Patent Publication Number: US-7585266-B2

Title: Methods for producing and using containers for housing product

Description:
RELATED APPLICATIONS 
   This continuation-in-part application claims the benefit of U.S. patent application Ser. No. 11/387,332, filed on Mar. 23, 2006, which is a continuation of U.S. patent application Ser. No. 10/390,959, filed on Mar. 18, 2003, now U.S. Pat. No. 7,217,032 which is a continuation of U.S. patent application Ser. No. 09/941,049, filed on Aug. 28, 2001, now U.S. Pat. No. 6,604,857, which claims priority from U.S. Provisional Application No. 60/228,581, filed on Aug. 29, 2000, the entire disclosures of which are incorporated herein by reference. 

   BACKGROUND 
   The present invention relates generally to containers for housing a product. More specifically, the present invention relates to methods of producing and using flexible containers for housing products. 
   There are a variety of types of containers for housing products. It is, of course, known to package products in rigid containers such as metal cans, glass bottles, or rigid plastic containers. Rigid containers, when empty, represent a high volume of empty space. As a result, rigid empty containers are cumbersome to ship to the destinations where they will be filled and sealed with product. In addition, such empty containers require significant space for storing and discarding. 
   It is also known to construct containers from flexible materials, such as sheets or rolls of plastic material. Such flexible containers have been in existence for a number of years. These containers offer many advantages over rigid containers. For example, flexible plastic bottles and cartons offer distinct advantages over metallic cans and glass bottles. In this regard, such flexible containers are lighter, typically far less expensive to produce, and much easier to discard. 
   However, there are inherent disadvantages with flexible containers. For example, flexible containers do not have the sturdiness of typical rigid containers. The sturdiness of the container can become an issue with respect to the stability of the container when they are filled with product and stood upright for storage, display, or other purpose. Moreover, heavier flexible containers are difficult to pick up and carry conveniently. 
   To overcome this stability issue, flexible containers have been formed with reinforced bottoms or sides. Such a container is shown in U.S. Pat. No. 5,135,464. In order to create such reinforced enforcements, layers of plastic film or paper are doubled in select locations along or adjacent to the container bottoms as they are manufactured. These double layers are fused by a heat sealing or stitching process. Such constructions, however, result in multiple layers of films or paper being brought together at junctions. In this regard, as many as six layers often meet and are interfused at a seam or junction. This multi-wall construction results in seals that possess a tendency to leak due to capillary action. 
   An additional problem with many flexible containers is that there is a lack of consistency in the production process. Typically, the manufacturing process associated with such products requires a web of film to be drawn through a series of forming stations where various folds, cuts, or seals are made to the film. In many of these manufacturing processes it is difficult to control and ensure the accuracy and consistency of the resultant product given the number of manipulations to the film and the number of folding, sealing and forming stations. In addition, there are hermetic sealing problems with the multi-wall bags presently available. To this extent, the bags are not “insect-tight” causing problems when the containers are stored with product. Also, the containers are not resealable for storage in-between uses. 
   A still further problem with flexible containers is their propensity to burst open. This is especially an issue should the container be dropped. 
   Moreover, another issue with such containers is their shape. Due to the flexible nature of the containers, the containers will take on the shape of the product contained therein and/or a bag-like shape. This makes it difficult to store the filled containers, stack same, and/or package the containers for shipping. Generally, the multi-layer bags have to be stored and displayed in a horizontal flat condition making it difficult to handle the bags. Moreover, it is also difficult to see the labeling on the bags when they are piled on top of each other in the horizontal flat condition. 
   The lack of stability also causes problems for the user when the user is trying to scoop or pour product from the bag. 
   Another problem with the current flexible bags is that they are not easily transported after the bags are filled with product at the distribution center or the manufacturing plant or after the filled bags arrive at the point of purchase location. Generally, packaged products are transported via conveyor systems at the manufacturing plant or point of purchase location. Often times, the conveyor systems include sharp turns (e.g., 90° turns) and gaps. The poor stability and awkward size of the large multilayer bags cannot maneuver around the turns or through the gaps. As a result, the large multi-layer bags cannot be transported on conveyor systems like other packaged products, they must be handled by hand. 
   There therefore is a need for an improved flexible container for storing and carrying a product, conveniently opening and closing the container and method for making such containers. 
   SUMMARY 
   Improved containers and methods for making same are provided. The improved container provides a flexible container that has sufficient stability to be used to house a product. At the same time, the container of the present invention provides desired flexibility. Moreover, the present invention provides improved methods of using containers, including the filling, sealing, handling, transportation, and merchandising of same. 
   To this end, in an embodiment, the present invention provides a method for improving the design of a pet food container as compared to a conventional pet food container comprising the steps of increasing a fill speed of the pet food container during the manufacturing process as compared to a fill speed of a conventional process; providing the pet food container with a greater volume utilization as compared to the conventional pet food container; and providing the pet food container with the ability to be sealed using a smooth sealing jaw during the manufacturing process. 
   In an embodiment, the fill speed is increased, at least in part, by increasing an opening of the pet food container as compared to a similar opening in the conventional pet food container. For example, the fill speed is increased, at least in part, by providing the pet food container with a flat bottom. 
   In an embodiment, the method of providing the pet food container with greater volume utilization is achieved by providing a bottom gusseted container. 
   In an embodiment, the pet food container does not have side gussets. 
   In an embodiment, the ability to be sealed with smooth jaws is achieved, at least in part, by providing the pet food container with a relatively consistent material thickness. 
   In an embodiment, the pet food container in an unfilled condition is so constructed and arranged so that a plurality of pet food containers lay flatter on a filling machine than a similar number of conventional pet food containers. 
   In a further embodiment, the present invention provides a method for improving the ability to display to consumers a pet food container comprising the steps of: providing a flexible pet food container having a substantially cuboid shape when filled with pet food and displayed to consumers; and providing the pet food container with handles that extend from a top surface of the pet food container until accessed by a consumer. 
   In an embodiment, the method includes the step of stacking a second flexible pet food container on the flexible pet food container when it is displayed to a consumer. 
   In another embodiment, the present invention provides a method for improving the design of a pet food container comprising the steps of: providing a pet food container that is constructed from a flexible material and includes handles; improving the filling characteristics of the container as compared to a similar conventional pet food container; improving the sealing characteristics of an opening of the container as compared to a similar opening in a conventional pet food container; and improving the stackability of the container as compared to the stackability of a similar conventional pet food container. 
   In an embodiment, the pet food container when filled has a cuboid design. 
   Additionally, the present invention provides a method of improving the filling characteristics of a pet food container comprising the steps of: providing the container with no side gussets allowing the container to be filled on conventional paper and plastic container filling equipment; providing the container with a mouth opening to allow for increased fill speeds as compared to a container with a smaller mouth opening; and providing the container with a bottom gusset to provide better container utilization as compared to a container including no bottom gusset. 
   Still further, in an embodiment, the present invention provides a method of improving the displayability of a pet food container comprising the steps of: providing a flexible pet food container that, when filled with a product, has a substantially cuboid shape allowing the container to be retailed standing up on a surface; providing on a wall of the container a display panel identifying the product; providing handles on the container that are visible to the consumer when the container is on the surface yet lay substantially flat on a surface of the container until accessed by the consumer; and providing the container with no side gussets. 
   In the method, various surfaces can be used including a shelf, a pallet, and a top surface of a second container. 
   Further, in an embodiment, a method for providing an improved pet food container is provided by the present invention comprising the steps of improving at least one of the filling, sealing, handling, transporting, and merchandising characteristics of a conventional pet food container by providing a container having a base portion including bottom side walls, and an interior, the side walls being defined by at least two sheets of flexible material sealed along two edges and defining two side seams located on opposite sides of the base, an upper panel portion having side panels that define a closure member wherein the upper panel portion extends below an upper end of the base portion, a pair of handles, and the pair of handles and upper panel are each sealed to the interior of the base portion. 
   Likewise, in an embodiment, a method for providing an improved pet food container is provided by the present invention comprising the steps of providing a base portion including a bottom, side walls, and an interior, the side walls being defined by at least two sheets of flexible material sealed along two edges and defining two side seams located on opposite sides of the base, an upper panel portion including side panels that define a resealable closure member, the upper panel defining a substantially flat surface when the container is in a closed position. 
   Accordingly, it is an advantage of the present invention to provide an improved flexible container. 
   A further advantage of the present invention is to provide an improved method for manufacturing containers. 
   Another advantage of the present invention is to provide a container that provides improved filling benefits for storing a variety of different products. 
   Furthermore, an advantage of the present invention is to provide a container that provides improved sealing benefits for storing a variety of different products. 
   Moreover, an advantage of the present invention is to provide a container that provides improved handling benefits for storing a variety of different products. 
   Further, an advantage of the present invention is to provide a container that provides improved transportation characteristics. 
   Another advantage of the present invention is to provide a container that provides improved merchandising characteristics. 
   Still, an advantage of the present invention is to provide a flexible container that provides for improved display of the container. 
   Moreover, an advantage of the present invention is to provide a flexible container that has improved characteristics for use with a pallet. 
   Furthermore, an advantage of the present invention is to provide a container that provides improved characteristics that are advantageous for use as a pet food container. 
   Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates a perspective transparent view of an embodiment of the container of the present invention filled with product prior to being sealed. 
       FIG. 2  illustrates a perspective transparent view illustrating separate components of the container prior to being bonded together. 
       FIG. 3  illustrates a perspective view of the container just prior to the closure members being sealed. 
       FIG. 4  illustrates a perspective view of the container in a sealed condition ready for storage. 
       FIG. 5A  illustrates a cross-sectional view of the container taken along lines V-V of  FIG. 4 . 
       FIG. 5B  illustrates a cross-sectional view of an alternative embodiment of the container of  FIG. 4  taken along V-V. 
       FIG. 6  illustrates a plurality of sealed/closed containers in a stacked position. 
       FIG. 7  illustrates a perspective bottom view of a section of the base portion incorporating the “hand-hold” cavity. 
       FIG. 8  illustrates a perspective view of a flat blank of the container during the manufacturing process. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention provides an improved container for housing products, method for manufacturing same, and methods of use of the container. The container is constructed from a flexible material, e.g., thin film of plastic, and has sufficient rigidity and strength to house and store a variety of products. Moreover, due to its construction, the container provides many design improvements and characteristics as compared to conventional containers, especially conventional pet food containers. As used herein, the term “conventional pet food container” or “conventional container” means containers for storing food products, including pet food, that were available and used prior to the inventions set forth herein. The background of the invention discusses some such containers. “Conventional process” means processes for manufacturing products that were used prior to the inventions set forth herein and that use or incorporate as a part thereof such conventional containers, e.g., filling the conventional container with product. 
     FIG. 1  illustrates a transparent perspective view of an embodiment of a container  10  of the present invention. The container  10  is illustrated filled with product  111  and in an open condition. As illustrated in  FIG. 4 , in its sealed condition, the container  10  takes on, in a preferred embodiment, a cuboidal shape. The cuboid, e.g., cube-shape, of the flexible container  10  provides a container with greater stability when stored. Moreover, the cuboidal shape of the container  10  allows for vertical stacking of a number of filled containers as illustrated in  FIG. 6 . This allows for the display of the container/product at the point of sale, as well as provides a container affording ease of storage for the consumer and provides a more compact product for shipping and storage. 
   The container  10  has a substantially consistent cuboid appearance whether the container stands or is laid down. Due to its design, the container  10  takes up less space on a retail shelf or in a consumer&#39;s home. Moreover, the container  10  allows for better palletization. To this end, the container  10  provides a flatter surface for stacking. The container  10  design eliminates head space, thus, there is less entrapped air for more stable stacking. 
   Further, the design of the container  10  allows for upright methods of handling, transporting and displaying the container  10 . This allows for an upright palletizing of the container  10 . Further, the design provides a square container bottom that does not vary with product density. The container  10  footprint remains the same regardless of varying product density so the container  10  never overhangs the pallet sides. This reduces possible container  10  damage in distribution channels. 
   Due to the design, only the container  10  height changes with density, which only affects stacked product height. The container  10  design provides a container that will typically fit on store shelves which may have limited space. For example, in a shelf having a reduced width dimension. Additionally, the design allows the same number of containers  10  as conventional side gusseted bags can be located on a shelf. 
   The container  10  design allows it to be retailed standing upright. Thus, pallets of containers  10  can be displayable and shoppable at retail. By providing a large display panel on the front of container  10 , it is easier for consumers to identify product brand on retail shelf. The design of the container  10  also provides handles that are always conveniently displayed on top of container  10  for easy removal of the container  10  from the shelf by the consumer. 
   Improved methods for palletizing containers  10  are also provided. In this regard, one can use column stacking with tie sheets to stabilize pallet. In addition, integrated stretch wrapper can be used in palletizer to stabilize the pallet. It is also possible to use a flat band conveyor to convey the containers. 
   Referring specifically to  FIGS. 1 and 2 , an embodiment of the container  10  is illustrated. Generally, the container  10  includes three main components: a base portion  12 ; an upper panel portion  14 ; and handles  16  and  18 . As discussed below, these three components are sealed together to create the container  10 . However, the handles are not essential to the formation of the container. As such, other embodiments of the present invention do not include handles. 
   The base portion  12  includes a bottom  20 . The bottom  20  is constructed so that it defines a substantially flat planar surface. The bottom  20  therefore provides a surface that can support product  11  that is stored in the container  10 . Moreover, the bottom  20  allows the container  10  to be supported on a flat surface providing stability to the filled container. In an embodiment, the bottom  20  is constructed from a rectangular sheet of material that is thermally sealed to a remaining portion of the base  12 . 
   The base  12 , in the preferred embodiment illustrated, includes four sides  22 ,  24 ,  26 , and  28 . The four sides  22 ,  24 ,  26 , and  28 , along with the bottom  20 , define an interior  30  for housing product  11 . In the preferred embodiment illustrated, the sides  22 ,  24 ,  26 , and  28  of the base  12  are defined by two sheets of material sealed together along side seams  29  and  31 . As illustrated, the side seams  29  and  31  are located on sides  22  and  26  of the base  12 . 
   Triangular base sections or end walls  34  and  36  are formed at a lower portion  23 ,  25  of each side  22  and  26 . Indeed, each of the triangular base sections  34  and  36  are defined by two sealed transitional side seams  33 ,  35  and  39 ,  41 , respectively. The transitional side seams  33 ,  35  and  39 ,  41  extend from end corners  20   a ,  20   b  and  20   c ,  20   d  of the bottom  20  to a vertex  29   a ,  31   a  located along the side seams  29  and  31 . Each triangular base section having a third side  42 ,  43  extending between end corners  20   a ,  20   b  and  20   c ,  20   d , respectively. A lower side seam  44  extends unitarily from vertices  29   a  and  31   a  along side seams  29  and  31  to the third sides  42 ,  43 . This structure results in the lower portions  23 ,  25  of the container sides  22  and  26  being reinforced along the seams  29  and  31 . The resultant seams are free of the presence of the intersection of six converging sealing layers which tends to create capillary leakage as in prior containers. Further, this structure allows for good web control resulting in a highly efficient method of manufacturing containers. 
   As shown in  FIG. 7 , the base  12  also includes interior triangular base sections  34   a  and  36   a  adjacent the exterior triangular sections  34  and  36 . The interior and exterior triangular sections  34   a ,  34  and  36   a ,  36  are compressed together when the container is filled with product. Advantageously, the triangular sections are capable of forming a slightly conical or pyramid shape that provides a “hand-hold” cavity between the interior and exterior triangular sections. In this regard, the “hand-hold” cavity acts as another handle and allows the consumer to pick up the container for ease of pouring or scooping product from the container. 
   It should be noted, that the base  12  can have a variety of sizes and shapes. For example, for a container  10  designed to house 18 pounds of dry product, e.g., cat food, in a preferred embodiment, the base has a height “a” of approximately 12 inches, sides  22  and  26  have a width “b” of approximately 7 inches, and sides  24  and  28  have a width “c” of approximately 12 inches. For a container designed to house 20 lbs of dry product, e.g., dog food, in a preferred embodiment the base has a height “a” of approximately 12¼ inches, sides  22  and  26  have a length “b” of approximately 9 inches, and sides  20  and  24  have a length “c” of 12 inches. 
   The base  12 , as well as the remaining portions of the container  10 , are preferably made of a thin plastic material. For example, the container base  12  can be made from a two-ply construction consisting of a layer of heat sealable polyethylene and a layer of imprintable polyester. Though both layers may be polyethylene. By way of example and not limitation, the material used to construct the container  10 , and therefore the base  12 , can include a polyethylene ply of 2½ mils and a polyester layer of ½ mil. 
   Preferably, the container  10  includes two handles  16  and  18 . The handles  16  and  18  provide grasping members for carrying the container  10  either prior to the container being filled or after it is filled. Of course, the handles  16  and  18  can take on a variety of shapes and sizes. Moreover, the handles  16  and  18  can be manufactured from a variety of materials suitable for variable load strengths. In a preferred embodiment, the handles  16  and  18 , prior to being secured to the container, have a length of 17 inches and are 2-ply thick. In this regard, they are constructed from a web of film that is folded over on to itself to increase the strength of the handles. To this extent, the handles  16  and  18  can be constructed from a single sheet of plastic film. 
   As illustrated in  FIGS. 1 and 2 , the container  10  includes an upper panel portion  14 . The upper panel portion includes four sides  46 ,  48 ,  50 , and  52 . The upper panel  14 , similar to the side wall portion  22 ,  24 ,  26 , and  28  of the base  12 , is constructed from two sheets of material sealed along two seams  54  and  56 . In a preferred embodiment, the seams  54  and  56  of the upper panel are in alignment with side seams  29  and  31  of the base  12  when the upper panel  14  is secured to the base  12 . In the container  10  illustrated in  FIG. 1 , the upper panel defines an opening  61  that affords access to the interior of the container  10 . 
   Preferably one of the sides  52 , of the upper panel  14 , has a length that is slightly greater than that of the other sides  46 ,  48 , and  50 . In the illustrated embodiment, this side  52  includes a closure member  60  for assisting in sealing the container  10 . The closure member  60  is designed to be secured to a corresponding closure member  62  on side  48 . 
   For example, in the embodiment illustrated, side  52  includes a hook and loop strip  60  that mates with a corresponding hook and loop strip  62  on side  48 . This allows the container  10  to be closed and opened in an easy manner. Thus, initially the container  10  can be filled with product  11  through the opening  61  and closed by the closure members  60  and  62 . The consumer can then access product through the opening  61  and reclose the container  10  by using the closure members  60  and  62 . It should, however, be noted that a variety of closure means and members can be used. For example, the closure can include a zipper, a ziplock or slider structure, or an adhesive or cohesive member. 
   As previously noted, preferably the upper panel  14  as well as the handles  16  and  18  are constructed from a different material than the base  12 . 
   Similar to the base, the upper panel  14  can have a variety of sizes and shapes. For example, for a container  10  designed to hold 18 lbs of dried products, referring to  FIG. 2  in a preferred embodiment of the container  10 , the sides  48 ,  50 , and  54  of the upper panel  14  have a length “d” of approximately 7⅜ inches, and side  52  has a length “e” of approximately 8½ inches. The width of the sides of the upper panel  14  will correspond to the width of the corresponding sides of the base  12 . For a container  10  designed to hold 20 lbs. of dry product, length “d”, in a preferred embodiment, will be approximately 9⅝ inches and length “e” approximately 10¾ inches. 
   The upper panel  14  is designed to be received within the base  12 . In a preferred embodiment, at least approximately 1 inch of the upper panel  14  is received within the base  12 . The upper panel  14  is then preferably heat sealed to the base  12 . It has been found that a heat seal of at least 1 inch provides a sufficiently strong connection between the upper panel  14  and base  12 . 
   In constructing the container  10 , the handles  16  and  18  are preferably received between the upper panel  14  and the base  12 . The base  12  is then thermal sealed to the upper panel  14  with the handles  16  and  18  being sealed therebetween. Specifically, the pair of handles  16  and  18  and the upper panel  14  are each thermally sealed unto themselves and to the interior of the base  12 . The interior side of the upper panel has a different sealant layer of polyethylene designed for sealing the interior of the containers, yet, allowing ease of opening the container. This provides a sufficiently strong structure as well as one that allows the weight of the contents to be evenly distributed over the base  12 . Further, such a structure allows the closure member  60  and  62  located on the upper panel  14  to be closed. 
   As a result, the base portion  12 , the upper panel  14  and the handles  16  and  18  are thermally bonded forming a hermetically sealed interior. 
   Moreover, the upper panel  14  can be manufactured from a non-slip plastic material. The non-slip plastic material allows the containers to be stacked vertically with limited slippage between the top and bottom containers. 
     FIGS. 3 ,  4 ,  5 A and  5 B illustrate how the container  10  can be closed. As illustrated in  FIG. 3 , first the closure members  60  and  62  are secured to each other. When so secured, sides  46  and  50  fold inward to create triangular portions  70 . Sides  48  and  52  are then folded over and down onto side  48  as illustrated in  FIGS. 4 and 5A . The method of folding the sides in this manner creates a flat top surface  72 . Generally, the length of the excess material of the sides  48  and  52  extending from the fold to the closure members may vary depending on the density of the product. Indeed, if the product is very dense then the product will take up less space within the container and vice versa. After the sides of the container are folded down, the sides  48  and  52  are tapped down along the outer fold to further seal the container  10 . 
   Alternatively,  FIG. 5B  illustrates another way the container can be folded and closed to create the desired flat top surface  72 . Specifically, the method shown in  FIG. 5B  incorporates a double fold in which the sides  48  and  52  are folded twice. The double fold adds even more strength to the top of the container and isolates the closure members  60  and  62 . 
   Once so closed, the container  10  takes on a substantially cubic-shape as illustrated in  FIG. 4 . The flat bottom  20  and flat top surface  72  allow multiple containers  10 ,  10   a ,  10   b ,  10   c ,  10   d , and  10   e  to be stacked vertically or otherwise stored or transported as illustrated in  FIG. 6 . 
   Container  10  of the present invention due to its structure also has anti-burst characteristics which are an improvement over those in the prior art. In prior art containers, the dropping of same causes the sides to expand upon impact. This expansion or swell is directly transferred to the inner section of the seams being pulled in the opposite directions. This often results in a breach of the container. 
   In the present invention, the side seams  29  and  31  of the container  10  extend to the lower side seams  44  which are formed from the transitional seams  33 ,  35  and  39 ,  41 . As such, should the container be dropped or otherwise caused to expand, the majority of the oppositely disposed forces are placed upon the lower side seam. Thus, should these forces cause one or both of the lower side seams to be pulled apart, this action does not cause a breach in the portion of the container containing the product, whether it be solid pellets or a liquid. 
   Other embodiments of the invention include containers of various shapes and sizes. For example, a container can be substantially triangular in shape. In this example, the container includes a flat bottom and two sides sealed together. However, the top portion folds down but is not flat as in a cubic-shaped container. 
   In an embodiment, the method of making the container involves a web roll process that results in a flat blank portion and a forming process that forms the base portion  12  and seals the base portion together. The result being a substantially flat container. After the web roll and forming processes, the flat containers are ready to be erected, filled with product, and sealed closed. Advantageously, the flat containers can be shipped to the manufacturing plant or distribution center where they are erected, filled with product and sealed closed. Of course, the erecting, filling and sealing of the containers can take place at the same location as the web roll and forming processes. 
   Turning to  FIG. 8 , in the web roll process, a master web roll of plastic material provides the base portion  12 . As mentioned earlier, the plastic material is a two-ply construction consisting of, for example, a layer of heat sealable polyethylene and a layer of imprintable polyester. 
   As the web roll unrolls, a flat sheet of plastic having a width that is approximately a length L of the base portion  12  is provided. This flat sheet may extend for hundreds of feet in length as it is indexed in a progressive mode along the process. 
   In general, the progressive mode of the process indexes the flat sheet forward at intervals that are at least a width W of the base portion  12 . In this example, the polyethylene side (ultimately the interior of the container) of the flat sheet is facing up or on a front side  100  while the polyester side (ultimately the exterior of the container) is facing down or on a back side  102  during the process. 
   As the flat sheet is indexed the width W of the container, the premade handles  16  and  18  are introduced and thermally bonded at each of the front (polyethylene) side  100  of the base portion  12 . 
   The handles  16  and  18  are also manufactured from a flat sheet of plastic having a width of approximately two inches. (See, e.g., handle  18  in  FIG. 3 .) Like the flat sheet for the base portion  12 , the flat sheet for the handles may also be provided from a web roll. As the flat sheet is unrolled from the web roll, each end of the width of the flat sheet is folded into the center partially overlapping each other so that a seam  18   a  exists down the middle. The seam is then thermally bonded, resulting in a ribbon-like strip. The ribbon is cut to the desired length of the handle. At this time, handles  16  and  18  are each shaped into a U-shape as shown in  FIG. 8 . 
   After the handles  16  and  18  are bonded to the base portion  12 , the flat sheet is indexed again for the introduction of a left panel  104  and a right panel  106 . The panels  104  and  106  will eventually form the upper panel portion  14  of the container. Each of the panels  104 ,  106  is positioned in line with the width W of the base portion  12 . Each panel  104 ,  106  overlaps a side  110 ,  112  of the flat sheet. The panels  104 ,  106  are then thermally bonded to the flat sheet and a side  107  of the handle that is opposite to a handle side  109  that was previously bonded to the base portion  12 . In this regard, a hermetic seal is formed due to the bonding process. Additionally, another sealant can be applied at each end  115 ,  117  of the handles  16  and  18 . In this example, the sealant encircles the ends  115 ,  117  of the handles prior to the introduction of the panels  104 ,  106 . 
   Next, the flat sheet is indexed forward again. At this point, the closure members  60 ,  62  (not shown in  FIG. 8 ) can be applied and thermally bonded to the free ends  114 ,  116  of the left and right panels  104 ,  106 , respectively. 
   Sections  120  of the free ends  114 ,  116  are cut-out to form flaps  122 . The flaps  122  are designed to be folded one over the other for the closure of the container. As such, the cutout sections  120  may vary depending on the type of closure member that will be used for the container. 
   In addition, a thin sealant  128  may be applied as a peel seal to the left and right panels  104 ,  106 . Specifically, the thin sealant extends along a width W of the panels  104 ,  106 . The peel seal is a temporary seal that is opened by the user of the product when the user opens the container. 
   At this point, the flat blank portion continues on to the forming process. Alternatively, the flat blank portion can be formed at a later time or at a different location. In this regard, the flat blank portion is rolled onto a large spindle-type web roll or layered back and forth and placed into a container for storage and shipping. 
   Generally, the forming process includes forming the base portion of the flat blank, sealing the base portion together and, if desired, folding the bottom of the base portion together so that the container is, once again, substantially flat for shipping or storage. By way of example, U.S. patent application Ser. No. 09/467,125 filed on Dec. 20, 1999, incorporated herein be reference, discloses a manufacturing technique that can be used to form the base portion of the containers of the present invention. 
   Specifically, the flat blank is indexed forward. As it moves forward, the flat blank is drawn over a v-shaped forming plow and through two rollers causing the flat blank to be folded in half down a center line  130  of the base portion  12  forming a web fold. The resultant folded portion has first and second layers. The first and second layers each have a bottom portion located adjacent the web fold. 
   Cutouts are formed in the bottom portion of each layer at spaced intervals that extend from each side of the web fold. An upper portion of the first and second layers are heat sealed together forming the eventual side seams  29  and  31  of the finished container  10 . The ends of the side heat seals are spaced from and aligned with the cutouts. The bottom portions of the first and second layers are folded upon themselves into two bottom folds. The bottom portions have sections aligned with the upper portion side seals. The bottom portion aligned sections are heat sealed together to form side seal extensions. An area of the bottom portions are heat sealed together adjacent the side seal extensions. The formed flat blank is then severed along the side seals and side seal extensions resulting in individual containers. 
   As described above, the flexibility of the container  10  of the present invention is advantageous because it can be initially manufactured as a flat structure. To this end, numerous containers can be condensed in a flat, compact state for shipping on pallets, etc., to a second manufacturing plant or distribution center for erecting and filling with product. During this step, the interior cavity  61  of the container  10  is erected, filled with product, sealed, and shipped to the point of purchase or storage. 
   The container  10  design provides many filling and sealing benefits. Because the container  10  has side gussets, this allows the container to be easily transported, gripped and filled on conventional premade paper and plastic container filling equipment. By providing the container  10  with a wider opening for larger fill spouts, this provides for increased fill speeds. 
   Due to the bottom gussets, the container  10  opens easier for better container volume utilization (versus side gusseted containers that tend not to open up completely). The container  10  design allows them to lie flatter allowing a greater number of containers to be stacked on the filling machine. This allows the use of simpler less expensive smooth sealing jaws (e.g., not profiled to accommodate different material layer thicknesses) to hermetically seal the bag top. The container  10  also allows the handles to be folded and tacked down keeping the long strap handles out of the way of filling machine grippers, transfer belts and sealers. 
   The design of the bottom of the container  10  also facilitates filling of the container  10 . For example, the flat bottom design of the container allows product to fill the bag more completely and quicker because the container  10  opens up faster when filling. 
   It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.