The present invention relates to a collapsed hand erectable carton. More particularly, but not exclusively, it relates to cardboard packaging for direct-contact with perishable goods, such as meat.

BACKGROUND OF THE INVENTION

In the perishable goods industry, it is particularly important to pack and transport perishable goods in packaging capable of storing the goods effectively. It is generally desirable to contain perishable goods such as meat within a container such that it is protected from contamination and liquid from the meat does not leak out.

To automate the process, typically folding and erecting machines are used, so that the cardboard containers are quickly erected, ready for receiving the meat, and so that a large quantity of containers can be formed quickly for use.

Generally, these machines are customised to the particular cardboard container blank and are employed to erect the cartons at the site of packing the meat. These folding and erecting machines are expensive, and generally take up a large amount of space at the packing locations.

It may therefore be desirable to provide an alternative packaging method which does not require these customised folding and erecting machines at the packing site, while still providing required quantities of the container which is effective for storing the perishable goods.

The packaging used for perishable goods is important, in order to maintain the quality of goods. Typically, cardboard containers are lined with a plastic bag to receive and store perishable goods such as meat. The plastic bag has two purposes, to prevent any liquid from escaping the packaging and to protect the contents from desiccation by moisture vapour transfer out of the packaging. However, these plastic liners increase costs to the packing operation, due to the cost of material and extra packing time required to line the containers and can negatively affect the environment due to the plastic wastage after use.

Furthermore, the use of these plastic bags can lead to contamination of the meat, as portions of the meat freeze around gussets in the plastic bag and traces of the plastic bag get trapped in the meat, an effect known as poly entrapment.

It is therefore desirable that the packaging is capable of protecting the goods, is cost-effective, saves time and/or have a reduced environmental impact.

In this specification, where reference has been made to external sources of information, including patent specifications and other documents, this is generally for the purpose of providing a context for discussing the features of the present invention. Unless stated otherwise, reference to such sources of information is not to be construed, in any jurisdiction, as an admission that such sources of information are prior art or form part of the common general knowledge in the art.

For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be chronologically ordered in that sequence, unless there is no other logical manner of interpreting the sequence.

It is an object of the present invention to provide a collapsed hand erectable carton which overcomes or at least partially ameliorates some of the abovementioned disadvantages or which at least provides the public with a useful choice.

BRIEF DESCRIPTION OF THE INVENTION

According to a first aspect the invention broadly comprises a method of forming an open top carton to receive goods, the method comprising: providing a flat carton blank having an outer surface and a moisture- resistant inner surface, the carton blank comprising: a base portion; a pair of opposed sidewalls depending from the base portion and connected at respective base fold lines; a pair of opposed end walls depending from the base portion and connected at respective base fold lines; each sidewall having a side flap depending from the sidewall and connected at respective flap fold lines; and each end wall having an end flap depending from the end wall and connected at respective flap fold lines; and passing the flat carton blank through a folding machine, the folding machine performing steps comprising: folding and gluing the side flaps and end flaps against the respective sidewall or end wall in any order to form a flat flap-folded precursor; subsequently folding one of the pair of opposed sidewalls or the pair of opposed end walls inwardly towards the base portion; applying glue to the outer surface of the folded sidewalls and/or end walls; and folding the remaining pair of opposed sidewalls or pair of opposed end walls inwardly towards the base portion to form a collapsed hand erectable carton.

According to another aspect the flat carton blank is in a flat configuration after each fold. According to another aspect in the flat configuration, the sidewalls, end walls, side flaps and ends flaps are on substantially the same plane or a plane substantially parallel to the base portion.

According to another aspect the sidewalls and end walls are pressed flat against the base portion to form the collapsed hand erectable carton.

According to another aspect the flat carton blank is fed into the folding machine with the outer surface facing upwards.

According to another aspect the method further comprises inverting the flat flap- folded precursor before folding the sidewalls and end walls.

According to another aspect the flat flap-folded precursor is inverted such that the inner surface faces upwards before folding and gluing the sidewalls and end walls.

According to another aspect the carton blank passes through the folding machine two or more times to form the collapsed hand erectable carton.

According to another aspect the folding machine forms the flat flap-folded precursor in a first pass through the folding machine and forms the collapsed hand erectable carton in a subsequent pass through the folding machine.

According to another aspect carton passes through the folding machine once to form the collapsed hand erectable carton.

According to another aspect the folding machine applies pressure downwards to fold and form the collapsed hand erectable carton

According to another aspect the outer surface of the side flaps and end flaps are folded and glued against the respective outer surface sidewall or end wall to form the flat flap-folded precursor.

According to another aspect the side flaps and end flaps are folded such that the inner surface of the flaps are located on an outer surface of the carton when erected.

According to another aspect the pair of opposed end walls are folded before the pair of opposed sidewalls are folded to form the collapsed hand erectable carton.

According to another aspect the method further comprises hand erecting the collapsed hand erectable carton to form the carton.

According to another aspect the carton is hand erected by pulling a pair of opposed sidewalls or pair of opposed end walls upwards and away from the base portion.

According to another aspect the end walls are pulled up and apart to erect the collapsed hand erectable carton.

According to another aspect each corner of the flat carton blank comprises corner gusset regions.

According to another aspect the corner gusset regions extend between neighbouring sidewalls and end walls. According to another aspect the method further comprises folding and gluing the gusset regions such that they are aligned parallel to the plane of the side wall or end wall which it is glued onto.

According to another aspect one of the gusset regions at each corner is glued to the outer surface of the side wall or end wall.

According to another aspect the gusset regions are glued onto the end walls of the carton.

According to another aspect another one of the gusset regions remains to unglued to allow the carton to be folded into the collapsed hand erectable carton.

According to another aspect the inner surface of the gusset regions is not glued to allow the carton to be folded into the collapsed hand erectable carton.

According to another aspect the adhesive is applied to the carton as it passes below application nozzles.

According to another aspect moisture- resistant coating is on the entire inner surface of the carton.

According to another aspect the moisture-resistant coating is on a substantial portion of the inner surface of the carton.

According to another aspect at least a portion of the folded side flaps and folded end flaps are uncoated on the inner surface and configured to be coupled to a corresponding uncoated region on a lid.

According to another aspect a moisture-resistant coating is applied as a layer onto the inner surface of the carton.

According to another aspect the flat carton blank is formed from corrugated cardboard.

According to another aspect the carton blank has a thickness less than 3mm.

According to another aspect the carton blank has a thickness of approximately

2mm.

According to another aspect the collapsed hand erectable carton is transported to a packing location before erecting the collapsed hand erectable carton.

According to another aspect the method further comprises stacking a plurality of the collapsed hand erectable cartons formed by the folding machine and transporting the cartons in the collapsed configuration.

According to another aspect the method further comprises filling the carton with meat after the carton is formed from the collapsed hand erectable carton.

According to another aspect the carton travels in a single transport direction through the folding machine.

According to another aspect the single transport direction is along a longitudinal direction of the folding machine. According to another aspect the folding machine comprises a conveyor belt in a longitudinal direction of the folding machine and the carton travels along the longitudinal direction during folding and gluing.

According to another aspect the folding machine is a specialty folder gluer.

According to another aspect the invention broadly comprises a method of forming a lidded container comprising: forming and erecting an open top carton as claimed in any one of the previous claims; and providing a lid to fit over and close the carton.

According to another aspect the method further comprises sealing the lid to the carton after fitting the lid over the carton.

According to another aspect the lid comprises: a lid outer surface and a lid moisture-resistant inner surface; a top portion; a pair of opposed lid sidewalls depending from the top portion; and a pair of opposed lid end walls depending from the top portion.

According to another aspect a lidding machine presses the pair of opposed lid sidewalls and opposed lid end walls downwardly over and against the respective sidewalls and end walls of the carton.

According to another aspect the method as herein described and with reference to any one or more of figures 1 to 8B.

Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

As used herein the term "and/or" means "and" or "or", or both.

As used herein "(s)" following a noun means the plural and/or singular forms of the noun.

The term "comprising" as used in this specification and claims means "consisting at least in part of". When interpreting statements in this specification and claims which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example only and with reference to the drawings in which:

Figure 1 shows a flat carton blank.

Figure 2 shows a simplified flow diagram of forming and erecting the carton. Figures 3A-C shows the process of forming a flat flap-folded precursor. Figures 4A-D shows the process of forming a collapsed hand erectable carton. Figures 5A-B shows the process of erecting the collapsed hand erectable carton. Figure 6 shows the process of forming the collapsed hand erectable carton from the flat carton blank.

Figures 7A-7C shows different gluing configurations. Figures 8A-8B shows the process of adding a lid to the erected carton.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

According to various aspects of the present invention as illustrated in figures 1- 8B, there is provided a method of forming and erecting a carton 100.

It will be appreciated that these figures illustrate the general principles of the structure and construction, and that the invention is not limited to the precise configurations illustrated.

The general structure of the various configurations of the present invention as shown in the figures will now be described followed by a description of the method of forming a flat collapsed hand erectable carton 60 and erecting it into a carton 100.

The carton 100 of the present invention is configured to receive perishable goods such as meat, poultry, seafood. This type of carton can be particularly useful for meat trimmings. It is anticipated that the carton 100 can be used for other goods. It can provide particular advantages to storing goods with a high moisture content or goods that are sensitive to moisture loss through the packaging materials, in the preferred configurations. The carton 100 of the present invention may be used for products currently that are shipped in polystyrene boxes due to large quantities of liquid/ water present in the contents. Examples may include meat, lettuce, cabbage celery and other wet-leaf vegetables.

It should be appreciated that the carton 100 of the present invention can be used as a more environmentally desirable alternative (e.g. to polystyrene boxes).

The carton 100 may also be of use where contents are packed in a dry hygienic environment that needs to be maintained through the supply chain.

In the preferred configurations, the flat carton blank 1 is formed from corrugated cardboard. The corrugated carboard comprising inner and outer kraft paper layers sandwiching an inner corrugated core.

In the preferred configurations, the carton blank 1 when erected into a carton 100 is structurally durable so that it can receive, store and/or transport the contents within the carton.

In the preferred configurations, the flat carton blank 1 comprises an outer surface 11 and a moisture-resistant inner surface 12.

Preferably, the moisture-resistant coating 2 is applied as a layer onto the inner surface 12. The moisture-resistant coating 2 is indicated in figures 3B and 8A as the shaded area 2. Preferably, the outer surface 11 of the carton blank 1 remains uncoated (paper-based outer surface 11 which does not have the moisture resistant coating 2).

In the preferred configurations, the moisture-resistant coating 2 is printed onto the paper-based cardboard. It is anticipated that the moisture-resistant coating 2 can be incorporated with the carton blank 1 with other techniques know in the art.

The moisture- resistant inner surface 12 is configured to be in direct contact with the contents (e.g. meat). Preferably the moisture-resistant inner surface 12 is a food contact safe coating 2 which is resistant to moisture vapour transfer.

In some preferred configurations, the coating 2 is a 'release' coating which prevents contents from adhering to the inner surface 12 of the carton 100.

An example of the moisture-resistant coating 2 applied is the VaporCoat® 2200R (by Michelman) which is a recyclable water-based coating to provide a moisture barrier to paper-based packaging.

Preferably, the moisture-resistant coating 2 used has a low Moisture Vapour Transfer Rate (MVTR), is water resistant, prevents/limits contents from adhering to box surfaces, and/or is resistance to oils, grease and fat.

Traditionally, plastic bags are used within cardboard cartons to receive and store meat for transport from a packing location to the point of sale. Plastic bags provide a barrier between the goods and the inner surface of the carboard carton, prevent leaks and act to prevent raw contents coming into content with exposed edges of the corrugated board (upwards facing flute cut edges).

The moisture-resistant inner surface 12 in the present invention is used in place of plastic inner packaging in traditional cartons, usually required to keep meat fresh and ensure the cartons are leak proof.

The carton blank 1 with a moisture-resistant inner surface 12 can reduce/ eliminate the use of these plastic liners which have some associated disadvantages such as cost of the plastic, extra packing time required to line the containers, and negative- impact on the environment.

In all the preferred configurations, the moisture-resistant coating is on the entire inner surfaces of the carton 100 when erected. These are the surfaces which will be in contact with the contents of the carton 100.

In the preferred configurations, the moisture- resistant coating is on the entire inner surface 12 of the carton blank 1. In these configurations, when erected, a lid 200 fits over the carton 100 such that the sidewalls of the lid 200 extend downwards past the flaps 6, 7 of the carton to adhere to the uncoated side walls 4 and end walls 5 of the carton. The side walls 204 of the lid 200 extend past the flaps 6, 7 and adhere onto the uncoated side and end walls 4, 5 as glue does not adhere well to some moisture- resistant/ release coatings 2. In the preferred configurations, external strapping or tape may be further applied to secure the lid 200 to the carton 100.

In other configurations, the sidewalls of the lid 200 extend and adhere onto/ over the flaps 6, 7 of carton (despite the entire inner surface having a moisture-resistant coating), due to the properties of the water-resistant coating.

In yet another configuration, the moisture-resistant coating 2 is on a substantial portion of the inner surface 12 of the carton blank 1 (but not the entire inner surface 12). In these configurations, at least a portion of the inner surface 12 of the carton is uncoated as shown at the extremities 17 of the flaps in figure 3B. In some configurations, at least a portion of folded side flaps 6 and folded end flaps 5 of the carton blank 1 are uncoated on the inner surface 12 and configured to be coupled to a corresponding uncoated region on a lid 200.

Adhesive can be applied to the uncoated outer surface portions of the carton 100, so that it can adhere to other uncoated portions of the carton (e.g. uncoated inner surface portions of the lid 200).

Uncoated portions of the carton may be necessary due to the properties of the moisture-resistant/ 'release' coating on the inner surface 12 of the carton (i.e. the adhesion/glue does not adequately adhere to the moisture-resistant coating).

Preferably the adhesive method utilised results in a leakproof seal around the entire perimeter.

It is anticipated, other techniques known to a person skilled in the art to adhere coated portions of the carton together may be used.

With particular reference to figure 1, a hand erectable carton 100 is shown in the form of a flat carton blank 1.

The carton blank 1 comprises a base portion 3, a pair of opposed sidewalls 4 depending from the base portion, and a further pair of opposed end walls 5 depending from the base portion.

Preferably, each sidewall 4 has a side flap 6 depending from the respective sidewall (best shown in figures 1 & 5B).

Preferably, each end wall 5 has an end flap 7 depending from the respective end wall.

Wall fold lines 8 illustrated on figure 1 show the location at which the depending sidewalls 4, and end walls 5 are connected to the base portion 3.

Flap fold lines 9 illustrate the location at which the side flaps 6 and end flaps 7 are connected to the respective sidewall 4 or end wall 5.

Preferably, the side flaps 6 and end flats 7 are folded downwardly along the flap fold lines 9 such that cut edges 10 of the flat carton blank 1 are facing downwards. It should be appreciated that folding the flaps 6, 7 downwards can hide the cut board edges 10 from direct contact with the meat. Furthermore, the folded flaps 4, 7 provide a clean fold line 9 as best shown in figure 5B.

Preferably, the fold lines 8, 9 are pre-scored, in order to aid assembly as shown in figure 1.

It will be appreciated that the illustrated carton 100 has a generally rectangular form, however the relative dimensions of the side walls 4, compared to the end walls 5 may vary, including square forms. Similarly, the height of the carton 100 formed when assembled may also vary in proportion to suit the desired need.

In the preferred configurations, at each corner of the flat carton blank 1, there are corner gusset regions 13, 14. The corner gusset regions 13, 14 extend between neighbouring sidewalls 4 and end walls 5.

It can be seen that the corner gusset regions 13, 14 when folded (along fold lines 15 in figure 1), form a triangular shape which can be aligned parallel to the plane of the side wall 4 or end wall 5 of carton which it is glued onto, as shown in figure 5B.

In the preferred configurations, the gusset regions 13, 14 are glued onto the outer surface 11 of the carton. In one configuration, gusset regions 13 are glued onto the end walls 5 of the carton as shown in figure 5A. The end walls 5 are the less wide in comparison to the side walls 4.

Gluing the gusset regions 13 to the end walls 5 can make it easier to glue with a specialty gluer process, or manually glue. It can also make it easier to hand erect as the end walls (shorter/ less wide walls) 5 are pulled apart as shown by the arrows in figure 5A. As the end walls 5 are pulled up and apart, the edges of the end wall press against and push up the side walls 6. In comparison, pulling on the side walls (longer/ wider walls) may be less desirable as they may be more likely to bend due to the pressure applied to pull the walls apart.

In other configurations, gusset regions 14 are glued (adhesive indicated by shading-lines) onto the outer surface 11 of the side walls 4 (as shown in figure 7C). the side walls 4 are folded first in these configurations, and similar sequence as described is followed.

In the preferred configurations, an outer surface of one of the gusset regions 13 at each corner is glued to the outer surface of the side wall 4, or end wall 5 (shown in figures 7B and 7C).

Preferably, the other one of the gusset regions 14 at each corner remains unglued to allow the carton to be folded into the collapsed hand erectable carton 60 configuration as shown in figure 5A.

Preferably at the gusset regions 13, 14, the inner surface 12 is not glued to allow the carton to be folded into the collapsed hand erectable carton 60. The unglued gusset region 16 is illustrated in figure 5A. In the preferred configurations, the thickness of the carton blank 1 is approximately 3mm or less. As the corrugated board thickness increases beyond 3mm (B-flute), it is likely to be harder to open the corrugated board, and/or fold into a flat condition. A thicker board prevents the collapsed hand erectable carton 60 from being folded flat or opened without over-stressing and damaging the box side walls.

Most preferably, the thickness of the carton blank 1 is approximately 2mm thick. A 2mm board (E-flute) is desirable as it can be folded and opened without over-stressing and damaging the box side walls, while being thick enough to have the structural integrity to receive the carton contents, and maintain a carton 100 structure. Alternatively, the board may be up to approximately 5 mm thick.

Following the description of the structure of the present invention described above, a general description of the method of forming the hand erectable carton 1 will now be described.

As shown in the simplified flow diagram of figure 2, the preferred steps to form and erect an open top carton can be broadly include: a) Providing a flat carton blank 1 as described above, b) Folding and gluing side flaps 6 and end flaps 7 to form a flat flap-folded precursor 40, c) Folding and gluing the sidewalls 4 and end walls 5 to form a collapsed hand erectable carton 60, and d) Hand erecting the collapsed hand erectable carton 60 to form the carton 100.

Preferably, the flat carton blank 1 passes through a folding machine to perform steps (a) to (c) to form the collapsed hand erectable carton 60. This process is illustrated in figure 6, as the folding machine folds the flat carton blank 1 and the resulting configuration of the carton is the collapsed hand erectable carton 60.

Passing the flat carton blank 1 through a folding machine to fold the carton can provide advantages such as rapid formation of a large quantity of collapsed hand erectable cartons 60.

Preferably, the folding machine does not erect the carton. Instead, the folding machine produces the collapsed hand erectable carton 60 in a flat/ collapsed configuration. The flat collapsed hand erectable carton 60 can be stacked for efficient storage and/or transportation to the desired site.

The folding machine can prepare a large quantity of collapsed hand erectable cartons 60 off-site, before the hand-erectable cartons 60 are easily distributed to the packing location or a number of different packing locations (i.e. a folding machine is able to centrally manufacture the collapsed hand erectable cartons 60 for distribution to any number of different sites). It should be appreciated that the present invention can provide advantages, such as cost-savings, as it can give the businesses the option to not invest in folding machines at the packing site (the folding machine can be located offsite at a box-plant). The collapsed hand erectable cartons 60 can be pre-folded off-site to achieve large economies of scale.

Preferably, the collapsed hand erectable carton 60 is transported to the packing location. The collapsed hand erectable carton 60 is hand erected to form the carton at the packing location (i.e. not erected before transportation to the packing site).

As the folding machines are not required on-site, as required with traditional packing methods, businesses may also save space which otherwise would be necessary for the folding machines.

The collapsed hand erectable cartons 60 can be easily distributed to packing locations anywhere on a packing site, without fixed materials handling systems. The packing points can be optimally located or easily changed as other production flow conditions warrant.

In the preferred configurations, the folding machine is a standardised folding machine for manufacturing cartons (known in the industry as a "specialty folder gluer").

It should be appreciated that these standardised folding machines are able to fold (and glue) cartons of different sizes and/or blank profiles. An example of a standardised folding machine which can be used as the folding machine in the present invention is a Bobst Expertfold series, Tanabe EF series, or similar machines know to a person skilled in the art. "Specialty folder gluer" is an industry term for a type of box making machine capable of folding any number of complex box styles that rely on folding and adhesion of box flaps and features for extended functionality.

It is anticipated that other folding machines known to a person skilled in the art capable of performing the folds and gluing as described may be used.

Standard folding (and gluing) machines are beneficial as they are often cheaper and less complex than customised machines for specific boxes.

Preferably, a traditional 'specialty folder gluer' can prepare the collapsed hand erectable cartons 60 as described without significant intervention or modification to the specialty folder gluer process. The described method has been carefully optimised to make it suitable for preparing a machine assembled, but hand erected carton, with relatively standard folder gluer equipment. This has been found to be an enormous advantage over known complex equipment utilised for constructing and/or erecting similar perishable goods cartons.

Preferably, the folding machine comprises a conveyor belt in a longitudinal direction of the folding machine and the carton travels along the longitudinal direction during folding and gluing. Preferably folding and gluing occurs as the carton is transported along the conveyor belt (during movement).

Typically, these standardised folding machines have two types of folding mechanisms: i) the leading and trailing flaps are folded by hooks and pushers that act in the machine transport direction; and ii) folding rails that fold in the machine cross direction by smoothly guiding the flaps to fold as it travels in the machine direction.

Preferably, the carton travels in a single transport direction through the folding machine as indicated by the arrow (X) in figure 6. In the preferred configurations, the carton travels in a single transport direction (X) along the longitudinal direction of the folding machine.

Preferably, the flat carton blank 1 passes through the folding machine in a flat configuration, such that it is in a collapsed/ flat configuration along most of the conveyor as shown in figure 6.

Preferably, the flat carton blank 1 is in a flat configuration after each fold, as shown in figures 3B, 4B, and 4D. In the flat configuration, the sidewalls, end walls, side flaps and ends flaps 4, 5, 6, 7 are on substantially the same plane or a plane substantially parallel to the base portion 3.

Forming the collapsed hand erectable carton 60 in a flat configuration is desirable, as it allows the effective application pressure onto the flaps and the glue to set. Preferably, the glue is a hot glue adhesive, which works with pressure applied and waiting a short period of time for it to set/ harden.

Figures 3A - 3C illustrate the process of forming a flat flap-folded precursor 40 (best shown in figure 3B).

In the preferred configurations, the flat carton blank 1 is fed into the folding machine with the outer surface 11 facing upwards, as shown in figure 6.

In other configurations, the flat carton blank 1 is fed into the folding machine with the inner surface 12 facing upwards (not shown). In these configurations, some of the directions of operation described are reversed accordingly.

Once the flat carton blank 1 has been fed in the folding machine, the machine folds and glues the side flaps 6 and end flaps 7 in a flat configuration. Preferably, the folding machine folds and glues the folded side flaps 6 and folded end flaps 7 against the respective sidewall 4 or end wall 5 to form a flat flap-folded precursor 40.

As shown by the arrows in figure 3A, preferably, the side flaps 6 and end flaps 7 are folded and glued such that the outer surface 11 of the side flaps and end flaps are folded and glued against the respective outer surface sidewall 4 or end wall 5 to form the flat flap-folded precursor 40. The folded side flaps and folded end flaps are folded such that the inner surface 12 of the flaps 6, 7 are located on an outer surface of the carton when erected as best shown in figure 8A.

In the preferred configurations, to form the flat flap-folded precursor as shown in figure 3B, the outer surface 11 of the flat carton blank 1 faces upwards, so that pressure (P) can be applied downwards onto the side flaps 6 and end flaps 7 to fold and glue the flaps, as indicated by arrow "P".

Preferably, glue (or other adhesive) is applied onto the outer surface 11 of the side flaps 6 and end flaps 7 and/or the respective sidewall 4 or end wall 5 (figure 7A), such that carton remains in the flat flap-folded precursor 40 configuration once the flaps have been folded.

In the preferred configurations, both the side flaps 6 and end flaps 7 are folded in one pass through the folding machine.

Preferably, the adhesive is applied to the carton as it passes below application nozzles. The glue is applied towards the fold line 9 to adhere the flaps, 7 to the respective walls 4, 5.

In some configurations, the carton blank 1 passes through the folding machine once to form the collapsed hand erectable carton 60.

In other configurations, the carton passes through the folding machine two or more times (multi-pass) to form the collapsed hand erectable carton 60. For example, the folding machine could form the flat flap-folded precursor 40 in a first pass through the folding machine and form the collapsed hand erectable carton 60 in a subsequent pass through the folding machine. Settings on the folding machine can be changed and configured between the different processes, or different lines may be implemented.

The available floor space can be a driver for a multi-pass procedure, however a single pass, multi-station folder glue may be preferred.

However, a multi-pass procedure may be useful as folding of the flaps 6, 7 takes place in the opposite direction to the side and end walls 4, 5. The two stages (folding flaps and folding walls), may be combined but will require collaboration with the specialty folder gluer.

Preferably, the flat flap-folded precursor 40 is inverted before folding the sidewalls 4 and end walls 5, as indicated by arrow (I) in figures 3B and 6.

Once the flat flap-folded precursor 40 has been inverted, preferably the opposite surface faces upwards. In the illustrated configurations, the inner surface 12 of the carton faces upwards in preparation for the sidewalls 4 and end walls 5 to be folded.

The flat flap-folded precursor 40 is inverted as the flaps 6, 7 are folded in an opposite direction to the side and end walls 4, 5 (the flaps 6, 7 are folded onto the outer surface of the carton as shown in figure 3B, and the walls are folded inwards towards the inner surface of the carton as shown in figures 4A and 4C). Inverting the flat flap-folded precursor 40, allows the folding machine to apply pressure (P) in the same direction (downwardly) to form the folds for both the flaps 6, 7 and the walls 4, 5 of the carton and so that the flaps or walls can be folded up and over by the specialty folder gluer.

In other configurations, the sidewalls 4 and end walls 5 can be folded without inverting the flat flap-folded precursor 40.

Figures 4A-D illustrate the process of forming a collapsed hand erectable carton 60 by folding and gluing the sidewalls 4 and end walls 5.

After forming the flat-flap folded precursor 40, one of the pair of opposed sidewalls 4 of pair of opposed end walls 5 are folded inwardly towards the base portion 3 as shown in figure 4A.

After folding a pair of the opposed sidewalls 4 or end walls 5, glue 20 is applied to the outer surface 11 of the folded sidewalls and/or end walls. As shown in figure 4B, glue 20 is applied to the corner regions of the carton, to adhere the corners of the sidewalls 4 and end walls 5 together, so that the carton forms a box shape once the walls are erected from the collapsed hand erectable carton configuration 60 as shown in figures 5A-5B.

Figures 7B and 7C show different gluing configurations for the carton at the corner regions. As shown in figure 7B, the gusset region 13 is adapted to be glued to the end wall 5. The glue 20 in these configurations, can be applied to the gusset region 13, the end wall 5, or both.

In figure 7C, the gusset region 14 is adapted to be glued to the side wall 4. The glue 20 in these configurations, can be applied to the gusset region 14, the side wall 4, or both.

Once the glue has been applied to the folded sidewalls and/or end walls, the remaining pair of opposed sidewalls 4 or end walls 5 are folded inwardly towards the base portion 3 to form the collapsed hand erectable carton 60.

Any suitable type of glue may be employed, such as, but not limited to, PVA or hot melt glue.

In the illustrated configuration, the pair of opposed end walls 5 are folded (figure 4A) before the pair of opposed sidewalls 4 (figure 4C) to form the collapsed hand erectable carton 60 (figure 4D). In other configurations, the order of folding the sidewalls 4 and end walls 5 may be reversed.

The sidewalls 4 and end walls 5 are pressed flat against the base portion 3 to form the collapsed hand erectable carton 60.

Preferably, with each fold, the walls 4, 5 and flaps 6, 7 fold back on itself (the carton blank), so that the folding machine can press downwards (to form the forms and/or to set the glue). Preferably, the folding machine applies pressure downwards to fold and form the collapsed hand erectable carton.

Figures 5A-B illustrate the process of erecting the collapsed hand erectable carton 60. Preferably, after the folding machine has prepared the collapsed hand erectable carton 60, the cartons are transported to a packing location, or at least to a location away from the folding machine.

For storage or transportation, a plurality of collapsed hand erectable cartons 60 may be stacked together in the collapsed configuration. The cartons 60, in this collapsed configuration are compact, and may be easily transported or stored until use for packing the meat.

The carton in the preferred configurations is machine formed and hand erected. The cartons 100 are preferably hand erected by simply pulling/ pushing them into shape, without additional or separate folding being required. The carton 100 can be easily and quickly erected from the collapsed hand erectable carton 60 by operators/ packers, requiring only a few seconds (typically less than 5 seconds).

The cartons can be erected by pulling a pair of opposed sidewalls 4 or pair of opposed end walls 5 upwards and away from the base portion 3. In the illustrated configuration, as shown in figure 5A, the carton can be easily erected by pulling the end walls 5 upwards and away from the base portion 3.

The erected carton 100 is able to maintain its shape as the sidewalls 4 and end up walls 5 engage with each other as shown in figure 5B.

After the carton 100 has been hand erected, the carton can be filled with goods, such as meat. Filling the carton 100 with the goods also forces the carton outwards, into its erected shape.

Figure 8A-B illustrate the process of fitting and closing a lid 200 over the carton 100 once the carton has been erected and filled.

Preferably, after the carton 100 has been erected the lid 200 fits over and closes the carton.

In the preferred configurations, the lid comprises a lid outer surface and a lid moisture-resistant inner surface, like the base carton. The inner surface of the lid 200 preferably has the same/ or similar coating 2 as the lid 100.

Preferably, the coating on the lid moisture-resistant inner surface is a food contact safe coating which is resistant to moisture vapour transfer. In some preferred configurations, the coating 2 is a 'release' coating which prevents (or at least partially inhibits) contents from adhering to the inner surface 12 of the carton 100.

The moisture-resistant inner surface is preferably applied onto the entire surface of the lid inner surface. In these configurations, the lid 200 fits over the carton 100 and is strapped/ taped onto the carton. In other configurations, a selected portion of the inner surface has the moisture- resistant layer. Preferably, the entire top inner surface of the lid is coated (as this one be in contact with the contents of the carton, but extremities/ perimeter of the lid sidewalls may be uncoated. In these configurations, the side walls 204 of the lid 200 extend past the flaps 6, 7 of the carton and the uncoated inner surface regions of the lid adhered onto the uncoated outer surface of the carton 100.

Preferably, the lid comprises a top portion 203, a pair of opposed lid sidewalls 204 depending from the top portion and a pair of opposed lid end walls 205 depending from the top portion.

Preferably, a lidding machine presses the pair of opposed lid sidewalls 204 and opposed lid end walls 205 downwardly over and against the respective sidewalls 4 and end walls 5 of the carton 100.

Preferably the lid is sealed to the carton after fitting the lid over the carton to keep the lid on the carton, and the goods inside the carton fresh.

The described configurations of the present invention can have a number of different advantages as described above. It should be appreciated that the different features of the present invention can provide one or more of the following advantages itself or in combination with other features. In summary the advantages include: a) the method of the invention lends itself to being able to use a standardised folding machine, which is comparatively simple b) increasing productivity, as the collapsed hand erectable cartons 60 can be rapidly formed; c) The resulting collapsed hand erectable cartons 60 can be stacked for efficient storage and/or transportation to desired packing location(s); d) Provides the option to form the collapsed hand erectable cartons 60 off site, saving costs and space, traditionally associated with keeping and running complex and expensive folding machinery at the packing sites; e) The resulting collapsed hand erectable carton 60 can be easily hand erected at the packing location; f) The carton 100 has a moisture-resistant and desiccation-resistant coating 2 which can preserve the goods, while saving costs and time associated with lining cardboard containers with plastic bags.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.