Products and method for packaging multiple rows of products

Abstract

A method and system are described for providing supports for multiple rows of stacked goods with edge protectors that can be separated at predetermined zones to allow one row of stacked goods to be readily separated from another row. Also described are separable edge protectors for use with the method and system. Also described is a method and system for providing customized packaging adapted for specific goods.

1 . A unit load comprising:
 a plurality of products stacked in a plurality of rows with breaks therebetween; and   at least one separable edge protector attached to at least one side of the unit load, the separable edge protector having a length that spans at least an upper row and an adjacent lower row of the plurality of rows, the at least one separable edge protector including a zone of weakness proximate to a break between the upper and lower rows of products,   wherein the zone of weakness of each of the at least one separable edge protectors is adapted to separate in response to the act of separating the upper row of products away from the lower row.   
     
     
         2 . The unit load of  claim 1 , wherein the separable edge protector is attached to the unit load by a flexible wrap surrounding at least part of the unit load. 
     
     
         3 . The unit load of  claim 1 , wherein the unit load has four corners, and wherein the separable edge protectors are provided along each of the four corners. 
     
     
         4 . The unit load of  claim 1 , wherein the at least one separable edge protector comprises a plurality of zone of weakness, each zone of weakness being generally aligned with a break between adjacent rows. 
     
     
         5 . The unit load of  claim 1 , wherein the at least one separable edge protector is free of zones of weakness other than those proximal to the breaks between the rows of product. 
     
     
         6 . The unit load of  claim 1 , wherein the separable edge protector comprises a laminate having a plurality of fibrous layers. 
     
     
         7 . The unit load of  claim 1 , wherein the separable edge protector comprises molded pulp. 
     
     
         8 . The unit load of  claim 1 , wherein the separable edge protector comprises a material selected from plastic, a fiber-resin composite, fiberglass, and metal. 
     
     
         9 . The unit load of  claim 1 , wherein the zone of weakness is produced by perforations. 
     
     
         10 . The unit load of  claim 1 , wherein the zone of weakness is produced by one of laser ablation, mechanical ablation, water jets, or chemical means. 
     
     
         11 . A unit load comprising:
 a plurality of products stacked in a plurality of rows with a break formed between adjacent rows of products, the plurality of rows being aligned to define corners of the unit load; and   a plurality of separable edge protectors attached at the corners of the unit load, the separable edge protectors each having a length that spans at least two rows of products and each comprising two legs joined at an apex extending along the length thereof and having one or more zones of weakness positioned such that each zone of weakness is proximate to one of the breaks between the rows of products.   
     
     
         12 . The unit load of  claim 11 , wherein the separable edge protectors are attached at the corners of the unit load by an adhesive fixing the separable edge protectors to products in the unit load. 
     
     
         13 . The unit load of  claim 11 , wherein the separable edge protectors are attached at the corners of the unit load at least in part by an overwrap. 
     
     
         14 . The unit load of  claim 11 , wherein the separable edge protectors are attached at the corners of the unit load at least in part by strapping. 
     
     
         15 . The unit load of  claim 11 , wherein each of the plurality of separable edge protectors is substantially free of zones of weakness other than those proximal to the breaks between the rows of product. 
     
     
         16 . A method for protecting a unit load having a plurality of rows of product containers comprising:
 (a) attaching one or more separable edge protectors each comprising a zone of weakness to the outer surface of the product containers in the unit load, the one or more separable edge protectors spanning at least two rows of product in the unit load, a break being defined between two adjacent rows of the at least two rows of product, the break being proximal to the zone of weakness in each of the one or more separable edge protectors; and   (b) applying a force to the uppermost row of the two adjacent rows to cause separation of the uppermost row from the remaining of the two adjacent rows, wherein the force causes the one or more separable edge protectors to detach in the zone of weakness proximal to the break, leaving a remaining portion of each of the one or more separable edge protectors in place to continue providing edge protection for the remaining rows of product in the unit load.   
     
     
         17 . The method of  claim 16 , further comprising applying an overwrap to the unit load after attaching the one or more separable edge protectors to the outer surface of the product containers in the unit load. 
     
     
         18 . The method of  claim 17  wherein the overwrap is adapted to split substantially at the break in response to applying the force. 
     
     
         19 . The method of  claim 18  wherein the overwrap is selected from stretch wrap and shrink wrap. 
     
     
         20 . A method for customizing separable edge protectors for a customer, comprising:
 (a) receiving product information from a customer for a planned unit load identifying the elevations in the unit load of one or more breaks between rows of a stack of products,   (b) preparing customized separable edge protectors having zones of weakness corresponding to the elevations in the unit load when the separable edge protectors are in place on an outer surface of the unit load, and   (c) delivering the customized separable edge protectors for use in a packaging facility.   
     
     
         21 . The method of  claim 20 , further comprising (d) applying one or more customized separable edge protectors to a stack of the products to form a protected unit load. 
     
     
         22 . The method of  claim 21 , wherein the zones of weakness are substantially aligned with the breaks in the unit load. 
     
     
         23 . The method of  claim 21 , further comprising (e) applying an overwrap to the unit load. 
     
     
         24 . The method of  claim 23 , further comprising (f) removing a row of products from the unit load, wherein the act of removing causes fracture of the separable edge protectors at a zone of weakness proximal to the break beneath the removed row of products. 
     
     
         25 . The method of  claim 24 , wherein the overwrap splits substantially at the break beneath the removed row of products during the act of removing.