Note: Descriptions are shown in the official language in which they were submitted.
CA 02604853 2007-09-28
EFFICIENT TISSUE ROLL CONFIGURATIONS
BACKGROUND OF THE INVENTION
The invention relates to tissue roll configurations that improve efficiencies
in material
use, product handling, and product stocking and display.
Because of tradition and the larger compressive strength of a tissue roll
along its
longitudinal axis, tissue rolls are always packaged such that the longitudinal
axis of
each roll is parallel to the front of the package but perpendicular to the
bottom of the
package. This essentially vertical orientation of the tissue rolls allows
multiple rolls,
multiple packages, and multiple cases to be stacked with less risk of crushing
the
tissue rolls on the bottom. For example, a package of twenty-four tissue rolls
is
packed either as a brick (four tissue roll diameters wide by two tissue roll
heights high
by three tissue roll diameters deep) or as a tower (three tissue roll
diameters wide by
four tissue roll heights high by two tissue roll diameters deep). Such
restrictions in
orientation, however, lead to inefficiencies in the amount of packaging
material
required and in the number of tissue rolls that can be shipped and handled.
In addition, tissue sales categories are undergoing transformation as
manufacturers
and retail outlets offer double rolls, triple rolls, extended life rolls, and
other variations
of a standard roll. Markings on such rolls are often confusing to consumers
who
don't know what they are getting unless they pull a package off a retail shelf
to
examine the rolls themselves. This wastes time for the consumer and, once they
do
this, there is no guarantee that they will replace the package in an orderly
or properly-
oriented manner.
In an increasingly demanding and competitive retail environment, there is a
need for
unique package and merchandising solutions critical to delivering on key
customer
desires, leveraging consumer insights, and delivering on the overall
objectives of a
business, while also delivering improved environmental sustainability.
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CA 02604853 2007-09-28
While particular aspects and/or individual features of the present invention
have been
illustrated and described, it would be obvious to those skilled in the art
that various
other changes and modifications can be made without departing from the spirit
and
scope of the invention. Further, it should be apparent that all combinations
of such
aspects and features are possible and can result in preferred executions of
the
invention.
SUMMARY OF THE INVENTION
Current packaging solutions require more resources in terms of materials and
handling time than they need to. Excessive packaging and inefficient shipping
and
stocking methods add to the cost of products. In addition, consumers seek
simplified
communication aids to understand what tissue products are in the packages on a
retail shelf.
A unique packaging, distribution, and merchandising solution supports new
business
ventures with key retailers/customers and provides an increased level of
environmental sustainability that is a key initiative in the marketplace.
The present invention relates to improved configurations for shipping and
handling
that reduce the time necessary for shipping and handling and also reduce the
amount of packaging materials used, thus reducing the cost to put a product on
a
retail shelf.
For example, in one aspect of the present invention, the invention includes a
package of tissue rolls, the package including two package sides, a package
bottom,
a package back, and a package top; a package front in a generally vertical
orientation, the package front spaced apart from and generally parallel to the
package back, wherein the package front and the package back are coupled to
and
generally orthogonal to the package bottom, the package front including a
primary
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CA 02604853 2007-09-28
package logo having a logo axis; and a plurality of tissue rolls, each tissue
roll having
a roll height, a roll diameter, and a longitudinal axis, wherein each of the
longitudinal
axes are generally horizontal when the logo axis is generally vertical.
In another aspect of the present invention, the invention includes a package
of tissue
rolls, the package including two package sides, a package bottom, a package
back,
and a package top; a package front in a generally vertical orientation, the
package
front spaced apart from and generally parallel to the package back, wherein
the
package front and the package back are coupled to and generally orthogonal to
the
package bottom, the package front including a primary package logo having a
logo
axis; and a plurality of tissue rolls, each tissue roll having a longitudinal
axis and a roll
end surface perpendicular to the longitudinal axis, wherein each of the
longitudinal
axes are generally horizontal and perpendicular to the package front when the
logo
axis is generally vertical, and wherein at least a portion of the package
front is
translucent such that at least a portion of one roll end surface is visible
through the
package front.
In another aspect of the present invention, the invention includes a case of
tissue
rolls, the case including two case long faces in parallel orientation, two
case short
faces connecting and perpendicular to the two case long faces, a case bottom,
and a
case top; a removable panel including a portion of one of the case long faces
and a
portion of one of the case short faces, at least a portion of the removable
panel
bordered by a frangible line. The case also includes a package including a
plurality
of tissue rolls, two package sides, a package bottom, a package back, and a
package top; a package front in a generally vertical orientation, the package
front
spaced apart from and generally parallel to the package back, wherein the
package
front and the package back are coupled to and generally orthogonal to the
package
bottom, the package front including a primary package logo having a logo axis,
wherein the package is oriented in the case such that the logo axis is
parallel to the
case short faces and perpendicular to the case long faces.
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CA 02604853 2007-09-28
In another aspect of the present invention, the invention includes a method
for
providing tissue rolls, the method including packaging a plurality of tissue
rolls in a
package including a package front defining a package front plane, a package
bottom
defining a package bottom plane, and a primary logo having a logo axis,
wherein
each tissue roll has a longitudinal axis, and wherein the tissue rolls are
oriented in the
package such that each longitudinal axis is parallel to the package bottom
plane; and
shipping the tissue rolls such that each longitudinal axis is generally
vertical.
In another aspect of the present invention, the invention includes a method
for
improving the volume efficiency for shipping rolls of tissue, the method
including
packaging a plurality of tissue rolls in a plurality of packages each
including a
package front defining a package front plane, a package bottom defining a
package
bottom plane, and a primary logo having a logo axis, wherein each tissue roll
has a
longitudinal axis, and wherein the tissue rolls are oriented in the plurality
of packages
such that each longitudinal axis is parallel to the package bottom plane; and
assembling the plurality of packages in a case.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and aspects of the present invention and the
manner of attaining them will become more apparent, and the invention itself
will be
better understood by reference to the following description, appended claims
and
accompanying drawings, where:
Figure 1 is a perspective view of a tissue roll of the present invention.
Figure 2 is a perspective view of a package of the present invention including
the
tissue rolls of Fig. 1.
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CA 02604853 2007-09-28
Figure 3 is a perspective view of an alternate aspect of a package of the
present
invention including the tissue rolls of Fig. 1.
Figure 4 is a perspective view of a case of the present invention including
the
packages of either Fig. 2 or Fig. 3.
Figure 5 is a perspective view of a unit of the present invention including
the case of
Fig. 4.
Figure 6 is a perspective view of a trailer of the present invention including
the unit of
Fig. 5.
Repeat use of reference characters in the present specification and drawings
is
intended to represent the same or analogous features or elements of the
present
invention. The drawings are representational and are not necessarily drawn to
scale.
Certain proportions thereof may be exaggerated, while others may be minimized.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood by one of ordinary skill in the art that the present
discussion is
a description of exemplary aspects of the present invention only, and is not
intended
as limiting the broader aspects of the present invention.
The invention relates to improved configurations for shipping and handling
that
reduce the time necessary for shipping and handling and also reduce the amount
of
packaging materials used, thus reducing the cost to put a product on a retail
shelf.
As used herein and unless otherwise described, the term "width" generally
refers to
the longest horizontal dimension of a structure, the term "height" generally
refers to
the vertical dimension of a structure, and the term "depth" refers to the
shortest
horizontal dimension of a structure.
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CA 02604853 2007-09-28
The consumer-oriented tissue rolls 10 of the present invention are illustrated
in Fig. 1
and include paper towels and bath tissue, also known as toilet paper and by
other
names. Each tissue roll 10 is generally cylindrical in shape with a roll
height 12 and a
roll diameter 14. The tissue roll 10 has a central longitudinal axis 20
therethrough,
and an outer surface 22 that is generally parallel to the longitudinal axis
20. The
tissue roll 10 also has two opposing end surfaces 24 generally perpendicular
to the
outer surface 22 and the longitudinal axis 20. An exemplary tissue roll 10 of
bath
tissue has an as-packaged roll height 12 of approximately 4 5/16 inches and an
as-
packaged roll diameter 14 of approximately 3.9 inches. In various aspects of
the
present invention, the tissue roll dimensions may be of any suitable size. An
exemplary tissue roll 10 of paper towels has an as-packaged roll height 12 of
approximately 11 inches and an as-packaged roll diameter 14 of approximately
4.6-
6.0 inches.
Each tissue roll 10 is formed by winding a continuous web of tissue 26 around
the
longitudinal axis 20 to form an empty central bore 30 centered on the
longitudinal
axis 20. The tissue 26 in the tissue roll 10 has an inner end 32 adjacent the
central
bore 30 and an outer end 34 at the outer surface 22 of the tissue roll 10. The
tissue
26 may be wound around a tubular core 36, or the tissue roll 10 may be formed
without a core 36. If the tissue roll 10 has a core 36, the inner end 32 of
the tissue 26
may be attached to the core 36 using adhesive or other suitable means. The
outer
end 34 of the tissue 26 may be attached to the outer surface 22 of the tissue
roll 10.
The tissue 26 may include score lines 40 at regular intervals that define a
sheet 42
between two successive score lines 40. In use, a tissue roll 10 is unwound by
rotating the tissue roll 10 about its longitudinal axis 20 and drawing tissue
26 from the
outer surface 22.
Due to the structure of the tissue roll 10, the tissue roll 10 has greater
compressive
strength in a direction along the longitudinal axis 20 than it does in a
direction
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CA 02604853 2007-09-28
perpendicular to the longitudinal axis 20. A force in a direction
perpendicular to the
longitudinal axis 20 tends to have a c'rushing effect on the tissue roll 10
and can
cause the central bore 30 to collapse or become partially or completely
flattened.
While tissue rolls 10 may be packaged and sold individually, the present
invention
relates to packaging a plurality of tissue rolls 10 in one package 50. In one
aspect of
the present invention, a package 50 for a plurality of tissue rolls 10 is
generally
rectilinear with a package front 52, a package back 54, two package sides 56,
a
package top 58, and a package bottom 60. The package front 52 includes a
package front width 62 and a package front height 64. The package bottom 60
includes a package bottom depth 66. The package 50 may be constructed from a
poly film or any other suitable material. Individual tissue rolls 10 or groups
of tissue
rolls 10 are typically packaged in smaller units prior to assembly into the
package 50,
yielding two layers of packaging material for each tissue roll 10. In one
aspect of the
present invention, the plurality of tissue rolls 10 are positioned in the
package 50
without additional inner packaging materials.
In prior art practice, tissue rolls 10 are always stacked such that their
longitudinal
axes 20 are vertical because of the strength profile of a typical tissue roll
10
described above. To minimize the volume occupied by a given number of tissue
rolls
10, tissue rolls 10 are usually stacked such that their longitudinal axes 20
are
collinear. Tissue rolls 10, whether individually wrapped or multiply packed,
are
transported, stored, and displayed on a retail shelf with their longitudinal
axes 20 in a
vertical orientation.
Although the package 50 may hold any suitable number of tissue rolls 10, in
one
particular example the package 50 includes twenty-four tissue rolls 10 in an
array of
three tissue rolls 10 by four tissue rolls 10 by two tissues rolls 10. In the
as-displayed
orientation illustrated in Fig. 2, the package 50 generally has dimensions of
three roll
heights 12 wide, four roll diameters 14 high, and two roll diameters 14 deep.
Using
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CA 02604853 2007-09-28
the tissue roll exemplary dimensions described above, an exemplary package 50
has
the outer dimensions of 12.938 inches wide, 15.625 inches high, and 7.813
inches
deep.
The package 50 also includes at least one primary package logo 70 or other
identifying feature on the package front 52. The primary package logo 70 is
properly
oriented in an upright, readable orientation as illustrated in Fig. 2 when the
package
50 is displayed on a retail shelf. The primary package logo 70 has a logo axis
74 that
is vertical when the primary package logo 70 is properly oriented in an
upright,
readable orientation. The package 50 may also include a secondary package logo
78 or other identifying feature on another side of the package 50, such as on
the
package bottom 60 as illustrated in Fig. 2, to allow a retailer some
flexibility in
displaying the package 50 on a retail shelf. The package 50 may include
additional
logos and other information as desired by the manufacturer, distributor,
retailer, or
other interested party.
The package 50 illustrated in Fig. 2 is designed to be displayed on a retail
shelf with
the longitudinal axes 20 of the tissue rolls 10 in a horizontal orientation
and parallel to
a front edge of the retail shelf such that the package front 52 is visible to
a consumer.
The tissue rolls 10 are resistant to crushing while on the retail shelf
because the
maximum weight to be borne by a tissue roll 10, that of the three tissue rolls
10
above it, does not easily crush a tissue roll 10.
Another aspect of the present invention illustrated in Fig. 3 provides a
response to
the consumer behavior of purchasing by roll count and, to a lesser degree,
roll size or
diameter. Using prior packaging methods and then displaying the packages 50 on
their sides provides such information to a consumer but eliminates the display
of a
logo and other information.
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CA 02604853 2007-09-28
In this aspect, the primary package logo 70 is still displayed on the package
front 52
but the tissue rolls 10 are oriented in the package 50 such that their
longitudinal axes
20 are perpendicular to the package front 52 rather than parallel to the
package front
52 in the previous aspect. When the package 50 in this aspect is displayed on
the
retail shelf with the longitudinal axes 20 of the tissue rolls 10 still
horizontal but
perpendicular to the front edge of the retail shelf, one end surface 24 of
each tissue
roll 10 can be visible to a consumer. In this orientation, the consumer may
immediately evaluate the diameter of each tissue roll 10 in the package 50 and
generally the number of rolls in the package 50 without removing the package
50
from the retail shelf.
To add further value to this aspect of the present invention, at least a
portion of the
package front 52 is translucent such that at least a portion of an end surface
24 of at
least one tissue roll 10 is visible through the package front 52. In another
aspect of
the present invention, all of an end surface 24 of one tissue roll 10 is
visible through
the package front 52. In another aspect of the present invention, at least a
portion of
an end surface 24 of a plurality of tissue rolls 10 is visible through the
package front
52. In another aspect of the present invention, all of an end surface 24 of a
plurality
of tissue rolls 10 is visible through the package front 52. In another aspect
of the
present invention, at least a portion of an end surface 24 of each tissue roll
10 is
visible through the package front 52. In another aspect, an end surface 24 of
each
tissue roll 10 is visible through the package front 52, although the primary
package
logo 70 may occlude a portion of the view of the end surfaces 24.
As used herein, the term "translucent" generally refers to permitting the
passage of
light, both in the sense of being transparent, in which objects may be seen
clearly
therethrough, and in the sense that light may be transmitted and diffused such
that
objects are not seen clearly therethrough.
Unlike prior products, the package 50 of the present invention is not
transported and
stored in the same orientation as it is displayed on a retail shelf, as will
be described
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CA 02604853 2007-09-28
further below. In the as-transported orientation illustrated in Fig. 4, the
package 50
generally has dimensions of four roll diameters 14 wide, three roll heights 12
high,
and two roll diameters 14 deep. This aspect of the present invention allows
the
tissue rolls 10 to be transported and stored with their longitudinal axes 20
in a vertical
orientation, but displayed on a retail shelf with their longitudinal axes 20
in a
horizontal orientation.
While packages 50 of tissue rolls 10 may be cased and sold individually, the
present
invention relates to casing a plurality of packages 50 of tissue rolls 10 in
one case 80.
In one aspect of the present invention, a case 80 for a plurality of packages
50 is
generally rectilinear with two case long faces 82, two case short faces 84, a
case top
85, and a case bottom 86. The case 80 also includes a case width 87, a case
height
88, and a case depth 89. The case 80 may be constructed from corrugated board
or
any other suitable material. The case 80 provides structural strength to
protect the
tissue rolls 10 from damage as well as a covering to protect the tissue rolls
10 and
packages 50 from dust and dirt during storage, handling, and shipment.
Packages 50 of tissue rolls 10 are always stacked such that the longitudinal
axes 20
of the tissue rolls 10 are vertical because of the strength profile of a
typical tissue roll
10 described above. To minimize the volume occupied by a given number of
tissue
rolls 10, tissue rolls 10 are usually stacked such that their longitudinal
axes 20 are
collinear. Tissue rolls 10 are therefore transported and stored with their
longitudinal
axes 20 in a vertical orientation.
Although the case 80 may hold any suitable number of packages 50 of tissue
rolls
10, in one particular example the case 80 includes six packages 50 of twenty-
four
tissue rolls 10 each in an array of three packages 50 by two packages 50. In
this
example, the case 80 includes six packages 50 in a two-by-three array such
that six
package tops 58 are in a face-to-face arrangement with one case long face 82,
two
package fronts 52 are in a face-to-face arrangement with one case short face
84, and
CA 02604853 2007-09-28
two package backs 54 are in a face-to-face arrangement with the other case
short
face 84. In the arrangement illustrated in Fig. 4, the case 80 generally has
dimensions of three package bottom depths 66 wide, two package front widths 62
high, and one package front height 64 deep. This translates to an array of
tissue
rolls 10 that, absent packaging, is six roll diameters 14 wide by six roll
heights 12
high by four roll diameters 14 deep for a total of 144 tissue rolls 10 in the
case 80.
Using the tissue roll and package exemplary dimensions described above, such
an
exemplary case 80 has the outer dimensions of 23.375 inches wide, 26.625
inches
high, and 15.563 inches deep.
The case 80 may include at least one primary case logo (not shown) or other
identifying feature on at least one of the case long faces 82, case short
faces 84,
case top 85, and case bottom 86. The case 80 may also include a secondary case
logo (not shown) or other identifying feature on at least one of the case long
faces
82, case short faces 84, case top 85, and case bottom 86. The case 80 may
include
additional logos and other information as desired by the manufacturer,
distributor,
retailer, or other interested party.
The case 80 also includes a perforated display feature in the form of a
removable
panel 94 of the case 80. The removable panel 94 is defined by lines 96 of
perforations or other frangible features in one case long face 82 and one case
short
face 84. As a result, the removable panel 94 includes part of that case long
face 82
and part of that case short face 84. Removal of the removable panel 94 exposes
packages 50; once the removable panel 94 is removed and the case 80 is
positioned
on a retail shelf as described above, two packages 50 are immediately viewable
and
in their proper orientation, with four more packages 50 behind them.
The case 80 illustrated in Fig. 4 is designed to be positioned on a retail
shelf with the
case top 85 to the left of a viewing consumer, the case bottom 86 to the right
of a
viewing consumer, a case short face 84 in a vertical orientation facing the
consumer,
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CA 02604853 2007-09-28
and a case long face 82 in horizontal orientation above the packages 50 of
tissue
rolls 10. In this orientation, longitudinal axes 20 of the tissue rolls 10 are
in a
horizontal orientation and parallel to a front edge of the retail shelf such
that package
fronts 52 are visible to a consumer.
The removable panel 94 allows for a quick transition from storeroom to shelf;
a
stocker simply removes the removable panel 94 by hand or using tools and
places
the case 80 on the retail shelf in the proper orientation. Packages 50 of
tissue rolls
are then immediately viewable and obtainable by a consumer. The display on the
10 shelf is six roll heights 12 wide and four roll diameters 14 high, with a
depth of six roll
diameters 14 while the case 80 is still full. The resulting presentation or
display
allows for two package facings and provides for a substantially larger package
graphics billboard than on comparative configurations and/or display
strategies.
Another aspect of the present invention uses the packages 50 illustrated in
Fig. 3 in
which the primary package logo 70 is still displayed on the package front 52
but the
tissue rolls 10 are oriented in the package 50 such that their longitudinal
axes 20 are
perpendicular to the package front 52 rather than parallel to the package
front 52. In
this example, the case 80 includes six packages 50 still in a two-by-three
array such
that six package tops 58 are in a face-to-face arrangement with one case long
face
82, two package fronts 52 are in a face-to-face arrangement with one case
short face
84, and two package backs 54 are in a face-to-face arrangement with the other
case
short face 84. Similarly to the arrangement illustrated in Fig. 4, the case 80
generally
has dimensions of three package bottom depths 66 wide, two package front
widths
62 high, and one package front height 64 deep. This translates to an array of
tissue
rolls 10 that, absent packaging, is six roll heights 12 wide by six roll
diameters 14
high by four roll diameters 14 deep for a total of 144 tissue rolls 10 in the
case 80.
Similarly to that described above for Fig. 4, the case 80 in this aspect is
designed to
be positioned on a retail shelf with the case top 85 to the left of a viewing
consumer,
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CA 02604853 2007-09-28
the case bottom 86 to the right of a viewing consumer, a case short face 84 in
a
vertical orientation facing the consumer, and a case long face 82 in
horizontal
orientation above the packages 50 of tissue rolls 10. In this orientation,
longitudinal
axes 20 of the tissue rolls 10 are in a horizontal orientation and
perpendicular to a
front edge of the retail shelf such that package fronts 52 and at least one
roll end
surface 24 are visible to a consumer upon removal of the removable panel 94.
Once
the removable panel 94 is removed and the case 80 is positioned on a retail
shelf as
described above, two packages 50 are immediately viewable and in their proper
orientation, with four more packages 50 behind them. Packages 50 of tissue
rolls 10
are immediately viewable and obtainable by a consumer. The display on the
shelf in
this aspect will be six roll diameters 14 wide and four roll diameters 14
high, with a
depth of six roll heights 12 while the case 80 is still full.
While cases 80 of packages 50 may be shipped and sold individually, the
present
invention relates to assembling a plurality of cases 80 in one unit 100. In
one aspect
of the present invention, a unit 100 is the primary arrangement for shipping
purposes,
and is generally rectilinear with two unit wide faces 102, two unit narrow
faces 104, a
unit bottom 105, and a unit top 106. The unit 100 also includes a unit width
107, a
unit height 108, and a unit depth 109. The unit 100 is typically an assembly
and not
constructed from packaging materials, although the unit 100 may be wrapped
with
poly film, corrugated board, or any other suitable material to protect the
unit 100 from
damage or disassembly during shipping.
Cases 80 of packages 50 are always stacked such that the longitudinal axes 20
of
the tissue rolls 10 are vertical because of the strength profile of a typical
tissue roll 10
described above. Tissue rolls 10 are therefore transported and stored with
their
longitudinal axes 20 in a vertical orientation.
Although the unit 100 may hold any suitable number of cases 80, in one
particular
example illustrated in Fig. 5 the unit 100 includes twenty cases 80 of six
packages 50
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CA 02604853 2007-09-28
each in an array of four tiers 110 with five cases 80 in each tier 110. In
this example,
.. '
each tier 110 of five cases 80 has three cases 80 in case long face 82 to case
long
face 82 alignment. Two cases 80 are added such that the additional cases 80
are in
case short face 84 to case short face 84 orientation with each other, and in
an
orientation of case long face 82 of the additional cases 80 to case short face
84 of
the original three cases 80. Adjacent tiers 110 may have alternating
arrangements
with respect to which side of a given tier 110 the first three cases 80 in
case long face
82 to case long face 82 alignment are positioned.
In the arrangement illustrated in Fig. 5, the unit 100 generally has
dimensions of
three case depths 89 or two case widths 87 wide, four case heights 88 high,
and one
case width 87 plus one case depth 89 deep. This translates to an array of
tissue rolls
10 that, absent packaging, is twelve roll diameters 14 wide by twenty-four
roll heights
12 high by ten roll diameters 14 deep for a total of 2880 tissue rolls 10 in
the unit 100.
Using the tissue roll, package, and case exemplary dimensions described above,
such an exemplary unit 100 has the outer dimensions of 46.75 inches wide,
106.5
inches high, and 38.94 inches deep.
This arrangement of the unit 100 yields a volume efficiency of 94.4 percent.
100
percent volume utilization or efficiency for a unit is defined as a volume
that is 48
inches wide, 107 inches high, and 40 inches deep for a total of 205,440 cubic
inches
or 118.88 cubic feet. The closer to the standard of 48 inches by 107 inches by
40
inches a shippable unit is, the more economical it is to store, handle, and
transport it.
Typical previous tissue unit volume efficiencies are 83 to 90 percent.
The unit 100 may also include one or more logos or other identifying features
and
other information as desired by the manufacturer, distributor, retailer, or
other
interested party.
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CA 02604853 2007-09-28
Another aspect of the present invention uses the packages 50 illustrated in
Fig. 3 in
which the primary package logo 70 is still displayed on the package front 52
but the
tissue rolls 10 are oriented in the package 50 such that their longitudinal
axes 20 are
perpendicular to the package front 52 rather than parallel to the package
front 52. In
this example, the unit 100 still includes twenty cases 80 of six packages 50
each in
an array of four tiers 110 with five cases 80 in each tier 110. Similarly to
the
arrangement illustrated in Fig. 5, the unit 100 generally has dimensions of
three case
depths 89 or two case widths 87 wide, four case heights 88 high, and one case
width
87 plus one case depth 89 deep. This translates to an array of tissue rolls 10
that,
absent packaging, is twelve roll heights 12 wide by twenty-four roll diameters
14 high
by six roll heights 12 plus four roll diameters 14 deep for a total of 2880
tissue rolls 10
in the unit 100.
While units 100 of cases 80 may be shipped and sold individually, the present
invention includes assembling a plurality of units 100 in one trailer 120. In
one
aspect of the present invention, a trailer 120 is the primary arrangement for
shipping
purposes, and is generally rectilinear.
Although the trailer 120 may hold any suitable number of units 100, in one
particular
example illustrated in Fig. 6 the trailer 120 includes thirty-two units 100 of
twenty
cases 80 each in an array of two rows of sixteen units 100 each, where the
units 100
within a row are in unit wide face 102 to unit wide face 102 orientation, and
wherein
the units 100 between rows are in a unit narrow face 104 to unit narrow face
104
orientation.
In the arrangement illustrated in Fig. 6, the trailer 120 generally has
dimensions of
sixteen unit depths 109 wide, one unit height 108 high, and two unit widths
107 deep.
This translates to an array of tissue rolls 10 that, absent packaging, is 160
roll
diameters 14 wide by twenty-four roll heights 12 high by twenty-four roll
diameters 14
deep for a total of 92,160 tissue rolls 10 in the trailer 120. Using the
tissue roll,
CA 02604853 2007-09-28
package, case, and unit exemplary dimensions described above, such an
exemplary
trailer 120 has the outer dimensions of 623.0 inches wide, 106.5 inches high,
and
93.5 inches deep.
This arrangement of the trailer 120 yields a volume efficiency increase of 22
percent
to a volume efficiency of 92 percent. The trailer fill efficiency of the
present invention
allows for an increase in capacity use in a standard 53-foot dry goods trailer
that
nominally measures 53 feet long (wide in the present description) by 98 inches
wide
(deep in the present description) by 110 inches tall. The accepted capacity of
a
standard dry goods trailer in the United States is 3300 cubic feet. The
present
invention allows for thirty-two units to be placed within that space, which is
an almost
perfect trailer fill situation. Previous attempts typically allow fewer tissue
rolls per
case 80 and unit 100, and only thirty units 100 per trailer 120.
Another aspect of the present invention uses the packages 50 illustrated in
Fig. 3 in
which the primary package logo 70 is still displayed on the package front 52
but the
tissue rolls 10 are oriented in the package 50 such that their longitudinal
axes 20 are
perpendicular to the package front 52 rather than parallel to the package
front 52. In
this example, the trailer 120 still includes thirty-two units 100 of twenty
cases 80 each
in an array of two rows of sixteen units 100 each. Similarly to the
arrangement
illustrated in Fig. 6, the trailer 120 generally has dimensions of sixteen
unit depths
109 wide, one unit height 108 high, and two unit widths 107 deep. This
translates to
an array of tissue rolls 10 that, absent packaging, is ninety-six roll heights
12 plus
sixty-four roll diameters 14 wide by twenty-four roll diameters 14 high by
twenty-four
roll heights 12 deep for a total of 92,160 tissue rolls 10 in the trailer 120.
The present invention provides the advantages of a unique manufacturing and
merchandising solution. The unique case count, configuration, orientation, and
presentation provide an entire at-retail-shelf solution. A case count of six
packages
50 of twenty-four tissue rolls 10 each provides a unique quantity over the
typical case
16
CA 02604853 2007-09-28
of four twenty-four-packs for shipment and retail shelf pack-out. Pack-out, or
stocking retail shelves, using cases 80 of six packages 50 each and wherein
the
cases 80 have removable panels 94 provides efficiency for retailers to stock
shelves
and leads to fewer out-of-stock situations. The case configurations and
orientations
of the present invention allow for a unique display of the packages 50. Due to
the
solution provided by the present invention, each case 80 will be oriented on
its side
during retail shelf presentation. In addition, environmental sustainability is
improved
due in part to the elimination of individually-wrapped packages. Environmental
sustainability is also improved due in part to the case quantity of six twenty-
four-
packs instead of four or fewer twenty-four-packs in a case. The present
invention
accomplishes at least an 11 percent reduction in packaging materials. Finally,
the
case quantity, configuration, and orientation improvements allow for increased
efficiency in distribution strategy.
These and other modifications and variations to the present invention may be
practiced by those of ordinary skill in the art, without departing from the
spirit and
scope of the present invention, which is more particularly set forth in the
appended
claims. In addition, it should be understood that aspects of the various
aspects of the
present invention may be interchanged either in whole or in part. Furthermore,
those
of ordinary skill in the art will appreciate that the foregoing description is
by way of
example only, and is not intended to limit the invention so further described
in such
appended claims.
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