Abbott Laboratories Corporation

Todd A Stevens

Lewis H Sita

David C Ulstad

W George Zeitler

Lori J Mihalov

Richard P Macauley

Brian K Murdick

Vera T Stavroff

A package is provided with a lid and container that are heat sealed together. A multi-ply sheet material is provided for being thermoformed to define the container which has a tapering wall and bulge-resistant bottom end. Prior to thermoforming the container from the sheet, the sheet is heated with oval pads on a plurality of plates which are arranged in a configuration to facilitate control of the sheet temperature. A plug is used in the thermoforming process to contact the sheet and position the sheet within a die. A lid sheet is heat sealed to the container sheet over the thermoformed containers so as to produce a pair of spaced-apart, annular bead heat seals. The package is completed by severing the sealed-together sheets at the periphery of the container with a punch and die set that produces and clean, smooth cut surface.

Container having tapered sidewall made from sheet material and lid to seal same

Aseptically sterilized package of a liquid nutritional product manufactured by (a) providing a multi-layered plastic sheet having at least one polymeric structural layer and at least one polymeric barrier layer; (b) passing the sheet through a peroxide bath; (c) locating the sheet in a sterile environment; (d) applying heat a plurality of times to the sheet; (e) forming the sterilized sheet into a container having a body portion; (f) filling the body portion with a liquid nutritional product; (g) sealing the container with a tabbed, multi-layered closure; and (h) separating the sealed container from the remainder of the sheet. Preferably the liquid nutritional product is infant formula. In the preferred embodiment of the invention, the sheet is a laminate having two structural layers, each being about 45% of the laminate thickness and secured to either side of the barrier layer, which is about 5% of the laminate thickness, by an adhesive layer of about 2.5% of the laminate thickness. The container is prepared by thermoforming and deep drawing the multi-layered sheet. Pressure forming of the container is performed with the sheet temperature being 162.degree. C. using a plug-assist and a pressure of about 5 BAR. Once filled, the container is sealed using a thermo sealing process.

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West Worthington, OH, United States of America

Todd A Stevens