Abstract:
A plastic or other film bag is formed from a continuous extruded tube. The tube is flattened and sealed across its width at intervals to form bag bottoms. The bags are joined to one another at a perforation line and folded in thirds lengthwise prior to being rolled into a compact roll, either with or without supporting core. After folding the bags may be chisel cut through the center of the perforation line to assist in dispensing of the bags. The chisel cut will extend through all layers of the bag when folded, resulting in three chisel cuts in the bag. The bags may be gusseted for part or as much as all of their width. The bags may also be corona treated and printed on their outer surfaces. The bags may be formed from partially recycled materials and various combinations of linear low density, medium and high density polyethylene.

Description:
RELATED APPLICATION 
     This application is a Continuation of PCT/US12/49999, filed Aug. 8, 2012 and currently pending, which is a Continuation-in-Part of pending U.S. application Ser. No. 13/072,630, filed Mar. 25, 2011, which is a Continuation-in-Part of U.S. application Ser. No. 10/847,690, filed May 18, 2004 and incorporates by reference the disclosure of said applications in their entirety. 
    
    
     FIELD OF INVENTION 
     The invention pertains to plastic and other film bags. More particularly, the invention relates to bags designed for fresh produce that are dispensed from compact rolls and designed to be easily opened. 
     BACKGROUND OF THE INVENTION 
     Plastic and other film bags have found wide use in grocery markets and retail applications for transporting produce groceries and various other items. To be most useful for consumers plastic bags should incorporate a number of features. These features relate to the ease of use of the bags with respect to opening them, placing goods inside, carrying them and dispensing them. As shelf space and floor space is always at a premium in grocery stores and supermarkets, more compact methods of storing and making available relatively large size bags is always desirable. The instant invention addresses the production of large size produce bags that are folded in thirds for use in compact rolls. These rolls fit in relatively small dispensers that make use of the available space most efficiently. 
     A variety of designs have been developed. U.S. Pat. No. 6,196,717, issued to Belias et al., is directed to a method of forming a plurality of easy to open handle bags including the steps of providing a flattened tube of thermoplastic material oriented in a generally longitudinal direction. The flattened tube has a first longitudinal side edge and a second longitudinal side edge, a transverse lower heat seal, and a transverse upper heat seal. The tube also has first, second, and third sections. The second section is disposed between the first and third sections. The first section is joined to the second section along a generally longitudinal first fold line. The second section is joined to the third section along a generally longitudinal second fold line. The second section is cut along a generally transverse first cut line extending between the first and second fold lines. The first section is folded over the second section along the first fold line. The third section is folded over the previously folded-over first section along the second fold line such that the first, second, and third sections overlap one another. 
     The overlapped first, second, and third sections are cut along a generally longitudinal second cut line that intersects the first cut line, the first fold line, and the second side edge at one end and intersects the upper heat seal at the other end. The overlapped first, second, and third sections are then cut along a generally longitudinal third cut line that intersects the first cut line, the second fold line, and the first side edge at one end and intersects the upper heat seal at the other end. 
     U.S. Pat. No. 5,890,810, issued to Barlow, discloses an extruded plastics tube that is flattened with the lateral side portions folded to form inwardly extending gussets. Each gusseted side portion is then folded about a longitudinal fold line onto the medial portion between the side portions. The resultant layers are heat sealed to form the bottom of the bag. 
     U.S. Pat. No. 6,488,222, issued to West et al., describes A folded gusseted plastic bag has a first side gusset formed by first, second, and third longitudinal folds, a second side gusset formed by fourth, fifth, and sixth longitudinal folds, a seventh longitudinal fold being on a side of the bag containing the first, second, and third folds and forming a first folded bag flap, and an eighth longitudinal fold which is on a side of the bag containing the fourth, fifth, and sixth folds, the eighth fold forming a second folded bag flap. The folded gusseted bag also is folded into a total of at least eight contiguous plies. A roll of the folded, gusseted bags includes a continuous web of the folded, flattened bags joined along perforated severance lines. Preferably the perforated severance lines further comprise a centrally-located slit. The dispensing system utilizes the roll of folded-gusseted bags in combination with a dispenser comprising: (i) a support member for attachment to a support surface; (ii) a pair of guide channels carried by the support member for rotatably supporting the roll of plastic bags for rotation of the roll on the core; (iii) a tongue spaced apart from and carried by said support member in a predetermined position corresponding to the predetermined position of the slit in the tear line. 
     U.S. Pat. No. 6,379,292, issued to Simhaee, illustrates a continuous web of bags formed of a plurality of layers to be separated along a line of perforations that extends through all of the layers transverse of the web, in which at least one of the outermost layers is detached from the web at the separation line. Apparatus accomplishes this detachment in a moving web by engaging the outermost layer outer surface and exerting a force in a manner to produce the detachment from the separation line. Both the outermost upper and lower web layers can be detached at the separation line. 
     U.S. Pat. No. 5,967,663, issued to Vaquero et al., discloses a thermoplastic bag structure and method for making and packaging thermoplastic bags such that their tops are easily identified and the bags are easily opened. The method for producing these bags begins with cutting a flattened thermoplastic tube into two portions. At least one of the two portions is then collapsed to form a sheet of material having a pair of thermoplastic layers, a straight folded bottom edge and a pair of top edges, at least one of which has a skewed-cut. Bag side structures are formed in the sheet of material at about bag-width distances apart. The bags are then folded a predetermined number of times, in a direction transverse to the bag side structures, so that the skewed-cut top edges of each of the bags remain exposed. 
     It is an objective of the present invention to provide plastic bags that can be easily stored on and dispensed from a variety of types of compact roll dispensers. It is a further objective to provide bags that can be formed into compact rolls on cores or without cores. It is a still further objective of the invention to provide bags that can be easily manufactured in gusseted or ungusseted form. Finally, it is an objective to provide roll mounted bags that are easily opened after dispensing and that are easily removed from the roll. 
     While some of the objectives of the present invention are disclosed in the prior art, none of the inventions found include all of the requirements identified. 
     SUMMARY OF THE INVENTION 
     The present invention addresses all of the deficiencies of prior art folded film bag inventions and satisfies all of the objectives described above. 
     (1) A tri-fold film bag providing the desired features may be constructed from the following components. A continuous web of film bags formed from plastic or other film material is provided. Each of the bags includes a front wall. The front wall has an inner surface, an outer surface, first and second side edges, a top edge and a bottom edge. A rear wall is provided. The rear wall has an inner surface, an outer surface, first and second side edges, a top edge and a bottom edge. The front wall is joined to the rear wall at respective first and second side edges thereof. The front wall is sealed to the rear wall adjacent respective bottom edges thereof. An open mouth is located at the top edges of the bag. 
     The front and rear walls of each of the bags are removably attached by a perforation line at the bottom edges to the top edges of a subsequent bag in the flattened tube. The tube is folded twice parallel to a long axis of the bags to form a compact flattened tube approximately one third of a width of the bags. The folded tube is rolled to form a compact bag roll. 
     (2) In a variant of the invention, a chisel cut is provided. The chisel cut extends through a center point of the perforation line of the folded tube. When the compact roll is installed in a bag dispenser the chisel cut will engage a separating tongue when bags are pulled from the roll. When the bags are opened to their full width, three chisel cuts will appear at the perforation line. 
     (3) In a further variant, the compact tube is rolled about a core. 
     (4) In still a further variant, the bags includes at least one side gusset, the side gusset extending inwardly from either of the first and second side edges of the front and rear walls. 
     (5) In yet a further variant, the side gusset extends inwardly from either of the first and second side edges of the front and rear walls for up to one third of the width of the bags. 
     (6) In another variant of the invention, the side gusset extends inwardly from either of the first and second side edges of the front and rear walls for up to one half of the width of the bags. 
     (7) In still another variant, the outer surface of at least one of the front wall and the rear wall of the bags is corona treated. 
     (8) In a further variant, the corona treatment of the outer surface of at least one of the front and rear walls of each of the bags is an amount sufficient to result in a surface tension on the wall of at least about 38 dynes/cm. 
     (9) In still a further variant, the outer surface of at least one of the front wall and the rear wall of the bags is printed. 
     (10) In yet a further variant, the first side edges are folded over the second side edges. 
     (11) In another variant of the invention, the first side edges are folded under the second side edges. 
     (12) In still another variant, the polyethylene material is formulated from about 40-48 wt. % high density, high molecular weight polyethylene, 12-20 wt. % high density, medium molecular weight polyethylene, 20-30 wt. % linear low density polyethylene, 0-8 wt. % color concentrate. 
     (13) In a further variant, the polyethylene material is formulated from about 10-20 wt. % recycled material, the recycled material includes about 40-48 wt. % high density, high molecular weight polyethylene, 12-20 wt. % high density, medium molecular weight polyethylene, 20-30 wt. % linear low density polyethylene and 0-8 wt. % color concentrate. 
     (14) In still a further variant, 10-15 wt. % of the linear low density polyethylene has a density ranging from 0.923-0.924 gm/cc. 
     (15) In yet a further variant, 10-15 wt. % of the linear low density polyethylene has a melt index ranging from 0.25-0.30 gm/10 minutes. 
     (16) In another variant of the invention, the high density, medium molecular weight polyethylene has a density ranging from 0.937-0.947 gm/cc. 
     (17) In still another variant, the high density, medium molecular weight polyethylene has a melt index ranging from 0.10-0.30 gm/10 minutes. 
     (18) In yet another variant of the invention, a method of making a tri-fold plastic bag roll includes the following steps: Extruding a tube of plastic or other film material. Flattening the tube to form a flattened tube that that has upper and lower surfaces and first and second side edges. Sealing the tube perpendicular to the first and second side edges at predetermined intervals to form bag bottoms. Folding the tube in thirds parallel to the first and second side edges to form a compact flattened tube. Perforating the compact flattened tube perpendicular to the first and second side edges to form a perforation line. Rolling the compact flattened tube into a compact bag roll. 
     (19) A further variant of the method includes the further step of chisel cutting the compact flattened tube at a center point of the perforation line prior to rolling the compact flattened tube into a compact bag roll. 
     (20) A still further variant of the method includes the further step of providing a bag roll core prior to rolling the compact flattened tube into a compact bag roll. 
     (21) Yet a further variant of the method includes the further step of gusseting the tube of film material prior to flattening the tube to form a continuous flattened tube. 
     (22) Another variant of the method includes the further step of corona treating at least one of the upper and lower surfaces of the continuous flattened tube prior to sealing the tube perpendicular to the first and second side edges. 
     (23) Still another variant of the method includes the further step of printing either of the upper and lower surfaces of the continuous flattened tube after corona treatment. 
     (24) In yet another variant of the invention, an apparatus for making a tri-fold bag roll, includes a supply of plastic or other extrudable film material. An extruder is provided. The extruder is capable of forming a seamless continuous tube of thin film from the material. A tubing flattener is provided. The flattener is capable of flattening the continuous tube into a flattened tube. The flattened tube has first and second side edges and upper and lower interior surfaces located adjacent one another. A sealer is provided. The sealer is capable of forming a series of seals in the flattened tube perpendicular to a long axis of the tube. A folder is provided. 
     The folder includes a platen. The platen has a first end and a second end, is located adjacent the flattened tube and has a width at the second end slightly less than a width of the tri-fold bag. First and second guide bars are provided. The bars guide the first and second side edges of the flattened tube over the platen and the first side edge over the second side edge to form a continuous, compact C-folded flattened tube surrounding the second end of the platen. A perforator is provided. The perforator is capable of perforating the compact flattened tube through six film layers and forming a perforation line. A bag roller is provided. The bag roller is capable of rolling the perforated compact flattened tube into a compact roll. 
     (25) In a variant of the invention at least one creasing roller is provided. The creasing roller is located adjacent the second end of the platen and bears against the C-folded flattened tube to reinforce folds in the flattened tube. 
     (26) In still another variant, the apparatus further includes a chisel cutter. The chisel cutter is capable of forming a chisel cut through the six film layers at a center point of the perforation line. 
     (27) In a further variant, the apparatus includes a supply of cores. The compact flattened tube is wound around the cores to form the compact bag rolls. 
     (28) In still a further variant, the apparatus includes a gusseter. The gusseter is capable of forming at least one side gusset in the continuous tube prior to flattening. 
     (29) In yet a further variant, the apparatus includes a corona treater. The corona treater is capable of corona treating at least one of the upper and lower surfaces of the continuous flattened tube prior to folding. 
     (30) In another variant of the invention, the apparatus includes a printer. The printer is capable of printing on at least one of the upper and lower surfaces of the continuous flattened tube after corona treatment. 
     (31) In still another variant of the invention, the folder divides the continuous flattened tube into a first side portion, a center portion and a last side portion and folds the first side portion over the center portion and the last side portion over the first side portion, thereby forming a C-fold flattened tube and C-fold bags. 
     (1) In yet another variant, an apparatus for making a tri-fold bag roll, includes a supply of either of plastic and other extrudable film material. An extruder is provided. The extruder is capable of forming a seamless continuous tube of thin film from the material. A tubing flattener is provided. The flattener is capable of flattening the continuous tube into a flattened tube. The flattened tube has first and second side edges and upper and lower interior surfaces located adjacent one another. A sealer is provided. The sealer is capable of forming a series of seals in the flattened tube perpendicular to a long axis of the tube. 
     A folder is provided. The folder includes first and second guide bars. The bars guide the first and second side edges of the flattened tube under and over each other to form a continuous, compact Z-folded flattened tube. Each of the guide bars has an outer side and an inner side, an end closer to the extruder and an end further from the extruder. The first guide bar has a wide horizontal platen at the closer end and a first curved portion at the outer side. The first curved portion extends under the platen. The second guide bar has a second curved portion at the closer end and a narrow supporting ledge. The second guide bar is spaced from a first side edge of the first bar with the supporting ledge located below the first side edge of the first bar. The second guide bar transitions to a wider, upper C-shape between the closer end and the further end. The upper C-shape has an upper portion and a lower portion. 
     The first guide bar transitions to a narrower, lower C-shape between the closer end and the further end. The lower C-shape has an upper portion and a lower portion. The upper portion of the second guide bar is located above the upper portion of the first guide bar. The upper portion of the first guide bar is located above the lower portion of the second guide bar. The lower portion of the second guide bar is located above the lower portion of the first guide bar. The flattened tube is located below a lower surface of the platen and above the supporting ledge at the closer ends of the guide bars and formed into a Z-folded flattened tube at the further ends of the guide bars. 
     A perforator is provided. The perforator is capable of perforating the compact flattened tube through six film layers and forming a perforation line. A bag roller is provided. The bag roller is capable of rolling the perforated compact flattened tube into a compact roll. 
     (2) In a further variant, at least one creasing roller is provided. The creasing roller is located downstream from said folder and bears against the Z-folded flattened tube to reinforce folds in the flattened tube. 
     (3) In still a further variant, a chisel cutter is provided. The chisel cutter is capable of forming a chisel cut through the six film layers at a center point of the perforation line. 
     (4) In yet a further variant, a supply of cores is provided. The compact bag web is wound around the core to form the compact bag roll. 
     (5) In another variant of the invention, a gusseter is provided. The gusseter is capable of forming at least one side gusset in the continuous tube prior to flattening. 
     (6) In still another variant, a corona treater is provided. The corona treater capable of corona treating at least one upper and lower surface of the continuous bag web prior to folding. 
     (7) In yet another variant, a printer is provided. The printer is capable of printing on at least one of the upper and lower surfaces of the continuous bag web after corona treatment. 
     (8) In a final variant, the folder divides the continuous flattened tube into a first side portion, a center portion and a last side portion. The folder folds the first side portion over the center portion and the last side portion under the center portion, thereby forming a Z-fold bag web and Z-fold bags. 
     An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and the detailed description of a preferred embodiment. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a perspective view of the preferred embodiment of the tri-fold plastic bag roll, illustrating a compact bag roll without core; 
         FIG. 1B  is a perspective view of the bag of the  FIG. 1A  embodiment; 
         FIG. 2A  is a perspective view of the preferred embodiment of the tri-fold plastic bag roll, illustrating a compact bag roll with core; 
         FIG. 2B  is a perspective view of the bag of the  FIG. 2A  embodiment; 
         FIG. 3A  is a perspective view of an alternative bag of the  FIG. 1A  embodiment, illustrating gussets approximately one third of the width of the bag; 
         FIG. 3B  is a side elevational view of the  FIG. 3A  embodiment, illustrating the first side edges folded over the second side edges; 
         FIG. 4A  is a perspective view of an alternative bag of the  FIG. 1A  embodiment, illustrating gussets approximately one half of the width of the bag; 
         FIG. 4B  is a side elevational view of the  FIG. 3A  embodiment, illustrating the first side edges folded under the second side edges; 
         FIG. 5  is a perspective view of the bag of the  FIG. 1A  embodiment illustrating printing on the outer surface of the bag; 
         FIG. 6  is a side elevational view of the  FIG. 5  embodiment, illustrating the first side edges folded over the second side edges; 
         FIG. 7  is a side elevational view of the  FIG. 5  embodiment, illustrating the first side edges folded under the second side edges; 
         FIG. 8  is a perspective view of an apparatus for forming the compact bag roll of the  FIG. 1A  embodiment; 
         FIG. 9  is a perspective view of perforation of the compact bag roll of the  FIG. 2A  embodiment; 
         FIG. 10  is a perspective view of an apparatus for gusseting, corona treating and printing the compact bag roll of the  FIG. 3A  embodiment; 
         FIG. 11  is a perspective view of the folder of the  FIG. 8  apparatus; 
         FIG. 12  is a cross-sectional view of the  FIG. 11  folder taken along the line  12 - 12 ; 
         FIG. 13  is a cross-sectional view of the  FIG. 11  folder taken along the line  13 - 13 ; 
         FIG. 14  is a perspective view of the folder of the  FIG. 8  apparatus illustrating the creasing rollers; 
         FIG. 15  is a perspective view of a second embodiment of a folder of the  FIG. 8  apparatus illustrating the creasing rollers; 
         FIG. 16  is a cross-sectional view of the  FIG. 15  folder taken along the line  16 - 16 ; and 
         FIG. 17  is a cross-sectional view of the  FIG. 15  folder taken along the line  17 - 17 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     (1)  FIGS. 1A, 1B, 2A and 2B  illustrate a tri-fold plastic bag roll  10  providing the desired features that may be constructed from the following components. A continuous web  15  of plastic bags  20  formed from polyethylene material  22  is provided. Each of the bags  20  includes a front wall  25 . The front wall  25  has an inner surface (not shown), an outer surface  35 , first  40  and second  45  side edges, a top edge  50  and a bottom edge  55 . A rear wall  60  is provided. The rear wall  60  has an inner surface (not shown), an outer surface  70 , first  75  and second  80  side edges, a top edge  85  and a bottom edge  90 . The front wall  25  is joined to the rear wall  60  at respective first  40 ,  75  and second  45 ,  80  side edges thereof. The front wall  25  is sealed to the rear wall  60  adjacent respective bottom edges  55 ,  90  thereof. An open mouth  95  is located at the top edges  50 ,  85  of the bag  20 . 
     The front  25  and rear  60  walls of each of the bags  20  are removably attached by a perforation line  100  at the bottom edges  55 ,  90  to the top edges  50 ,  85  of a subsequent bag  20  in the web  15 . The web  15  is folded twice parallel to a long axis  105  of the bags  20  to form a compact bag web  110  approximately one third of a width  115  of the bags  20 . The folded web  110  is rolled to form a compact bag roll  120 . 
     (2) In a variant of the invention, as illustrated in  FIGS. 2A and 2B , a chisel cut  125  is provided. The chisel cut  125  extends through a center point  130  of the perforation line  100  of the folded web  110 . When the compact roll  120  is installed in a bag dispenser (not shown) the chisel cut  125  will engage a separating tongue (not shown) when bags  20  are pulled from the roll  120 . When the bags  20  are opened to their full width  115 , three chisel cuts  125  will appear at the perforation line  100 . 
     (3) In a further variant, as illustrated in  FIG. 2A  the compact web  15  is rolled about a core  135 . 
     (4) In still a further variant, as illustrated in  FIGS. 3A, 3B, 4A and 4B , the bags  20  includes at least one side gusset  145 , the side gusset  145  extending inwardly from either of the first  40 ,  75  and second  45 ,  80  side edges of the front  25  and rear  60  walls. 
     (5) In yet a further variant, as illustrated in  FIGS. 3A and 3B , the side gusset  145  extends inwardly from either of the first  40 ,  75  and second  45 ,  80  side edges of the front  25  and rear  60  walls for up to one third of the width  115  of the bags  20 . 
     (6) In another variant of the invention, as illustrated in  FIGS. 4A and 4B , the side gusset  145  extends inwardly from either of the first  40 ,  75  and second  45 ,  80  side edges of the front  25  and rear  60  walls for to up one half of the width  115  of the bags  20 . 
     (7) In still another variant, the outer surface  35 ,  70  of at least one of the front wall  25  and the rear wall  60  of the bags  20  is corona treated. 
     (8) In a further variant, the corona treatment of the outer surface  35 ,  70  of at least one of the front  25  and rear  60  walls of each of the bags  20  is an amount sufficient to result in a surface tension on the wall  25 ,  60  of at least about  38  dynes/cm. 
     (9) In still a further variant, as illustrated in  FIG. 5 , the outer surface  35 ,  70  of at least one of the front wall  25 , and the rear wall  60  of the bags  20  is printed. 
     (10) In yet a further variant, as illustrated in  FIG. 6 , the first side edges  40 ,  75  are folded over the second side edges  45 ,  80 . 
     (11) In another variant of the invention, as illustrated in  FIG. 7 , the first side edges  40 ,  75  are folded under the second side edges  45 ,  80 . 
     (12) In still another variant, the polyethylene material  22  is formulated from about 40-48 wt. % high density, high molecular weight polyethylene, 12-20 wt. % high density, medium molecular weight polyethylene, 20-30 wt. % linear low density polyethylene, 0-8 wt. % color concentrate. 
     (13) In a further variant, the polyethylene material  22  is formulated from about 10-20 wt. % recycled material, the recycled material includes about 40-48 wt. % high density, high molecular weight polyethylene, 12-20 wt. % high density, medium molecular weight polyethylene, 20-30 wt. % linear low density polyethylene and 0-8 wt. % color concentrate. 
     (14) In still a further variant, 10-15 wt. % of the linear low density polyethylene has a density ranging from 0.923-0.924 gm/cc. 
     (15) In yet a further variant, 10-15 wt. % of the linear low density polyethylene has a melt index ranging from 0.25-0.30 gm/10 minutes. 
     (16) In another variant of the invention, the high density, medium molecular weight polyethylene has a density ranging from 0.937-0.947 gm/cc. 
     (17) In still another variant, the high density, medium molecular weight polyethylene has a melt index ranging from 0.10-0.30 gm/10 minutes. 
     (18) In yet another variant of the invention, as illustrated in  FIG. 8 , a method of making a tri-fold plastic bag roll  10 , includes the following steps: Extruding a tube  150  of polyethylene material  22 . Flattening the tube  150  to form a continuous web  15  that has upper  155  and lower  160  surfaces and first  165  and second  170  side edges. Sealing the tube  150  perpendicular to the first  165  and second  170  side edges at predetermined intervals  175  to form bag bottoms  180 . Folding the web  15  in thirds parallel to the first  165  and second  170  side edges to form a compact web  110 . Perforating the compact web  185  perpendicular to the first  165  and second  170  side edges to form a perforation line  100 . Rolling the compact web  110  into a compact bag roll  120 . 
     (19) A further variant of the method, as illustrated in  FIG. 9 , includes the further step of chisel cutting the compact web  110  at a center point  130  of the perforation line  100  prior to rolling the compact web  110  into a compact bag roll  120 . 
     (20) A still further variant of the method, as illustrated in  FIG. 9 , includes the further step of providing a bag roll core  135  prior to rolling the compact web  110  into a compact bag roll  120 . 
     (21) Yet a further variant of the method, as illustrated in  FIG. 10 , includes the further step of gusseting the tube  150  of polyethylene material  22  prior to flattening the tube  150  to form a continuous web  15 . 
     (22) Another variant of the method, as illustrated in  FIG. 10 , includes the further step of corona treating at least one of the upper  155  and lower  160  surfaces of the continuous web  15  prior to sealing the tube  150  perpendicular to the first  165  and second  170  side edges. 
     (23) Still another variant of the method, as illustrated in  FIG. 10 , includes the further step of printing either of the upper  155  and lower  160  surfaces of the continuous web  15  after corona treatment. 
     (24) In yet another variant of the invention, as illustrated in  FIGS. 8-12 , an apparatus  190  for making a tri-fold bag roll  10 , includes a supply of plastic or other extrudable film material  22 . An extruder  195  is provided. The extruder  195  is capable of forming a seamless continuous tube of thin film  150  from the material  22 . A tubing flattener  200  is provided. The flattener  200  is capable of flattening the continuous tube  150  into a flattened tube  15 . The flattened tube  15  has first  17  and second  19  side edges and upper  21  and lower  23  interior surfaces located adjacent one another. A sealer  205  is provided. The sealer  205  is capable of forming a series of seals  210  in the flattened tube  15  perpendicular to a long axis  215  of the tube  15 . 
     A folder  220  is provided. The folder  220  includes a platen  222 . The platen  222  has a first end  224  and a second end  226 , is located adjacent the flattened tube  15  and has a width  228  at the second end  226  slightly less than a width  27  of the tri-fold bag  10 . First  232  and second  234  guide bars are provided. The bars  232 ,  234  guide the first  17  and second  19  side edges of the flattened tube  15  over the platen  222  and the first side edge  17  over the second side edge  19  to form a continuous, compact C-folded flattened tube  110  surrounding the second end  226  of the platen  222 . A perforator  225  is provided. The perforator  225  is capable of perforating the compact flattened tube  110  through six film layers  230  and forming a perforation line  100 . A bag roller (not shown) is provided. The bag roller is capable of rolling the perforated compact flattened tube  110  into a compact roll  120 . 
     (25) In a variant of the invention at least one creasing roller  260  is provided. The creasing roller  260  is located adjacent the second end  226  of the platen  222  and bears against the C-folded flattened tube  110  to reinforce folds  265  in the flattened tube  110 . 
     (26) In still another variant, as illustrated in  FIG. 9 , the apparatus  190  further includes a chisel cutter  240 . The chisel cutter  240  is capable of forming a chisel cut  125  through the six film layers  230  at a center point  130  of the perforation line  100 . 
     (27) In a further variant, as illustrated in  FIG. 9 , the apparatus  190  includes a supply of cores  135 . The compact bag web  110  is wound around the cores  135  to form the compact bag rolls  120 . 
     (28) In still a further variant, as illustrated in  FIG. 10 , the apparatus  190  includes a gusseter  245 . The gusseter  245  is capable of forming at least one side gusset  145  in the continuous tube  150  prior to flattening. 
     (29) In yet a further variant, as illustrated in  FIG. 10 , the apparatus  190  includes a corona treater  250 . The corona treater  250  is capable of corona treating at least one of the upper and lower surfaces  155 ,  160  of the continuous bag web  15  prior to folding. 
     (30) In another variant of the invention, as illustrated in  FIG. 10 , the apparatus  190  includes a printer  255 . The printer  255  is capable of printing on at least one of the upper and lower  155 ,  160  surfaces of the continuous bag web  15  after corona treatment. 
     (31) In a final variant of the invention, the folder  220  divides the continuous flattened tube  15  into a first side portion  27 , a center portion  29  and a last side portion  31  and folds the first side portion  27  over the center portion  29  and the last side portion  31  over the first side portion  27 , thereby forming a C-fold flattened tube  110  and C-fold bags  20 . 
     (1) In yet another variant, as illustrated in  FIGS. 8 and 15-17  an apparatus  190  for making a tri-fold bag roll  10 , includes a supply of either of plastic and other extrudable film material  22 . An extruder  195  is provided. The extruder  195  is capable of forming a seamless continuous tube of thin film  150  from the material  22 . A tubing flattener  200  is provided. The flattener  200  is capable of flattening the continuous tube  150  into a flattened tube  15 . The flattened tube  15  has first  17  and second  19  side edges and upper  21  and lower  23  interior surfaces located adjacent one another. A sealer  205  is provided. The sealer  205  is capable of forming a series of seals  210  in the flattened tube  15  perpendicular to a long axis  215  of the tube  15 . A folder  306  is provided. The folder  306  includes first  310  and second  314  guide bars. The bars  310 ,  314  guide the first  17  and second  19  side edges of the flattened tube  15  under and over each other to form a continuous, compact Z-folded flattened tube  304 . 
     Each of the guide bars  310 ,  314  has an outer side  312 ,  316  and an inner side  320 ,  324 , an end closer  328  to the extruder  195  and an end further  332  from the extruder  195 . The first guide bar  310  has a wide horizontal platen  336  at the closer end  328  and a first curved portion  340  at the outer side  312 . The first curved portion  340  extends under the platen  336 . The second guide bar  314  has a second curved portion  344  at the closer end  328  and a narrow supporting ledge  348 . The second guide bar  314  is spaced from a first side edge  352  of the first bar  310  with the supporting ledge  348  located below the first side edge  352  of the first bar  310 . The second guide bar  314  transitions to a wider, upper C-shape  356  between the closer end  328  and the further end  332 . The upper C-shape  356  has an upper portion  360  and a lower portion  364 . 
     The first guide bar  310  transitions to a narrower, lower C-shape  368  between the closer end  328  and the further end  332 . The lower C-shape  368  has an upper portion  372  and a lower portion  376 . The upper portion  360  of the second guide bar  314  is located above the upper portion  372  of the first guide bar  310 . The upper portion  372  of the first guide bar  310  is located above the lower portion  364  of the second guide bar  314 . The lower portion  364  of the second guide bar  314  is located above the lower portion  376  of the first guide bar  310 . The flattened tube  15  is located below a lower surface  380  of the platen  336  and above the supporting ledge  348  at the closer ends  328  of the guide bars  310 ,  314  and formed into a Z-folded flattened tube  304  at the further ends  332  of the guide bars  310 ,  314 . 
     A perforator  225  is provided. The perforator  225  is capable of perforating the compact flattened tube  110  through six film layers  230  and forming a perforation line  100 . A bag roller (not shown) is provided. The bag roller is capable of rolling the perforated compact flattened tube  304  into a compact roll  120 . 
     (2) In a further variant, at least one creasing roller  260  is provided. The creasing roller  260  is located downstream from said folder  306  and bears against the Z-folded flattened tube  304  to reinforce folds  308  in the flattened tube  304 . 
     (3) In still a further variant, as illustrated in  FIG. 9 , the apparatus  190  further includes a chisel cutter  240 . The chisel cutter  240  is capable of forming a chisel cut  125  through the six film layers  230  at a center point  130  of the perforation line  100 . 
     (4) In yet a further variant, as illustrated in  FIG. 9 , the apparatus  190  includes a supply of cores  135 . The compact Z-folded flattened tube  304  is wound around the cores  135  to form the compact bag rolls  120 . 
     (5) In another variant of the invention, as illustrated in  FIG. 10 , the apparatus  190  includes a gusseter  245 . The gusseter  245  is capable of forming at least one side gusset  145  in the continuous tube  150  prior to flattening. 
     (6) In still another variant, as illustrated in  FIG. 10 , the apparatus  190  includes a corona treater  250 . The corona treater  250  is capable of corona treating at least one of the upper and lower surfaces  155 ,  160  of the continuous bag web  15  prior to folding. 
     (7) In yet another variant, as illustrated in  FIG. 10 , the apparatus  190  includes a printer  255 . The printer  255  is capable of printing on at least one of the upper and lower  155 ,  160  surfaces of the continuous bag web  15  after corona treatment. 
     (8) In a final variant, as illustrated in  FIGS. 16 and 17 , the folder divides the continuous flattened tube  15  into a first side portion  27 , a center portion  29  and a last side portion  31 . The folder  306  folds the first side portion  27  over the center portion  29  and the last side portion  31  under the center portion  29 , thereby forming a Z-fold bag web  304  and Z-fold bags  318 . 
     The tri-fold plastic bag roll  10  and apparatus  190  for making same have been described with reference to particular embodiments. Other modifications and enhancements can be made without departing from the spirit and scope of the claims that follow.