product to be packaged; - a desired width of an envelope into which a particular product is to be packaged; - a location or area on the product where a particular preparation is to be made; and/or - a location or area on the product which is to be aligned with an opening in the envelope.

By virtue of methods, preparations stations, and systems of the present disclosure, product data can vary between consecutive products which are packaged in consecutive envelopes formed from adjacent section of packaging material from the web of packaging material, and thus the consecutive envelopes formed may vary in length, width, position and/or number of folding lines, position and/or number of embossments, area or areas where adhesive is applied, position and/or number of openings, and/or position and/or number of any other preparation.

Fig. 1B and 1C show an example of an envelope 101 formed from packaging material for forming the envelope 101, which material has one or more preparations made to it at a preparation station, as for example depicted in Fig. 1A. The envelope 101 is respectively depicted in a schematic front view and a schematic rear view.

The envelope 101 comprises a front pane 111 and a rear pane 113, formed by folding the packaging material, optionally over a folding line 104 formed at the first preparation substation 301. The envelope 101 further comprises a flap 115 formed by folding a flap section of the packaging material, optionally over a folding line 105 formed at the first preparation substation 301. The flap 115 may be tapered in shape by virtue of circumferential cut-outs 110 of material having been removed at the fourth preparation substation 304, for example to prevent a side of the flap 115 protruding over the rear pane due to a slight misalignment of the folding line 115, for example when the folding line 115 is not exactly perpendicular to one or both sides the envelope formed at the separation substation and/or when the folding line 115 is not exactly parallel to bottom folding line 104. The circumferential cut-outs 110 are located at a circumferential edge of the envelope.

By virtue of the adhesive 107 applied at the fifth preparation substation 305 the front pane 111 and the rear pane 113 have been connected, preferably at both sides of the envelope 101. Fig. 1C shows another example of an area of adhesive 107, applied onto the flap 115, for adhering the flap 115 onto the rear pane 113 of the envelope. Adhesive 107 may thus be located between the front pane and the rear pane, and/or between the flap and the rear pane.

The envelope 101 depicted in Fig. 1B comprises an opening 108 in the packaging material, at a distance from the edges of the envelope. The opening 108 has been formed at the third preparation substation 303. A viewing window 112 has been positioned over the opening 108 at the sixth preparation substation 306.

Fig. 2 schematically shows a packaging system 200 for packaging products into envelopes, for example in a top view. The system 200 for example comprises an unwinder 201 onto which a roll 100 of packaging material can be mounted. From the roll 100 of packaging material, a continuous web 102 of packaging material is unwound. The unwinder 201 is an example of a mount for mounting a supply of packaging material onto.

Although not depicted in Fig. 2, any system 200 disclosed herein may comprise a transport module for transporting the continuous web 102 of packaging material in the transport direction T. In the example of Fig. 2, as an option applicable to any method and system, two sections of the web 102 are transported in perpendicular orientations T°, T”. To achieve the 90 degree angle between the transport directions T° and T”, the web 102 may be guided over a folding bar 220 positioned at a 45 degree angle relative to the transport direction T°. Alternatively, for the entire web 102, the transport direction T can be in the same direction. At least up to the separation substation 500, the web 102 preferably moves at a constant speed. At and/or downstream of the separation substation 500, the speed of the packaging material may be higher than the speed of the web 102 of packaging material.

The transport module of any system 200 comprises one or more transport units arranged for moving the continuous web 102 of packaging material in the transport direction T. A transport unit may comprise one or more rotating rollers, one or more transport belts, and/or one or more further movers.

Downstream of the unwinder 201, a preparation station 300 of the system 200 1s positioned. The preparation station 300 comprises one or more or all of the substation disclosed in conjunction with Fig. 1, in any particular order, although preferably in the order as depicted in Fig. 1. Although not depicted in Fig. 2, one or more preparation substations may be positioned downstream of the product positioning station 400.

Downstream of the preparation station 300, the system 200 comprises a product positioning station 400, at which products M can be positioned onto the web 102 of packaging material. As depicted in Fig. 2, subsequent products M’, M” may have a different length in the transport direction. Additionally or alternatively for any set of subsequent products, products may require a different position and/or size of an opening and/or a different location for an embossment and/or a different location for a cut-out, and/or a different area and/or location to which adhesive is applied, and/or a different location for any one or more preparations in general. Per product, data may be provide to a controller 800 of the system indicative of a preferred position and/or size of an opening and/or a different location for an embossment and/or a different location for a cut-out, and/or a different area and/or location to which adhesive is applied, and/or a different location for any one or more preparations in general. Based on this data, the controller 800 may control the product preparation station 300 to make preparations to the web 102 of packaging material at a location on the web 102 corresponding to a location where the particular product will be placed at the product positioning station 400.

Downstream of the product positioning station 400, the system 200 comprises an envelope forming station 600 at which the envelop 101 is folded around the product M. At the envelop forming station 600, individual envelops 101 may be folded about one or more folding lines formed in the packaging material previously at the preparation station 300, in particular to form a tube 103 of packaging material.

The envelope forming station 600 comprises a separation substation 500, at which individual envelops 101 are formed from the web 102 of packaging material. Typically, per envelope 101, one product M is provided, although it is also envisioned to package multiple products in a single envelop — for example next to each other or at least partially stacked on top of each other. Preferably, the continuous web 102 of packaging material is continuous up until the separation substation 500. It is envisioned that the separation substation 500 is positioned to separate the tube 103 of packaging material. Alternatively, not depicted in Fig. 2, the separation substation 500 can be positioned to separate the web 102 of packaging material prior to a location where the packaging material 1s wrapped around the product.

The separation substation 500 comprises at least one separator, for cutting, tearing, or otherwise disconnecting packaging material for forming an individual envelope 101 from the web 102 of packaging material. For example, the separation substation 500 comprises a cutting wheel 502 as a separator for cutting through the web 102 of packaging material in a direction perpendicular to the transport direction T”. As an alternative, a cutting beam or cutting bar may be used as a separator.

Preferably, the envelop 101 is sealed at the envelop forming station 600, for example using adhesive. The adhesive may be applied at the envelop forming station 600, and/or at a substation of the preparation station 300.

Downstream of upstream of the separation substation 500, the flap 115 can be folded back onto the envelope, and the flap 115 can be connected to the envelope, for example using adhesive.

When the system 200 comprises the envelop forming station 600, downstream of the envelop forming station 600, the system 200 may comprise an exit station 700, in which for example multiple envelops 101 may be collected for further transport.

Fig. 3 shows another example of a packaging system 200, in an isometric view. Fig. 3 indicates part of a continuous web 102 of packaging material, which extends through a preparation station 300, up to a separation substation 500.

As options indicated in Fig. 3, but also applicable to any other system 200, the transport direction for the web 102 through the preparation station 300, or at least part thereof, may be oriented perpendicular to the transport direction for the web 102 through the envelope forming station 600.

Additionally or alternatively, at least part of the web 102 in the preparation station 300 may be positioned below the web 102 in the product positioning station 400. As a further option indicated in Fig. 3, part of the web 102 of packaging material may be oriented vertically.

Figs. 4A-4C schematically show a part of a web 102 of packaging material passing through a schematically depicted preparation station 300 for preparing packaging material in a web of packaging material to be formed into envelopes. At the preparation station 300, the web 102 of packaging material is prepared with one or more preparations 330, at one or more preparation substations, of which a substation 331 as an example is depicted in Figs. 4A-4C. The substation 331 may be any of the preparation substations disclosed herein, and the preparation station 300 may comprise any number of further substations, positioned in any order with respect to each other.

In general, a preparation may be a folding line, embossment, opening, adhesive, viewing window, circumferential cut-out, and/or image printed onto the packaging material.

As an option depicted in Figs. 4A-4C, any preparation substation may comprise a set of rollers 332, 333 in use positioned on opposite sides of the web 102 of packaging material. In the example of Figs. 4A-4C a first roller 333 comprises a raised surface 334, for example for forming an embossment into the packaging material or for forming an opening into the packaging material when the raised surface 334 is a sharp cutting surface.

In Fig. 4A and 4B, it is schematically depicted that preparations 300 may be made at a constant spacing sl between subsequent preparations 330, 330’. The constant spacing s is dictated by the circumference of the first roller 333 with the raised surface 334. With the constant spacing, typically, envelopes with the same length can be formed, wherein the length is defined parallel to the transport direction T.

However, for any method, preparation station, and system for packaging products into envelopes disclosed herein, it may be an aim to form envelopes with different lengths from the same web of packaging material, for example to efficiently accommodate products with different lengths,

preferably without having to reduce the speed at which the web of packaging material moves in the transport direction. To allow envelopes with different lengths to be formed from the same web of packaging material, it is envisioned that a spacing sl between a first preparation 330’ and a second preparation 330” downstream of the first preparation 330° can differ from a spacing s2 between the first preparation 330’ and a third preparation 330” upstream of the first preparation 330’.

While the raised surface 334 contacts the web 102 of packaging material, the tangential speed of the portion of the raised surface 334 contacting the web 102 is preferably essentially equal to the speed of the web 102 of packaging material, for example to prevent slippage between the raised surface 334 and the

As an example of how the spacing s1 can differ from the spacing s2, as depicted in Figs. 4B, the rotational speed of the roller 331 with the raised surface 334 can be temporarily increased or decreased while the raised surface 334 is not in contact with the web 102 of packaging material. As such, when the rotational speed is temporarily increased, the spacing between preparations 330 can be decreased. When the rotational speed is temporarily decreased, the spacing between preparations 330 can be increased.

Figs. 4A-4C shows the preparation station 300 further comprising the optional preparation substation 305 for applying adhesive to the web 102 of packaging material. By controlling the timing at which the adhesive is applied to the web 102, for example by jetting adhesive onto the web, the length of the envelope 101 eventually formed may be controlled. With reference to Fig. 1B, the distance between the areas on which adhesive 107 is applied is dictated by the timing at which the adhesive is applied by the preparation substation 304 and the speed at which the web 102 of packaging material moves.

Any system 200 for packaging products into envelopes disclosed herein may comprise a controller 800, such as an electronic controller with an electronic processing unit. The controller 800 may receive as an input data for example related to a length of a product to be packaged and/or data related to a length of an envelope to be formed. Based on the input data, the controller 800 may control at least part of the preparation station in forming the preparations with a particular spacing between them. For example, the controller 800 may control a rotational speed of any roller, such as any roller with a raised surface on it and/or a timing of a preparation substation for applying adhesive to the web 102.

The controller 800 may further control directly or indirectly via a further control system the envelope forming station 600, in particular the separation substation 500, in separating packaging material from the web 102 based on the input data related to a length of a product to be packaged and/or data related to a length of an envelope to be formed.

Although in the figures, the entire preparation station is depicted positioned upstream of the product packaging station, it is envisioned that one or more preparation substations are positioned downstream of the product packaging station. For example, one or more or all of the preparation substations for forming one or more folding lines in the web of packaging material, for forming one or more embossments in the web of packaging material, for applying adhesive to the web of packaging material, and/or for printing one or more graphical images, for example letters or a logo, onto the web of packaging material, may be positioned downstream of the product packaging station.

Claims

Conclusions

1. Method for packaging a product (M) in an envelope (101), the method comprising the steps of: - feeding a web (102) of packaging material through a packaging system (200); - at a preparation station (300) of the packaging system (200), preparing the web of packaging material by at least one of the following preparations: - forming one or more fold lines in the web of packaging material; - forming one or more reliefs in the web of packaging material; - forming one or more openings in the web of packaging material; - applying adhesive to the web of packaging material; and - bonding a viewing window to the web of packaging material; - at a product positioning station (400), positioning the product (M) on the web of packaging material; and - at an envelope forming station (600), forming the envelope with the product in the envelope by folding packaging material around the product and separating the envelope from the web of packaging material.

2. The method of claim 1, wherein the packaging material comprises or consists of paper.

3. A method according to any preceding claim, wherein the product is a postal item comprising one or more printed pages.

4. A method according to any preceding claim, wherein at the preparation station, the web of packaging material is prepared by at least the following preparations: - forming one or more fold lines in the web of packaging material; - forming one or more reliefs in the web of packaging material; - forming one or more openings in the web of packaging material; - applying adhesive to the web of packaging material; and - bonding a viewing window to the web of packaging material.

5. A method according to any preceding claim, wherein the path (102) of packaging material is continuous from a stock to at least the envelope forming station, in particular to a separation substation (500) of the envelope forming station.

6. A method of packaging two products each in an envelope, the method comprising: - packaging a first of the products in a first envelope according to a method according to any one of the preceding claims; - packaging a second of the products in a second envelope according to a method according to any one of the preceding claims; wherein the first and second envelopes are formed from adjacent sections of packaging material from the same web (102) of packaging material, and a length of the second envelope in the direction of transport is greater than a length of the first envelope.

7. The method of claim 6, wherein a length of the product packed in the second envelope is greater than a length of the product packed in the first envelope.

A method according to claim 5 or 6, further comprising: - receiving, by a controller (800), data related to a length of a product to be packaged and/or data related to a length of an envelope to be formed; and - controlling, by the controller, a timing with which at least one of the preparations is or are formed in the web (102) based on the received data.

9. Preparation station for preparing packaging material in a web (102) of packaging material to be formed into envelopes (101), the preparation station comprising one or more of: - a first preparation substation (301) for forming one or more fold lines in the web of packaging material; - a second preparation substation (302) for forming one or more reliefs in the web of packaging material; - a third preparation substation (303) for forming one or more openings in the web of packaging material; - a fourth preparation substation (304) for forming one or more circumferential cutouts (110) in the web of packaging material; - a fifth preparation substation (305) for applying adhesive to the web of packaging material; and - a sixth preparation substation (306) for bonding a viewing window to the web of packaging material.

10. Preparation station according to claim 9, further comprising: - a seventh preparation substation (307) for printing one or more graphic images, e.g. letters or a logo, on the web of packaging material.

11. A preparation station as claimed in any one of claims 9 to 10, comprising the third preparation substation and the sixth preparation substation, wherein the sixth preparation substation is aligned to position the viewing window over an opening formed through the third preparation substation.

12. A preparation station according to any one of claims 9 to 11, comprising the first, second, third, fourth, fifth and sixth preparation substations.

13. A system (200) for packaging products (M) in envelopes (101), the system comprising: - a holder (201) for mounting a supply (100) of packaging material thereon; - a preparation station (300) according to any one of claims 9 to 12 for preparing packaging material in a web (102) of packaging material to be formed into envelopes; - a product positioning station (400) for positioning products on the web of packaging material; and - an envelope forming station (600) for forming an envelope with a product therein from packaging material and for separating the envelope from the web of packaging material.

A system according to claim 13, wherein a roll (100) of packaging material is mounted on the holder, and a continuous path (102) of packaging material extends from the supply to the envelope forming station, in particular to a separation substation thereof, via the preparation station.

15. The system of claim 14, wherein the packaging material comprises or consists of paper.

16. A system as claimed in any one of claims 13 to 15, wherein a direction of transport for packaging material through the preparation station is oriented perpendicular to a direction of transport for packaging material through the envelope forming station.

17. A system according to any one of claims 13 to 16, further comprising a controller for controlling a timing at which at least one preparation is formed in the path of packaging material at the preparation station, based on data related to a length of a product to be packaged and/or data related to a length of an envelope to be formed.