Systems, apparatus and method for forming, filling, closing, and sealing gable top cartons for use with liquid soap compositions

Abstract

The present disclosure provides systems, apparatus and methods for forming, filling, closing, and sealing gable-top cartons with liquid detergent compositions such as all-purpose cleaners, dish soaps, and hand soaps, and without incurring leaking. The liquid detergent compositions in the corresponding gable-top are generally from a wide spectrum of high to low viscosity and PH levels. Once properly formed, filled, and sealed the liquid detergent compositions may remain inside the gable-top carton without leaking or degradation for at least the liquid detergent composition's shell life.

What is claimed is: 
     
         1 . A method, comprising:
 operating a machine for forming, filling, closing, and sealing a carton having a liquid soap composition, four sides, a gable top structure with top flaps meeting to form a top fin, a bottom panel, and a circular hole on one of the top flaps, wherein the operating comprises:
 (i) removing, using a plurality of vacuum suction cups assembled to an inside of the machine, a flat carton from a conveyor belt attached to the machine; and 
 (ii) forming, using the plurality of vacuum suction cups, a formed carton from the flat carton by applying force to one or more of the four sides of the flat carton. 
   
     
     
         2 . The method of  claim 1 , wherein the operating further comprises: lifting, using a lift table, the formed carton into a mandrel rod attached to a rotary apparatus placed inside the machine. 
     
     
         3 . The method of  claim 1 , wherein the operating further comprises: rotating, using a rotary apparatus placed inside the machine, the mandrel rod with the formed carton to a second 45-degree position. 
     
     
         4 . The method of  claim 1 , wherein the operating further comprises: pre-forming, with a bottom pre-forming tool located inside the machine at the second 45-degree position, the bottom panel of the formed carton. 
     
     
         5 . The method of  claim 1 , wherein the operating further comprises: rotating, using the rotary apparatus, the mandrel rod with the formed carton, to a third 90-degree position. 
     
     
         6 . The method of  claim 1 , wherein the operating further comprises: heating, with a heating tool placed at the third 90-degree position inside the machine, the pre-formed bottom panel of the formed carton to a temperature between 110 and 150 degrees Celsius. 
     
     
         7 . The method of  claim 1 , wherein the operating further comprises: rotating, using the rotary apparatus, the mandrel rod to a fourth 135-degree position. 
     
     
         8 . The method of  claim 1 , wherein the operating further comprises: folding, with a bottom folding tool, the pre-formed and heated bottom panel of the formed carton. 
     
     
         9 . The method of  claim 1 , wherein the operating further comprises: extracting, using a plurality of bottom suction cups, the formed carton from the mandrel rod. 
     
     
         10 . The method of  claim 9 , wherein the operating further comprises: loading the formed carton onto a first position of a carton guide rail, using the plurality of bottom suction cups. 
     
     
         11 . The method of  claim 1 , wherein the operating further comprises: welding, using a welding cap applicator, a cap to the formed carton at the second position of the carton guide rail. 
     
     
         12 . The method of  claim 1 , wherein the operating further comprises: inserting a top mandrel attached to the inside of the machine into the formed carton, and holding a gable top structure of the formed carton using an L-shaped fixture. 
     
     
         13 . The method of  claim 12 , wherein the operating further comprises: crimping the gable top structure of the formed carton using a top crimping tool. 
     
     
         14 . The method of  claim 13 , wherein the operating further comprises: filling the formed carton with the liquid soap composition using a filling system nozzle connected to a liquid soap container tank. 
     
     
         15 . The method of  claim 14 , wherein the operating further comprises: re-crimping the crimped gable top structure of the formed carton filled with the liquid soap composition by applying a force to the crimped gable top structure using a top re-crimping head. 
     
     
         16 . The method of  claim 15 , wherein the operating further comprises: heating the crimped gable top structure of the formed carton filled with the liquid soap composition to a temperature between 110 and 150 degrees Celsius. 
     
     
         17 . The method of  claim 16 , wherein the operating further comprises: sealing the crimped and heated gable top structure, using a movable jaw apparatus. 
     
     
         18 . The method of  claim 17 , wherein the operating further comprises: discharging the formed carton filled with the liquid soap composition and having the crimped, heated, and sealed gable top structure onto a conveyor belt positioned outside the machine.