WO2008068779A2

WO2008068779A2 - Water soluble film based package, process and apparatus for sealing said package

Info

Publication number: WO2008068779A2
Application number: PCT/IN2007/000633
Authority: WO
Inventors: Shilpan Pravinchandra Patel; Nikita Thanawala
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-12-07
Filing date: 2007-12-07
Publication date: 2008-06-12
Anticipated expiration: 2009-06-07
Also published as: WO2008068779A3

Abstract

A method of packaging using packaging material with at least one layer of water soluble film to allow the sealing to be carried out at lower temperatures with the aid of steam/moisture and pressure. Process and apparatus for packaging in a water soluble film based packaging material using moisture/steam.

Description

WATER SOLUBLE FILM BASED PACKAGE, PROCESS AND APPARATUS FOR SEALING THE SAME USING MOISTURE/ STEAM

FIELD OF THE INVENTION

The invention relates to water soluble film based packaging material, process and apparatus for packaging by way of using steam and/or moisture. The packaging method allows the packaging of substances having low melting points or flash points thereby being economical and cost effective.

BACKGROUND OF THE INVENTION

There are many chemicals and solvent based materials available in the market having low flash points/melting points and hence cause great difficulties while packaging. Also, certain materials like agrochemicals consists some actives like pretilachor, profenofos, cyphermethrin, lamda, etc which further lowers the flashpoint of the agrochemicals. Flexible packaging can be done on FFS (form fill seal) machines which can be either horizontal or vertical. Packaging can also be done by thermoforming method. Form, fill, and seal machines are packaging equipment that uses flexible, heat-sealable, films to form packages that can be filled with a product and then sealed, and cut. Some devices transport the plastic film horizontally. Others transport the film vertically. But, during heat sealing of these films, the heating temperature is high and due to this there are chances of fire if the material filled inside the pouch has a low flash point.

Therefore the industry uses solid containers like plastic bottles, tin containers, etc to pack materials, particularly liquids, which have a low flash point so as to avoid fire while packaging. These packaging methods are expensive compared to flexible packaging. The packaging lines and equipments are also expensive and so are the labeling lines. While in case of flexible packaging the cost of materials, equipment and online digital printing is an economical method of preferred system. Pre-printed flexible packaging materials are an economical option, compared to present system of rigid packaging.

Hence, there is a need for a packaging material which can be sealed at lower temperatures for materials having low flash points, thus avoiding any sort of accidents and at the same time will not increase the packaging costs. SUMMARY OF INVENTION

The invention relates to a method of packaging using packaging material with at least one layer of water soluble film, wherein the sealing is carried out at lower temperatures with the aid of steam/moisture and pressure.

The method of the instant invention allows packaging of substances having low flash points and eliminating the chances of any accidents. This also increases the speed in production and saves on energy costs as well. The method of the instant invention also allows for packaging of low melting point products in a low temperature thereby avoiding loss/damage of the product being packed and hence making packaging cost effective.

The said water soluble film can be non-edible film forming materials. It can be cold water soluble, hot water soluble or warm water soluble or non water soluble but hydrophilic depending upon the material to be packed and the end use.

The thickness of the water soluble film ranges from 5 microns to 100 microns, preferably from 15 microns to 75 microns, more preferably from 25 microns to 50 microns.

The said materials to be packed are any materials having low flash point or melting point or may also be food stuffs or other items such as agrochemicals, detergents, drugs and the like. Heat sensitive products such as chocolates can be safely packed in the water soluble film containing packaging material with the method described in the instant invention.

The method for manufacture of packages disclosed in the instant invention has several advantages over the traditional Form Fill Seal machines. The time and pressure required in the traditional machines to heat seal the packages is much more as compared to the instant invention. In case of instant invention the total sealing process is more environmental friendly as heat generated is minimal.

Fig - 1 - Horizontal Sealing

1. Water Soluble Packaging Material 2. Packaging Material

3. Jaws

4. Steam

5. Water or Steam Tubing

6. Pressure Roll ig — 2 - Water Soluble Packaging Material

7. Water Soluble Film or Coating

8. Non Soluble Substances like Aluminum Foil, Polyester etc. ig - 3 - Horizontal Sealing for Substrate of Fig - 2

9. Water Soluble Film or Coating

10. Non soluble Substance 1 1. Packaging Material

12. Perforation Apparatus

13. Jaws

14. Steam

15. Water or Steam Tubing ig - 4 - Horizontal Sealing Using Steam / Water

16. Pouch With Horizontal Sealing

17. Horizontal Sealing Fig - 5 - Vertical Sealing

18. Water Soluble Packaging Material 19. Pressure Roll

20. Jaws

21. Steam

22. Water or Steam Tubing

Fig - 6 - Pouch With Vertical Sealing

23. Horizontal Sealing

24. Vertical Sealing

DETAILED DESCRIPTION OF THE INVENTION

The method of packaging to prepare pouches or sachets or like packages which are flexible and hence easy to handle has been described herewith. The method of packaging relates to packaging a product in a packaging material which contains at least one layer of water soluble film, wherein the sealing is carried out using steam/moisture and pressure.

Accordingly, the invention provides a packaging material with at least one layer of water soluble film, wherein the sealing is carried out at lower temperatures with the aid of steam/moisture and pressure to allow the packaging of substances having low flash points and eliminating the chances of any accidents. This will also increase the speed in production and save on energy costs also.

The thickness of the water soluble film ranges from 5 microns to 100 microns, preferably from 15 microns to 75 microns, more preferably from 25 microns to 50 microns. The water soluble film can be made of non-edible film forming materials like polyvinyl alcohol copolymer ionomers, polyvinyl alcohol homopolymer, non- ionomeric poly vinyl alcohol polymer, polymethacrylate, polyvinyl alcohol, polyacrylamide, polymethacrylamide, polyacrylic acid, polymethacrylic acid or polyurethane and the like or edible film forming materials like polyethyleneglycol, polyvinylpyrrolidone, proteinaceous binders such as gelatin, modified gelatins such as phthaloyl gelatin, polysaccharides such as starch, gum arabic, pullulan or dextrin or water-soluble cellulose derivatives such as methyl cellulose, hydroxyl propyl cellulose, hydroxyl propyl methyl cellulose, hydroxyl propyl ethyl cellulose, hydroxy ethyl cellulose or carboxyl methyl cellulose and the like or combination thereof.

The different embodiments of the invention lead to manufacture of a non soluble hydrophobic film based pouch, a metallic foil based pouch a paper based pouch, a fabric based pouch etc. having the inner side coated/cast/extruded with at least one layer of water soluble film, wherein the sealing is carried out at lower temperatures with the aid of steam/moisture and pressure and thus helps in packaging chemicals having low flash points and eliminating the chances of any accidents. This will also increase the speed in production and save on energy costs also.

The said layer of water soluble film on the inner side of a non soluble polymeric film or metallic foil or paper or fabric can be cold water soluble, hot water soluble, warm water soluble or non soluble but hydrophilic depending upon the application.

The said packaging material is optionally primer coated on the inner side prior to coating/casting/extrusion of water soluble film so that the water soluble film will adhere properly to the packaging material which can be a hydrophobic film, metallic foil, paper or fabric.

The said packaging material having the inner side coated with at least one layer of water soluble film is optionally perforated on the edges, so that the moisture/steam comes in contact with the water soluble film during sealing. The perforations are done either online or offline. In case of water soluble film based packaging material consisting a layer of a hydrophobic film or a foil, perforations are done offline during the process of printing the water soluble film based packaging material or else perforations are done online during the process of form, fill and seal.

Accordingly, the invention relates to a pouch wherein a cold seal adhesive layer or cold seal coating applied on the water soluble film or non soluble polymeric film or metallic foil or paper or fabric instead of a water soluble film layer.

The invention further provides an apparatus for sealing consisting of a perforation unit, steam sealer and pressure module, moisture absorption and pressure module and feeder.

As per the invention, steam based sealing jaws are used for sealing the filled pouch on a form fill seal machine instead of direct heat or heated jaws. Water soluble film is hydrophilic in nature and hence will become tacky after applying steam/moisture. So that, the edges will stick together and less heat will be required for sealing.

Accordingly, the invention provides a process of manufacturing pouches out of the said water soluble film based packaging material.

Packaging materials with lower flash points by Vertical form fill seal method

A single web of water soluble film is fed down over a forming shoulder that converts the flat web into a tubular shape around the product feed tube with the two sides of the web overlapping. A vertical steam heat sealer seals these two edges as the water soluble film progresses. The steam heat sealer will pass steam through the holes so that the edges of water soluble films will become tacky and will seal properly after the pressure is applied. Due to the hydrophilic nature of the water soluble film very less heat will be required for sealing. The material to be packed is fed into the tubes from volumetric or scale feeders above, falls into the partially formed package, which is then cross sealed with the help of a steam sealer to complete the pouch and severed from the web. The final seal not only forms the closure on the sealed package, but also the bottom seal on the next pouch.

A vertical seal that prefers two webs can also be used for packaging. Here, the two webs of water soluble films are unwound and brought together face to face. Vertical steam roller sealers form a series of channels in the films for filling by tubes positioned in the centre of each one.

Packaging materials with lower flash points by Horizontal form fill seal method

Here the water soluble film is formed into a V-shape before being sealed vertically to form individual pockets. The pockets are filled with material to be packed before the top is sealed and the sachets are separated. The water soluble film can also be formed into a horizontal tube around an indexed conveyor. The material to be packed is fed along the conveyor before the cross seals and longitudinal seals are formed with the help of steam sealers. The sachets are then separated.

In case a material having low flash point has to be packed in a non soluble hydrophobic film or a metallic foil or a paper or a fabric pouch, then the non soluble polymeric film or the metallic foil or paper or fabric may be coated/cast/extruded with at least one layer of water soluble film. Hence, while packaging, the water soluble films will be face to face and with the help of steam sealers the sachet can be made at lower temperatures, with the help of steam and pressure. The non soluble hydrophobic film or metallic foil or paper or fabric can be optionally perforated on the edges so as to allow moisture/steam from the steam heaters to come in contact with the water soluble film layer. The perforations are done either online or offline. In case of water soluble film based packaging material consisting a layer of a hydrophobic film or a foil, perforations are done offline during the process of printing the water soluble film based packaging material or else perforations are done online during the process of form, fill and seal.

In this way a package is achieved, wherein sealing has been done at lower temperatures with the aid of moisture/steam and pressure; and hence will help in packaging materials having low flash points. The instant invention thus discloses a package containing edible and non edible materials packed therein. -

The invention thus provides for manufacture of packages with the help of steam/moisture and pressure by using a water soluble film as a packaging layer. The Form, Fill, Seal machines and packaging machines use heat and pressure to seal the edges and other sides of plastic films, but the instant method discloses use of steam and water seal instead of heat.

While the present invention has been described with respect to certain preferred embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims.

Claims

We Claim:

1. A method of packaging a product in a water soluble film based packaging material comprising the steps of: (a) taking a water soluble film based packaging material containing at least one layer of water soluble film,

(b) sealing the packaging material at the edges leaving space for filling of the product, characterized in that the sealing is carried out using steam/moisture and pressure (c) filling the product in the partially sealed packaging material

(d) sealing the package.

2. A method of packaging as claimed in claim 1 wherein said sealing is carried out at low temperature.

3. A method of packaging as claimed in claim 1, wherein the product packed has low flash points or low melting index.

4. A method of packaging as claimed in claim 1, wherein said water soluble film is coated/casted/extruded over a second layer of packaging material.

5. A method of packaging as claimed in claim 4, wherein said second layer of packaging material is a non soluble polymeric film or metallic foil or paper or fabric based pouch.

6. A method of packaging as claimed in claim 1, wherein water soluble film is of non-edible film forming materials selected form the group consisting of polyvinyl alcohol copolymer ionomers, polyvinyl alcohol homopolymer, non- ionomeric poly vinyl alcohol polymer, polymethacrylate, polyvinyl alcohol, polyacrylamide, polymethacrylamide, polyacrylic acid, polymethacrylic acid or polyurethane and the like.

7. A method of packaging as claimed in claim 1, wherein water soluble film is of edible film forming materials like polyethyleneglycol, polyvinylpyrrolidone, proteinaceous binders such as gelatin, modified gelatins such as phthaloyl gelatin, polysaccharides such as starch, gum arabic, pullulan or dextrin or water-soluble cellulose derivatives such as methyl cellulose, hydroxyl propyl cellulose, hydroxyl propyl methyl cellulose, hydroxyl propyl ethyl cellulose, hydroxy ethyl cellulose or carboxyl methyl cellulose and the like or combination thereof.

8. A method of packaging as claimed in claim 1, wherein said water soluble film is cold water soluble, hot water soluble or warm water soluble or non water soluble but hydrophilic depending upon the material to be packed and the end use.

9. A method of packaging as claimed in claim 1, wherein the thickness of said water soluble film ranges from 2 microns to 100 microns, preferably from 15 microns to 75 microns, more preferably from 25 microns to 50 microns.

10. A method of packaging as claimed in claim 4, wherein said second layer of packaging material is optionally primer coated prior to the coating/casting/extrusion of water soluble film.

11. A method of packaging as claimed in claim 4, wherein said second layer of packaging material is optionally perforated on the edges to allow the moisture/steam to come in contact with the water soluble film during sealing.

12. A method of packaging as claimed in claim 1 1 wherein said second layer of packaging material is perforated either online or offline.

13. A method of packaging as claimed in claim 12, wherein said offline perforations are done in packaging material consisting a layer of a hydrophobic film or a foil during the process of printing the packaging material.

14. A method of packaging as claimed in claim 13, wherein online perforations are done during the process of form, fill and seal.

15. A method of packaging as claimed in claim 11-14, wherein said perforations are sealed by the process of pressure after the steam or moisture comes in contact with the water soluble film forming a non porous joint.

16. A method of packaging as claimed in any preceding claim, wherein a cold seal adhesive or cold seal coating is applied on the water soluble film or non soluble polymeric film or metallic foil or paper or fabric instead of a water soluble film layer.

17. A method of packaging as claimed in any preceding claim, wherein the packaged product is edible and non edible materials including food, drugs and non edible materials like Agrochemicals, detergents and the like.

18. A package as and when packaged by using the method as claimed in any preceding claim.

19. An apparatus for sealing of packaging material containing at least one layer of water soluble film comprising a steam sealer for sealing the package, a pressure module, a moisture absorption module, a feeder and optionally a perforation unit.

20. An apparatus for sealing of packaging material as claimed in claim in 19, wherein said steam sealeivcomprises steam based sealing jaws.

21. An apparatus for sealing of packaging material as claimed in claim in 20, wherein said steam based sealing jaws are provided on a form fill seal machine.

22. A process for manufacture of packages using a packaging material containing at least one layer of water soluble film by vertical form fill seal method comprising the steps of:

(a) forming a tubular shape around the product feed tube from a web of water soluble film overlapping the two sides of the web,

(b) sealing the two edges by steam, (c) optionally perforating the film,

(d) passing the steam through the holes,

(e) applying pressure to seal the edges of the water soluble films,

(f) feeding the material to be packed into the tubes by product feeders,

(g) cross sealing, (h) optionally severing the pouch from the web.

23. A process for manufacture of packages as claimed in claim 22, wherein steps (a) to (d) are optionally replaced by following steps

(a) unwinding two water soluble films and bringing them face to face,

(b) forming a series of channels in the films using vertical steam roller sealers for filling by feeder tubes.

(c) optionally perforating the film before sealing.

24. A process for manufacture of packages using a packaging material containing at least one layer of water soluble film by horizontal form fill seal method comprising the steps of:

(a) forming horizontal tube of water soluble film, (b) feeding the material to be packed into the tube,

(c) cross sealing and longitudinal sealing the tube with steam sealer,

(d) optionally separating the packages.

25. A process for manufacture of packages as claimed in claim 24, wherein said horizontal tube is formed around an indexed conveyor and said feeding the material is along the conveyer.

26. A water soluble film based package comprising at least one layer of water soluble film which is sealed using the water soluble property of said water soluble film, characterized in that the sealing is carried out by using steam/moisture and pressure.

27. A method of packaging substantially as herein described with reference to the foregoing examples.

28. An apparatus for sealing substantially as herein described with reference to foregoing examples.

29. A process for manufacture of packages using a packaging material containing at least one layer of water soluble film substantially as herein described with reference to foregoing examples.