Note: Descriptions are shown in the official language in which they were submitted.
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Packaging unit and method for packing products
The present invention relates to a packaging unit for products like eggs and
similar
products like kiwis and tomatoes, for example.
Egg cases, containers or cartons known in practice are generally fabricated
from carton
made of moulded pulp from paper material. Such units comprise a bottom part
provided with
compartments for individual products, and a cover part that is often hingedly
connected to the
bottom part. Products like eggs are transported in these units and displayed
on shelves in
supermarkets, for example. Packaging units are often provided with labels that
are often made of
paper provided with a print and glued to the carton of the packaging unit. One
of the problems
associated with providing a paper label with a carton is the restriction for
recycling possibilities.
The present invention has for its object to obviate or at least reduce the
above stated
problems with known packaging units, for example packaging units for products
like eggs, such as
egg cases or egg cartons.
The present invention provides for this purpose a packaging unit according to
the
invention, the packaging unit comprising:
- a container made of moulded pulp with a bottom part for holding a
product; and
- a label made of moulded pulp comprising an embossing with the label being
attached to the container.
By providing a packaging unit comprising a container, preferably a carton,
made of
moulded pulp together with a label that is made of moulded pulp a full fibre
packaging unit is
achieved. Such full fibre packaging unit can be recycled favourably. In
addition, the packaging unit
according to the present invention can be provided free of addition or
chemical substances that are
required for units with conventional paper labels. This achieves a significant
effect on
sustainability. This effect can be improved further by having the label shaped
in the form of a
rectangle such that no production waste is created.
As a further advantage of the packaging unit according to the present
invention the
freedom for designing such a packaging unit is significantly increased. So it
would be possible to
present brand and/or product specific designed features possibly presenting
the brand or product
identity using the embossed label for the packaging unit according to the
present invention. This
provides additional possibilities in the design process. For example, one
container or carton design
can be used for a range of products for different brands as the specific
design features and
identifications are provided on the label. This significantly reduces of
change-overs related to the
containers or cartons such that the cost can be carried by a (large) number of
products if the
designed features for which the change-over is done. Laborious adaptations to
the production
process can be kept to a minimum while improving the design options for the
packaging unit.
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The moulded pulp is manufactured from so-called mouldable paper relating to
paper that
has been compacted in the wet phase. This compacting of the wet pulp improves
the flexibility of
the label material when the paper is dried such that it can be stretched
plastically without breaking
the surface of the paper. This enables the provision of embossing on the
label. For example, with a
10-20% elongation of the fibres without breaking the surface of the label it
is possible to impose an
embossing on the flat surface with a depth of about 1 mm. This enables the
generation of strong
and surprising visual and optic effects, for example.
As a further advantage of a full fibre packaging unit comprising a container,
such as a
carton, made of moulded pulp and a label made of moulded pulp is over all
visual appearance
providing a unitary look or visual associated with the packaging unit.
Furthermore, providing the
container and a label of the packaging unit according to the present invention
of similar material
improves the haptic perception of someone handling the packaging unit. In
fact, someone is
provided with a unitary product when touching the product. Such tactile
feedback of the unitary
material packaging unit according to the present invention to the user and/or
person handling the
packaging unit provides this user and/or person with a unitary and association
with sustainability.
The haptic effect described earlier that is associated with the packaging unit
according to
the present invention is further enhanced by providing the label with an
embossing such that the
optic effect is approved and/or the visual appearance of the packaging unit is
strengthened due to
the three-dimensional effect of such embossing on a label.
As a further advantage the label optionally is printed as a matt surface
combined with a
relatively soft touch. These properties are similar to the properties of the
container such that a
unitary visual appearance is achieved strengthening the sustainable effect of
the packaging unit
according to the present invention.
Furthermore, the combination of the container, such as a carton, and label
according to the
invention further reduces any ridging effects that may occur when handling the
packaging unit.
In a presently preferred embodiment a container that is made of moulded pulp
can be made
of recycled fibres. In a presently preferred embodiment the label that is also
made of moulded pulp
is made of so-called virgin fibres that are better equipped to deal with the
embossing of the label.
Preferably, the embossing has a depth in the range of 0.1 ¨ 1.5 mm, and more
preferably in
a range 0.5 ¨ 1.0 mm. Especially an embossing in the range of 0.5 ¨ 1.0 mm has
shown an optimal
visual appearance without putting too much restrictions on the manufacturing
equipment for
producing the packaging units according to the present invention.
In a presently preferred embodiment of the packaging unit according to the
invention the
container further comprises a cover part with a top, front and rear surface
with a label being
attached to at least the top surface.
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By providing a cover part the products are amongst other things protected by
the
packaging units according to the present invention. By providing a label that
is attached to at least
the top surface a visual and haptic effect is achieved wherein the packaging
unit remains the full
fibre such that the packaging unit is a sustainable packaging unit that can be
recycled relatively
easily. Preferably, the top surface of the label also comprises an embossing.
Besides the visual and
haptic effect thereof, this embossing increases the friction resistance
between two packaging units
according to the present invention that are stapled on top of each other. This
improves the stability
of a stack of packaging units according to the present invention. This reduces
damages to the
packaging units and the products contained thereby during transport and
handling thereof.
In a presently preferred embodiment the friction coefficient of the mouldable
label is about
0.53, and above 0,45. Additional measures, such as providing an embossing, may
further increase
the friction resistance.
Preferably the bottom part of the packaging unit is provided with friction
resistance
increasing elements. Such elements may comprise ridges, grooves, pins, notches
etcetera. This
further improves the stability of a stack of packaging units, according to the
present invention.
Preferably, the friction resistance increasing elements provided on the bottom
part of the packaging
unit engage the embossing that is provided on the label provided on the cover
part of the packaging
unit to further improve the stability of a stack of packaging units.
As a further advantage of providing cover part with an embossed label is that
an impact of
a packaging unit that is stacked on another packaging unit will not result in
impact effects, such as
indentation that significantly affects the overall visual appearance of the
packaging unit according
to the present invention. Such indentation will not change the overall
appearance of the embossed
label.
The shape of the embossing may also contribute to the an impact resistance.
For example,
walls and elements, preferably substantially oriented in the direction of the
impact force, may
improve the impact resistance.
In a presently preferred embodiment according to the present invention the
label is
attached to the top surface such that air cushions are formed between the
label and the cover part.
By providing air cushions the impact resistance of the label against loads put
thereon is
greatly increased. This reduces the risk of products held by the packaging
unit according to the
present invention being damaged. Also, the overall visual appearances being
maintained more
easily. By providing an embossing a type of relief or a topography or engraved
surface is provided
such that small air rooms or air cushions are defined between the top surface
of the cover part and
the label that is attached thereto.
As a further effect, the air cushions provide an insulating effect. For
example, this
improves handling the container or packaging unit containing heated products.
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In a presently preferred embodiment of the present invention the label of the
packaging
unit is provided with a visual appearance substantially similar to that of the
container.
Providing the label and container with a substantial similar visual appearance
contributes
to the effect on sustainability. This visual appearance may involve roughness,
hardness etc.
Preferably, the label comprises an average surface roughness between 0.1 and
100 [tin, more
preferably between 0.5 and 10 gm, and most preferably between 1 and 4 gm.
Preferably, the label further comprises a number of glue edges. These edges
are glued
when attaching the label to the container. This assures that the edges of the
label are strongly
attached to the container. In addition, this minimizes the amount of glue that
is required when
attaching the label to the container. Furthermore, this maintains the effect
the air cushions may
have on the impact resistance that is described earlier. Alternatively, or in
addition thereto, the
contact areas of the embossing with the container or packaging unit are glued
to the container of
packaging unit. This increases the impact resistance. In addition, this
contributes to an anti-ridging
effect.
In a presently preferred embodiment according to the present invention the
front surface of
the bottom part of the packaging unit comprises a protrusion and the cover
part comprises a front
surface provided with a corresponding opening together defining a lock, and
further the label
comprises a surface provided with an embossing at the location of the opening
in the cover front
surface to enhance the locking function of the lock.
By locking the cover part and the bottom part at the front surface the
packaging unit can be
closed. In a presently preferred embodiment the rear surfaces of the cover
part and the bottom part
are hingedly connected. Preferably, the bottom part is provided with a
protrusion shaped as an edge
or a notch, and cover part is provided with a corresponding opening. As the
protrusion fits in the
opening a lock is achieved. The protrusion can be provided directly on the
bottom part or on a
closing flap that is hingedly connected to the bottom part. Optionally, the
lock is kept out of sight
in the closed position due to the provision of the label over the opening,
preferably by providing in
the label an embossing at the location of the opening in the cover part. This
provides an additional
room or cavern for receiving the locking edge. This is especially advantageous
for a packing unit
with a concealed lock. For example, the label can be embossed with a depth of
1 mm, such that the
protrusion in the bottom part can be 1 mm larger or be manoeuvred 1 mm further
into the opening
in the cover part. This enhances the locking function of the lock such that
the packaging unit
according to the present invention is firmly closed. In a presently preferred
embodiment the
locking edge connected to the bottom part of the packaging unit protrudes
outwards through the
opening in the cover part at a slightly downward angle. This improves the
locking function.
In a further embodiment according to the invention the label further comprises
a groove
through which an end of the protrusion protrudes in a closed position of the
packaging unit. This
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further enhances the locking function. Furthermore, extending an and of the
protrusion of the
locking member slightly through the groove in the label provides a consumer
with an indication
where to find the lock and how to open the packaging unit from a closed
position.
In a presently preferred embodiment according to the present invention the
label comprises
5 an embossing with a shape such that the embossed label behaves as a
stacking element.
Often packaging units are provided with so-called denesting or stacking nocks
that
function as a type of spacer maintaining a distance between individual
packaging units when they
are stacked in an open position awaiting for the products to be put inside the
packaging unit, for
example. The label is provided with an embossing with a shape such that the
embossed label
behaves as a stacking element. For example, this shape relates to an embossing
with a sufficient
depth. This may obviate the need for separate stacking nocks or other
denesting/stacking elements
such that the overall design of the packaging unit according to the present
invention can be made
simpler and possibly less costly.
In a presently preferred embodiment according to the present invention the
label comprises
a two-sided print.
By providing the label with a two-sided print it is possible to provide
information with
both sides of the label. Therefore, the two-sided print preferably is combined
with a container
having an opening that corresponds to the label print or at least one side
thereof. This achieves that
one side of the label is in plain sight and the other (back) side of the label
is visible through the
opening of the carton. For example, the top surface of the label can be
provided with the general
markings indicating the type of product as a branch information. The back side
of the label can be
provided with specific product information that would be visible when the
cover part is lifted from
the bottom part and the specific product information is made visible through
an opening provided
in the cover part of the packaging unit. This prevents the need for a separate
print on the inside of
the cover part of the packaging unit thereby making the manufacturing process
of such packaging
unit more simple. In addition, the manufacturing process with the method
according to the
invention is more cost effective. For example, this is achieved by reducing
the amount of MF
material and/or omitting the inside print on the MF material. In addition, the
MF product does not
necessarily require a MF printer and can be handled on the labelling
equipment.
The present invention further relates to a method for packing products
comprising the step
of providing a packaging unit as described above and placing therein one or
more of the products.
Such method provides the same effects and advantages as described in respect
of the
packaging unit. In fact, the method can be used on a large number of different
embodiments of the
packaging unit according to the invention.
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Further advantages, features and details of the invention are elucidated on
the basis of
preferred embodiments thereof, wherein reference is made to the accompanying
drawings, in
which:
- figure 1 shows an embodiment of the packaging unit according to the
invention in a
closed position;
- figure 2 shows a front view of the packaging unit of figure 1;
- figure 3 shows a side view of the packaging unit of figure 1;
- figure 4 shows a top view of the packaging unit of figure 1;
- figure 5 shows a cross section of the packaging unit of figure 4;
- figure 6 show the packaging unit without label; and
- figures 7, 8 and 9 show alternative embodiments of the packaging unit
according to the
invention.
A packaging unit 2 (Figures 1-4) comprises a bottom part 4 with a front
surface 6, two side
surfaces 8, a back side 10, and a bottom side 12. In the illustrated
embodiment, a cover part 14 is
hingedly connected with hinge 16 to bottom part 4 to allow cover part 14 to
move relatively to
bottom part 4 between an open and a closed position. Cover part 14 further
comprises front surface
18, two side surfaces 20, a back side surface 22 and a top surface 24.
Label 26 is provided with top surface 28 on which text and/or images are
printed. In the
illustrated embodiment, for illustrative purposes, label 28 is provided with
embossed wording "ei"
(egg). In the illustrated embodiment label 28 is provided with front surface
30. Label 26 comprises
an embossing 32 with "peaks" 34 and "valleys" 36, and glue edges 38.
On the inside of bottom part 4 (Figure 5) product receiving compartments 40
are provided
having contours matching at least partially the outer contours of products,
like eggs, kiwis and
tomatoes, for example. Support cones 42 are provided to add stability and
strength to packaging
unit 2.
In the illustrated embodiment of packaging unit 2 front surfaces 6, 18 of
bottom part 4 en
top part 14 are locked with lock 44 in the closed position of packaging unit
2. In figure 6 packaging
unit 2 is illustrated without label for illustrative purposes. In the
illustrated embodiment bottom
part 4 is provided with front edge 46 comprising connecting end 48 connecting
to the front surface.
From connecting end 48 edge 46 comprises first edge part 50, which extends in
a slightly inclined
downwards direction from connecting end 48. At first transition 50 second edge
part 52 starts to
extend in a downward direction at an increased angle as compared to first edge
part 50. Second
transition 54 connects second edge part 52 to free end 56 of locking edge 46.
In the illustrated closed position of packaging unit 2 (Figure 5) free end 56
extends through
opening 58 in front surface 18 of cover part 14 into hollow part or cavern 60
at the location of the
inside of a peak 34 of embossing 32 provided in label 26.
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In the illustrated embodiment (Figure 5), in the closed position, connecting
end 48 is
preferably positioned above opening 58 and first transition 50 preferably
engages the upper edge of
opening 58. Furthermore, in the illustrated embodiment locking edge 46
protrudes outwardly
through opening 50 at a slightly downward angle to increase the locking
function. It will be
understood that according to the invention other locks may also be applied,
preferably using the
hollow embossing part 60 for receiving a locking part. In the illustrated
embodiment this results in
a concealed lock 44. Lock 44 enhances the locking friction as the edge,
protrusion or projection
can be dimensioned larger or can be pushed further into opening in a closed
position of packaging
unit 2 as compared to conventional packaging units with flat labels.
Alternative packaging units 62, 94 (figures 7, 8 and 9) are provided with an
alternative
lock 64. Lock 64 comprises first edge part 66 that is connected to edge 68 of
front surface 70 of
bottom part 72. In the illustrated embodiment first edge part 66 extends in a
slightly inclined
downwards direction from edge 68. At first transition 74 second edge part 76
starts to extend in a
downward direction at an increased angle as compared to first edge part 66. In
the illustrated
embodiment (figure 7) there is provided second transition 78 that connects
second edge part 80 to
free end 82 that protrudes through groove or slit 84 in label 86 of cover part
88 of locking edge 46.
In the illustrated embodiment two grooves 84 (figure 8) are provided.
Preferably, free end 82 only
slightly protrudes through groove 84 (figure 8), for example 1 mm. In the
illustrated embodiment
second edge part 76 extends through opening 90 in cover part 88 into cavern or
room 92 in label
86. Free end 82 extends through groove 84. This improves the locking function.
In addition, free
end 82 extending through groove 84 provides an indication to a consumer of
where to find lock 64
for opening packaging unit 62. Free end 82 may extend, in first alternative
embodiment 62,
through label 86 as a protruding part (figure 7). In a second presently
preferred embodiment 94,
free end 82 also (slightly) extends through the label material, however, in
this second alternative
embodiment 94 free end 82 remains in a recessed part 96 of label 86 (figures
8, 9) as illustrated
with groove or opening 84 (figure 8). Free end 82 may be provided at an angle
with the second
edge part to improve the locking function, for example similar to the first
alternative embodiment
62, and/or with an additional edge (not shown) on free end 82.
In the illustrated embodiment, the cover part is provided with an optional
window opening
(not shown) through which the back side of the label is visible. This back
side of the label is
optionally provided with text and/or images.
The weight of the label material in a presently preferred embodiment is in the
range of 90-
200 g/m2, preferably about 120-150 g/m2. This maintains a relatively low
weight of the entire
packaging unit according to the present invention. In addition, when applied
to a container, such as
a carton, having a bottom and a cover part, especially the cover part can be
provided with small
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dimensions, more specifically having a reduced thickness thereof, such that
the overall weight of
the packaging unit according to the present invention is maintained or even
slightly reduced.
Alternative packaging units according to the invention may hold other
products, like a
hamburger, salad etc.
When packing products like kiwi's, eggs etc. the products are placed in
compartments 40.
In the illustrated embodiment cover part 14 is closed and engages bottom part
4. Lock 44 locks
packaging unit 2. In the illustrated embodiment, when locking packaging unit
2, free end 56
protrudes through opening 50 of front surface 18 of cover part 14 into hollow
part/room or cavern
60 thereby enhancing the locking function.
The present invention is by no means limited to the above described, preferred
embodiments thereof. The rights sought are defined by the following claims,
within the scope of
which many modifications are possible. For example, second edge part 54, 76
and first edge part
50, 66 can be integrated into one edge part.
