Method of manufacturing and filling a package and corresponding package

Abstract

The present invention relates to a method of manufacturing and filling a package with a powdered nutritional product, such as infant nutrition or milk formula, the method comprising providing a thermoformed tub having sidewalls and a base defining a product receiving space, filling the product receiving space with the powdered nutritional product, and sealing a membrane across an open mouth of the tub to seal the product therein; and folding a carton blank with a plurality of panels around the filled tub to form a carton sleeve, wherein the carton sleeve comprises a peripheral wall enclosing at least the sidewalls of the tub. The invention also relates to a package for such a powdered nutritional product manufactured according to this method.

1 . A method of manufacturing and filling a package with a powdered nutritional product, the method comprising:
 a) providing a thermoformed tub having sidewalls and a base defining a product receiving space, filling the product receiving space with the powdered nutritional product, and sealing a membrane across an open mouth of the tub to seal the product therein;   b) folding a carton blank with a plurality of panels around the filled tub to form a carton sleeve, wherein the carton sleeve comprises a peripheral wall enclosing at least the sidewalls of the tub.   
     
     
         2 . The method according to  claim 1 , wherein the carton blank comprises a bottom panel and side wall panels and wherein after folding the carton blank to a sleeve, the sleeve encloses the sidewalls and at least a part of the base of the tub. 
     
     
         3 . The method according to  claim 1 , wherein step b) further comprises gluing the panels to the tub. 
     
     
         4 . The method according to  claim 1 , wherein step b) further comprises connecting the panels to each other. 
     
     
         5 . The method according to  claim 2 , wherein step b) further comprises gluing the bottom panel to the base of the tub. 
     
     
         6 . The method according to  claim 1 , wherein step b) comprises applying a lateral displacement to panels to bring them into engagement with the sidewalls of the tub after folding towards the sidewalls of the tub. 
     
     
         7 . The method according to  claim 1 , wherein step b) further comprises providing the carton blank from a carton blank magazine holding multiple carton blanks. 
     
     
         8 . The method according to  claim 1 , wherein step b) further comprises centring the carton blank and the thermoformed tub with respect to each other. 
     
     
         9 . The method according to  claim 1 , wherein step a) further comprises fitting a lower rim to an upper edge of the tub. 
     
     
         10 . The method according to  claim 9 , wherein step a) further comprises fitting a lid assembly to the tub, the lid assembly comprising an upper rim and a recloseable lid. 
     
     
         11 . The method according to  10 , wherein the upper rim and the lower rim are mechanically connected together in an interference fit. 
     
     
         12 . The method according to  claim 1 , wherein step a) takes place in a high care zone defined by a supra-atmospheric pressure and a filtered atmosphere. 
     
     
         13 . The method according to  claim 12 , wherein step b) takes place outside the high care zone. 
     
     
         14 . The method according to  claim 1 , wherein filling the product receiving space with the powdered nutritional product takes place in a low oxygen atmosphere. 
     
     
         15 . The method according to  claim 14 , wherein the low oxygen atmosphere comprises a carbon dioxide atmosphere. 
     
     
         16 . The method according to  claim 1 , wherein the tub has a wall thickness of between 0.10 mm and 0.50 mm. 
     
     
         17 . The method according to  claim 1 , wherein the carton blank has a weight of between 50 g/m 2  and 400 g/m 2 . 
     
     
         18 . The method according to  claim 1 , wherein the tub and the sleeve have tapered sidewalls, with a taper of between 1° and 7°. 
     
     
         19 . The method according to  claim 1 , wherein the membrane comprises a weakened tear line defining an opening region, and a pull tab. 
     
     
         20 . A package for a powdered nutritional product manufactured by a method comprising:
 a) providing a thermoformed tub having sidewalls and a base defining a product receiving space, filling the product receiving space with the powdered nutritional product, and sealing a membrane across an open mouth of the tub to seal the product therein;   b) folding a carton blank with a plurality of panels around the filled tub to form a carton sleeve, wherein the carton sleeve comprises a peripheral wall enclosing at least the sidewalls of the tub.   
     
     
         21 . (canceled) 
     
     
         22 . (canceled)