Patent Publication Number: US-2007110344-A1

Title: Flexible pouch with ergonomic shape and method of forming

Description:
RELATED APPLICATION  
      This application is a continuation-in-part of U.S. patent application Ser. No. 11/195,906 filed Aug. 3, 2005, which claims priority of U.S. Provisional Patent Application Ser. No. 60/598,394 filed Aug. 3, 2004, which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates generally to a flexible pouch for packaging a product and, more specifically, to a flexible pouch with an ergonomically beneficial shape for packaging a product and a method of manufacturing the same.  
      2. Description of the Related Art  
      Various types of disposable, portable containers are known in the art for storing a fluid or dry product, such as a liquid, granular material, powder or the like. Examples of containers include a cup, a metal can, a plastic bottle, a glass bottle or a flexible pouch. Consumers prefer the convenience of flexible pouches over other types of containers due to their shape, size, shelf life and storage adaptability. Manufacturers recognize the packaging benefits of a flexible pouch, since the pouch can be formed and filled on the same manufacturing line. An example of a method and apparatus for filling a flexible pouch with a product is disclosed in commonly assigned U.S. Pat. No. 6,199,601, which is incorporated herein by reference.  
      Flexible pouches have been used for some time to distribute noncarbonated beverages, such as fruit juice and the like. However, their use with other types of beverages, including carbonated beverages, has been limited. With respect to carbonated beverages, the presently available materials are somewhat permeable, thereby allowing loss of the internal carbon dioxide gas from the pouch and its replacement with oxygen. The presence of oxygen in the filled pouch increases the chance of bacteria forming, or may affect the taste. An example of a pouch for a carbonated beverage is disclosed in commonly assigned PCT Patent Application No. PCT/US03/034396, which is incorporated herein by reference.  
      The flexible pouch is made from a flexible material, preferably a laminate composed of sheets of plastic or aluminum or the like. An outer layer of the material may include preprinted information, such as a logo or the like, to provide the consumer with information regarding the contents of the pouch. The pouch may be formed and/or filled using conventionally known manufacturing techniques, such as a horizontal form-fill-seal machine with a single or multiple lanes, a flat bed pre-made pouch machine, a vertical form-fill machine, or the like. The pouch includes a front panel joined to a back panel. Edges of the panels, such as a side edge, are joined together using a sealing technique such as bonding or welding. The sealed edge resembles a fin.  
      While the above described pouch functions well, the exposed “fin” edge may be sharp. Also, the potential shapes for the pouch are limited using a “fin” edge. Thus, there is a need in the art for a flexible pouch with an ergonomically beneficial shape, and an improved method of making a flexible pouch, that can be used to hold various types of prnducts.  
     SUMMARY OF THE INVENTION  
      Accordingly, the present invention is an improved flexible pouch. A flexible pouch with a flat seam for a product and a method for manufacturing the pouch is provided. The pouch includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and two side edges extending therebetween. A first side edge is positioned over the folded second side edge and sealed to form a seam that lies flat against the outer surface of the panel. An upper edge of the pouch includes a first ultrasonic closing seal, and a second closing seal is positioned above the first closing seal. The pouch also includes an opening means integral with the panel for accessing a product contained within the pouch.  
      The method includes the steps of forming a pouch by forming a fold along each side edge of the panel and positioning the panel so that the fold in each side edge is aligned and the first side edge extends beyond the second side edge. The extending portion of the first side edge is folded over the second edge to form a flap, and is sealed. The lower edge of the pouch is sealed. The flap may be tacked down to the lower edge and upper edge of the pouch during the sealing step, so that the flap lies flat against the walls of the pouch. The flap may also be sealed to the outer surface of the pouch using a cover strip. The flap may also be folded into the inside of the pouch or formed into a side gusset.  
      An ergonomic flexible pouch for a carbonated product includes a panel having an inner surface and an outer surface, and an upper edge, an opposed lower edge and a first side edge and a second side edge extending therebetween said upper edge and said lower edge. A side seal joins the first side edge of the panel to the second side edge of the panel to form a body of the pouch having a front wall and a back wall, and a smooth side edge and a sealed side edge. A first closing seal seals lower edges of the front wall and the back wall together, and a second closing seal seals the lower edges of the front wall and the back wall together. The second closing seal is spaced a predetermined distance outboard of the first closing seal, and the carbonated product is trapped between the first closing seal and the second closing seal. An opening means is disposed between upper edges of the front wall and the back wall.  
      One example of an opening means is a fitment ultrasonically sealed between the upper edges of the front wall and the back wall. The fitment includes a base portion having a vertically oriented wall, a pair of opposed fins extending outwardly from an outer surface of the wall, and a lip extending outwardly from an upper edge of the wall. A spout projects upwardly from the upper edge of wall, and the spout includes a thread encircling the spout with a plurality of vertically oriented vents bisecting the thread. A replaceable cap is secured to the fitment. The cap is a cylindrical member, having a closed and an open end. An inner surface of the cylindrical member includes a thread with a plurality of vertically oriented vents bisecting the thread, such that the cap vents are disposed between the fitment vents when the cap is secured to the fitment to control a release of pressure from the pouch due to the carbonated product. The pressure in the pouch from the carbonated product ergonomically shapes the pouch, such that the front wall and the back wall each have a longitudinally oriented convex shape and the sealed side edge and the smooth side edge each have a longitudinally oriented concave shape.  
      One advantage of the present invention is that a flexible pouch with an ergonomical shape and an improved method of making the flexible pouch is provided. Another advantage of the present invention is that a flexible pouch and method of making a flexible pouch is provided that utilizes a laminate material that includes PET, foil, nylon and cast polypropylene. Still another advantage of the present invention is that a flexible pouch and the method of making a flexible pouch is provided that includes a flat seam with edges that overlap. A further advantage of the present invention is that a flexible pouch and method of making a flexible pouch is provided that includes a flat seam with edges that fold over to form a flap, and the flap lies flat against the pouch with no sharp edges. Still a further advantage of the present invention is a flexible pouch and a method of making a flexible pouch filled with a product is provided that is cost effective to manufacture. Yet a further advantage of the present invention is that the flexible pouch retains its shape as the product is removed. Still yet a further advantage of the present invention is that the flexible pouch includes an insert so that it can stand upright unsupported. Another advantage of the present invention is that the pouch stands up and is made of a laminate material with an opening means. Still another advantage of the present invention is that the flexible pouch is filled with a carbonated product, has an ergonomic shape and is comfortable for a user to hold. A further advantage of the present invention is that the flexible pouch is filled with a carbonated product and has a spout fitment and cap.  
      Other features and advantages of the present invention will be readily appreciated, as the same becomes better understood after reading the subsequent description taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is an elevational view of a flexible pouch with a flat seam, according to the present inventions.  
       FIG. 2   a  is an elevational view of a flexible pouch with a folded flat seam according to the present inventions.  
       FIG. 2   b  is a perspective side view illustrating a folded flat seam for the pouch of  FIG. 1 , according to the present inventions.  
       FIG. 2   c  is a partial elevational view of a flexible pouch with a folded flat seam, according to the present inventions.  
       FIG. 3  is an elevational view of a panel with an integrally formed gusset prior to sealing the side edges, according to the present inventions.  
       FIG. 4   a  is an elevational view of a pouch having an integrally formed gusset and an overlap flat seam, according to the present inventions.  
       FIG. 4   b  is a detail view of the overlap flat seam, according to the present inventions.  
       FIG. 5  is a side view of a flexible pouch with a seal strip covering the flat seam, according to the present inventions.  
       FIG. 6   a  is an elevational view of a stand-up flexible pouch with a flat seam, tear notch and insert, according to the present inventions.  
       FIG. 6   b  is an end view of the pouch of  FIG. 6   a , according to the present inventions.  
       FIG. 6   c  is a partial view of an insert for the pouch of  FIG. 6   a , according to the present inventions.  
       FIG. 7   a  is an elevational view of a stand-up flexible pouch with a flat seam, straw hole, pull tab opening means and insert, according to the present inventions.  
       FIG. 7   b  is a top view of an insert with a pull tab and straw hole, according to the present inventions.  
       FIG. 7   c  is a cutaway view of an insert, according to the present inventions.  
       FIGS. 8   a  and  8   b  are partial views of a stand-up flexible pouch with a flat seam, fitment and side gussets, according to the present inventions.  
       FIGS. 9   a - 9   c  are elevational views of a stand-up flexible pouch with a flat seam, fitment and insert, according to the present inventions.  
       FIG. 10  is another elevational view of a stand-up flexible pouch with a flat seam and fitment, according to the present inventions.  
       FIGS. 11   a - 11   d  are elevational views of stand-up caps for the flexible pouch with fitment, according to the present inventions.  
       FIG. 12  is a flowchart of a method of forming a flexible pouch with a flat seam, according to the present inventions.  
       FIG. 13  is a schematic top view of a rotary fill machine according to the present inventions.  
       FIGS. 14-16  are examples of fill machines according to the present inventions.  
       FIG. 17  is an elevational view of a receptacle for transporting the pouch, according to the present inventions.  
       FIG. 18   a  is an elevational view of a pouch with an overlap flat seam in a side gusset, according to the present inventions.  
       FIG. 18   b  is a detail view of the overlap flat seam in side gusset, according to the present inventions.  
       FIG. 18   c  is another detail view of the overlap flat seam in side gusset, according to the present inventions.  
       FIG. 19   a  is an elevational view of a panel for a pouch with an overlap S-type flat seam, according to the present inventions.  
       FIG. 19   b  is a sectional view of a pouch formed using the panel of  FIG. 19   a , according to the present inventions.  
       FIG. 19   c  is a detail view of the S-type flat seam, according to the present inventions.  
       FIG. 20  is an elevational view of an empty ergonomic pouch, according to the present inventions.  
       FIG. 21  is an elevational view of the filled ergonomic pouch of  FIG. 20 , according to the present inventions.  
       FIG. 22  is an elevational view of the filled ergonomic pouch of  FIG. 21  with a sleeve, according to the present inventions.  
       FIG. 23  is an elevational view of an unfilled ergonomic pouch with a fitment for a carbonated product, according to the present inventions.  
       FIG. 24   a  is a perspective view of the spout fitment for a carbonated product for the pouch of  FIG. 23 , according to the present inventions.  
       FIG. 24   b  is a perspective view of the cap for the spout fitment of  FIG. 24   a , according to the present inventions. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT(S)  
      Referring to  FIGS. 1-11  and  18   a - 23 , a flexible pouch  10  is illustrated. The pouch  10  may be filled with a product (not shown) and sealed. Various types of products are contemplated, such as a dry product or a fluid product. In addition, the product may be a food item, or a non-food item. It is contemplated that the pouch may contain a single portion or multiple portions of the product. In this example, the product is a carbonated product.  
      The flexible pouch  10  is preferably formed from a roll of preprinted material of laminate layers. The laminate material is typically a three, or four, or five gauge material, and is non-limiting. The outer layer is usually preprinted. Alternatively, at least a portion of the material may be not printed, i.e. translucent, in order to view the contents contained therein, as shown in  FIGS. 6   a  and  7  at  98  as a window. The clear portion could be in a gusset or insert. An outer layer of material may include preprinted information on this outer layer may be a sleeve, to be described.  
      The choice of sheet layer material is non-limiting, and is influenced by factors such as the product contained in the pouch, the shape of the pouch, or the anticipated use of the pouch. One example of a laminate material structure includes at least one layer of virgin polyethylene terphalate (PET), at least one layer of aluminum foil and another layer such as EVOH, PET, polyethylene or nylon or the like. Another type of laminate material structure may also include a metalized foil paper layer laminated to a cast polypropylene layer and another layer of PET, polyethylene or EVOH. There may be a fourth layer of nylon. Similarly, the laminate structure may include a cast polypropylene (CPP) layer, a polyethylene (PET) layer, a foil (AL) layer, a nylon (ONO) layer and another CPP layer. Another structure is the use of nylon, foil, nylon and cast polypropylene (ONO/AL/ONO/CPP) or CPP/NY/AL/CPP. Another example of a material structure is ONO/AL/COEX-ONO-LDPE. Material structures that include CPP are well suited for packaging a beverage, such as beer, wine or other carbonated fluids, to add strength to the walls of the pouch, preserve the carbonation, and protect the AL layer from cracking. Carbonation is beneficial since it acts as a microbiocide and preserves the flavor and aroma of the products. The use of cast polypropylene laminate material also assists in retaining the filled shape of the container, even as the product is removed from the pouch  10 . The pouch  10  may have a generally cylindrical shape, similar to a traditional metal can, although other shapes are contemplated, as shown in  FIGS. 5-10 . A further example of a laminate material structure is CPP/AL/ONO/PE. This structure works well when the product has a short shelf life, and the nylon eliminates stretching or cracking of the AL layer.  
      It should be appreciated that if the filled carbonated pouch is stored at ambient temperature, the laminate will start to creep after a period of time, such as ten days. The laminate material may include an extrusion layer to contain “creepage” or “stretch” of the film after filling due to carbonation expansion, if the product is carbonated. In addition, the selected material may be organoleptic compliant in order to avoid the transfer of odor contaminates to the product, or product contamination during the shelf life period of the product.  
      The formed pouch includes a front wall  12  and a back wall  14 . Each wall  12 ,  14  is further defined by an upper edge  16 , an opposed lower edge  18 , and side edges  20  extending therebetween the upper and lower edges  16 ,  18 . The edges of the panel are joined along a seam. The pouch may include two side seams, or one single seam. In addition, the side edges  20  may be joined along a flat seam  50 , or a “fin” style seam. In an example of a pouch formed using a single panel  48  of material, the side edges  20 , or joined along a flat center seam. In another example of a pouch formed from a single panel, the side edges are formed along one side seam. In an example of a pouch formed using two sheets of material, the edges are joined along two flat side seams. The panel  48  has an inner surface  24  that is adjacent the product, and an outer surface  22 .  
      In an embodiment of a pouch  52  illustrated in  FIGS. 2   a - 2   c , the flat seam  50  is a folded seam or reverse seal. A first and second side edge includes a fold, as shown at  54  and  56 . The first fold  54  forms an obtuse angle along the first edge and the second fold forms an acute angle  56  along a second edge  56 . It should be appreciated that only a minimal portion of the first side edge  54  extends beyond the second side edge  56 . The first side edge  54  is positioned over the second side edge  56 , so that the folds are in alignment and that a portion of the first side edge  54  extends beyond the second side edge  56 , as shown at  58 . The first and second edges  54 ,  56  are sealed together in a manner to be described, and the extending edge  58  is folded over to form a flap  60  that can lie flat against the outer wall of the pouch  52 . Preferably, the flap  60  is secured to the outer wall of the pouch  52 . For example, the flap  60  may be secured along an upper edge and a lower edge to the walls of the pouch. Alternatively, the length of the pouch may be secured to the walls of the pouch. The flap can be secured using a sealing means, such as a tack seal, or an adhesive or monolayer film or the like. In another alternative, the flap may be sealed to the outer surface of the pouch using a second strip  92  of material covering the seam, as shown in  FIG. 5 . The seam cover  92  is secured using a sealing means, such as a weld or an adhesive. The folded seal is advantageous, since it has a higher seal bond strength than a typical layer on layer seal.  
      Another embodiment of a pouch  62  with an overlap flat seam is illustrated in  FIGS. 3-4 . In this example, a first side edge  64  overlaps a second side edge  66  a predetermined amount. Alternatively, each side edge  64 ,  66  may include a corresponding fold, as shown at  64   a  and  66   b  in  FIGS. 18   a - 18   c . The first side edge  64  is positioned over the second side edge  64  so that the edges overlap. Preferably, the amount of overlap is between 5-12 mm. The first and second edges are sealed together using a technique to be described. It should be appreciated that the inclusion of a CPP layer of material on the inside of the pouch and on the outside improves the seal strength of the overlap seal, since it has a higher bond strength and prevents delamination.  
      Still another embodiment of a pouch  300  formed from one panel of material  348  and having an overlap flat seam is illustrated in  FIGS. 19   a - 19   c . In this example, a first side edge  302  overlaps a second side edge  304  a predetermined amount. The second side edge includes a fold along a seal fold line, as shown at  306 . The first side edge does not include a fold. The second side edge  304  is folded outwardly  180  degrees along the seal fold line  306 , and the first side edge  302  is positioned over the second side edge  304  so that the first side edge  302  is adjacent the folded second side edge  304 . Preferably, an outer portion of the first side edge and an outer portion of the second side edge are in alignment with each other and shown at  308 . Preferably, the amount of overlap between the first side edge and second side edge is about 5-12 mm. The first and second edges are sealed together using a technique to be described. It should be appreciated that the inclusion of a CPP layer of material on the inside of the pouch and on the outside, improves the seal strength of the overlap seal, since it has a higher bond strength and prevents delamination. As previously described, a seam cover may be positioned over the seam and sealed to the outer wall of the pouch.  
      Any of the pouches may include an insert, sidewall or gusset  70 . The gusset  70  may be integrally formed in the panel  48 , as shown in  FIGS. 3 and 4 , or a separate piece of material. The gusset may be disposed between the front and back walls, and positioned between the side edges of the walls, the lower edges, the upper edges, or any desired combination. It should be appreciated that the shape of the gusset  70  is nonlimiting. For example, the gusset  70  may be generally wider at one end and taper upwardly towards the opposite end. The gusset  70  may also be of a uniform width. The use of the gusset  70  may be functional, i.e. it may allow the pouch  10  to acquire another shape, such as cylindrical, or to stand upright. The gusset  70  also enhances the strength and rigidity of the pouch  10  during filling and processing. A side gusset is advantageous since it allows the walls of the pouch to expand as the internal pressure within the pouch increases. A gusset  70  positioned between the lower edges of the pouch  10  forms a base, which may enable the pouch  10  to stand upright.  
      Similarly, the pouch may include an insert, as shown in  FIGS. 6-9 . The insert  72  is a generally planar member that is inserted between the walls  12 ,  14  of the pouch  10 . The shape of the insert  72  is nonlimiting, and generally influences the shape of the flexible pouch. The insert  72  may be positioned internally within the pouch or externally. Various materials may be utilized for the insert, such as foil, cardboard, plastic, nylon, laminate or the like. Further, the insert  72  may be formed from a printed material, or it may be clear. In one example, the insert  72  is inserted between the lower edges of the panel and sealed to the walls of the panel. The seal may be an ultrasonic seal or a heat weld or the like.  
      Referring to  FIG. 7 , a pouch with two inserts is illustrated. In this example, there is a first insert  72   a  positioned between the lower edges of the panel, and a second insert  72   b  positioned between the upper edges of the panel. The first insert  72   a  may include an integral fitment means, such as a straw hole  80  for receiving a straw. The pouch of this example has a generally square shape. As shown in  FIGS. 6   a - 6   c , the insert has a round shape and the pouch has a tapered shape. Similarly, in  FIGS. 9   a - 9   c , the insert has a square shape and the finished pouch has a tapered shape similar to a bottle.  
      The pouch  10  incorporates an opening means  74  for accessing the contents of the pouch. Various types of opening means  74  are known in the art for this purpose. It should be appreciated that the opening means  74  may be incorporated into the pouch  10  prior to filling the pouch  10 . One example of an opening means is a tear-off portion  76 , as shown in  FIG. 6 . The tear-off portion  76  usually has an integral tear notch  78 . The tear notch is typically formed near the upper edge, for accessing the product contained therein although it could be located elsewhere. Another example of an opening means  74  is a weakened, straw-pierceable portion  80  in the pouch for receiving a straw. A further example of an opening means  74  is a pull tab  82  covering an opening in the pouch. Both are illustrated in  FIG. 7 . Yet another example of an opening means is a reseal able zipper, such as a hermetic seal.  
      Still a further example of an opening means  74  is a removable and replaceable cap  84  secured to a fitment  86 . The cap and fitment may be positioned between the upper edges  16  or lower edges  18  of the pouch. The cap  84  screws onto a spout end  88  of the fitment  86 . The cap  84  can be the traditional round shape. Alternatively, the cap  84  can have an elongated oval shape so that the pouch may stand up on its own, as shown in  FIGS. 11   a - 11   d  and  21 - 22 . The cap  84  and fitment  86  can be made from a variety of materials. For example, the cap  84  may be made from plastic, such as reground resins. The fitment  86  may be made of polypropylene (PP), depending on the product. The fitment  86  is sealed into the upper edges of the panel using a sealing means, such as an ultrasonic seal or a heat weld, or the like. The spout portion of the fitment  86  may include a removable seal  90  to prevent leakage of the product or evidence of tampering.  
      Referring to  FIGS. 20-22 , examples of an ergonomic pouch  400  are illustrated. The ergonomic pouch has similar features as the previously described pouches. In this example, the pouch is formed from a single panel of material  402 , and the side edges are joined along one side seam  404 . The one side seam may be a “fin” style seam, or a flat seam formed as previously described. In this example, a “fin” style side seam is shown. If the pouch  400  is filled with a carbonated product, the carbonation causes the pressure within the pouch to increase. As a result of this increased pressure, the front wall  406  and back wall  408  each assume a longitudinally oriented convex shape, and each side edge  410  assumes a longitudinally oriented concave shape. Thus, the width across the pouch is less in the middle as shown at  412 , than at the upper edge  414  or lower edge  416 . The overall hourglass shape assumed by the pouch  400  due to the internal pressure within the pouch is ergonomically advantageous.  
      Referring to  FIG. 22 , the flexible pouch may include an outer layer or sleeve  420  covering the outer surface of the pouch. The sleeve may be a label containing information about the product, such as a barcode or the like. The sleeve  420  may cover only a portion of the pouch outer surface. Preferably, the sleeve  420  is shrunk over the outer surface of the pouch after the pouch is formed and filled with the product. The sleeve is advantageous because it covers the side seam. It also adds one or more layer of material to strengthen the pouch and improve its durability. Various types of material may be utilized for the sleeve, such as paper or plastic including PET or PVC and the choice is non-limiting.  
      Referring to  FIGS. 23-24   b , still another example of a flexible pouch with a fitment for preserving carbonation of a carbonated product is illustrated. In this example, an unfilled ergonomic pouch  400  is illustrated by way of example; however, other types of flexible pouches are contemplated. Further, the pouch may assume the hourglass shape previously described, when filled. The fitment  472  includes a canoe-shaped base  487  that is heat sealed between the edges of the pouch, and an upwardly projecting spout  486 . A removable and replaceable cap  484  is secured to the spout  486 .  
      The cap  484  and spout  486  can be made from a variety of materials. For example, the cap  484  may be made from plastic, such as reground resins. The spout  486  may be made of PE or polypropylene (PP), depending on the product.  
      The base  487  or canoe portion of the fitment includes a vertically extending wall  488   a . In this example, the base portion has an elongated oval shape. The base  487  also includes a pair of sealing ribs  488   b  protruding outwardly from the wall  488   a . Preferably, one rib  488   b  is positioned on each outermost edge of the base  487 . An upper edge of the wall  488   a  includes an integrally formed lip  489  that extends outwardly a predetermined distance. The base  487  is fixedly retained within the flexible pouch when the walls of the pouch are sealed around the base portion using a sealing means, such as an ultrasonic seal. Alternatively, a heat weld, or the like could be utilized to seal the fitment into the pouch. Advantageously, the symmetrical shape of the base portion and protruding lip allows for enhanced precision in positioning the spout between the walls of the pouch during the pouch forming process. During sealing, material flows around the sealing rib  488   b  and fills in any void between the panel wall and the fitment, to increase the retention of the fitment  472  within the panel walls.  
      The spout  486  also includes at least one outwardly extending flange or collar  490   a . The flange  490   a  is spaced a predetermined distance above the lip  489 , and the space in between provides a tool support surface for a holding means during the manufacturing operation, as shown at  495 . For example, the tool support surface  491  is used to support; the pouch  400  during manufacturing operations, such as filling, sealing or the like. The spout  486  includes a second flange  490   b  parallel to, and spaced a predetermined distance above the first flange  490   a . In this example, the first flange extends out farther than the second flange. As such, the first flange  490   a  also serves as a lower “stop” for the cap  484 , while the second flange  490   b  serves as an upper “stop” for the tamperproof feature of this cap, in a manner to be described.  
      The spout  486  includes an elongated thread  491  encircling the outer surface of the tube, just above the second flange. In this example, the thread  491  has a spiral shape. The thread  491  assists in retaining the cap on the spout. The spout includes a plurality of vertically oriented vent channels or grooves  492  that bisect the thread. The grooves  492  are spaced a predetermined distance apart, around the outer surface of the spout. The grooves  492  provide for the controlled release of pressure from within the pouch due to the carbonated product, when the cap  484  is secured to the spout  486 . Another feature of the spout is a removable seal (not shown) located on the upper, open end of the spout, to prevent leakage of the product or provide evidence of tampering.  
      The cap  484  includes a cylindrical member  484   a  having an open end  484   b  for receiving the spout, and a closed end  484   c . The cap may include a tamperproof feature, which in this example is a detachable collar  493  connected to the cylindrical member  484   a  by a plurality of connecting walls  494 . The connecting walls  494  are thin wall sections that break away from the cylindrical member  484   a  upon the application of a force, so that the cap  484  can be removed from the spout  486 . The detachable collar  493  is retained on the spout and is held in place between the first and second flanges. The outer surface of the cylindrical member may include a plurality of vertically oriented gripping ribs  484   d  that assist a user in removing or replacing the cap on the spout.  
      An inner surface of the cylindrical member  484   a  also includes an outwardly projecting thread  484   e . The thread  484   e  has a spiral shape. The inner surface of the cylindrical member also includes a plurality of vertically oriented vent channels grooves  484   f  that bisect the thread  484   e . It should be appreciated that the vent grooves  484   f  in the cap  484  are located between the vent grooves  492  in the spout  486 , when the cap is screwed onto the spout.  
      In operation, the cap  484  is initially pushed on the spout  486  and retained by the engagement of the detachable collar between the spout second flange and first flange. To remove the cap, the user grips the cap by the outer surface of the cylindrical member, and twists the cap until the thin wall sections between the cylindrical member and detachable collar are severed. The cap can then be twisted off from the spout. The detachable collar may be retained on the spout, and only the cylindrical member is removable. The cap can be replaced on the spout to reseal the spout. Alternatively, the collar may have a tab that is pulled to sever the connecting walls  70  to remove the cap from the spout.  
      The flexible pouch may incorporate any of the above-described features in any combination. For example, any of the pouches may include an insert  72  in the bottom portion of the pouch and a tapered top portion, or an insert  72  in the bottom portion of the pouch and a fitment and cap in the top portion of the pouch, or an insert  72  in the bottom portion and the top portion of the pouch. The flexible pouch may include any one of the described opening means. In addition, the finished pouch may assume various shapes, such as cylindrical, cubical, and conical, hourglass or the like, as influenced by the type of product and intended usage of the pouch.  
      It should be appreciated that any of the above-described flexible pouches may advantageously include other features that are known in the art. For example, the flexible pouch may include a guide pocket formed in a wall of the pouch prior to filling and sealing, to facilitate the separation of the front and back walls prior to the filling of the pouch. An example of such a pouch is disclosed in commonly assigned U.S. patent application Ser. No. 10/310,221.  
      It is also contemplated that any of the described pouches may undergo a secondary process after it is filled with the product. For example, the filled pouch may be frozen. Alternatively, the filled pouch may be pasteurized in order to have an extended shelf stable life under ambient temperature. Examples of pasteurized food products include dairy products such as milk, or meat products such as chicken or the like.  
      Referring to  FIG. 12 , a method for forming and filling any of the previously described flexible pouches using a high-speed machine, such as that described with respect to  FIGS. 13-16 , is illustrated. The flexible pouch  10  described above is referenced by way of example. The method begins in block  100  at a first station with the step of forming the body of the pouch. For example, a roll of laminate material, as previously described, is unrolled along a horizontally oriented plane. The initial width of the roll of material is determined by the desired finished size of the pouch  10  and the number of pouches to be obtained from the width. For example, three or four or six pouches, representing six to twelve panels, can be obtained from a width of the roll of material on a three-lane machine or four-lane machine, respectively. Each panel  48  has an inner surface  24  and an outer surface  22 . One layer of the material is preferably preprinted with information or locating indicia (not shown), such as a registration mark. The registration marks are located on the material to denote an edge of a wall  12 ,  14 . The registration marks are read by an optical reading device (not shown), such as a scanner, to index the material in a predetermined position at the cutting station. The preprinted information may include labeling information that describes the product contained within the pouch. in this example, the layer of preprinted information is located on an outer layer of the material.  
      The methodology advances to block  105  and a feature, such as a gusset  70  or insert  72 , is optionally positioned between the aligned first and second unrolling sections of material. In addition, an opening means may be applied at this time. For example, an opening means  74 , such as a press-to-close zipper, may be positioned between the panels. Another opening means such as a straw hole, patch or tear notch may be applied.  
      The methodology advances to block  110  and the edges of the walls are sealed together to form a flat seam  50 . For example, to form a folded flat seam  52 , a fold is formed along an edge of the sheet of material. The angle of the fold is determined, according to the width of seam desired, as previously described. The fold in the first edge  54  is aligned with the fold in the second side edge  56  and the edges are sealed together, in a manner to be described. The extending edge  58  is folded over to form the flap and sealed. At least a portion of the flap may be secured to the outer portion of the material.  
      To form an overlap flat seam  68 , the edges of the sheet of material are positioned together, such that a first edge  64  overlaps a second edge  68  a predetermined amount, and the edges are sealed together. To form an overlap flat seam as shown in  FIGS. 19   a  and  19   b , the second edge is folded outwardly along a seam line. The first edge is positioned over the second edge a predetermined overlap amount. The outer portion of the first edge and the outer portion of the second edge are in alignment. The edges are sealed together as previously described. With either of these types of flat searns, a second strip of material  92  may be positioned over the seam and sealed onto the wall or the pouch.  
      Various techniques are contemplated for sealing the edges together. For example, an adhesive may be used to seal the first and second edge of the flat seam together. Alternatively, the edges may be sealed using an ultrasonic sealing process. Another technique is a heat weld that includes the application of heat and compression.  
      In still another example, the edges are sealed using a seal bar or forming plate having a plasma coating. One advantage of the plasma coating is that the line speed may increase. Another advantage is that the coating makes the surface of the seal bar or forming plate more resilient. When the seal bar is heated, the coating expands due to this resiliency. The shear stress on the inner edge of the seal is reduced; resulting in reduced creepage of the material and greater durability of the seal. The plasma coating reduces the opportunity for potential damage to the material during the sealing step. In this example, the plasma coating is a smooth, hard plastic that mimics glass. Since the outer layer of material is not weakened, there is no creepage of the outer layer.  
      In still another example of a sealing technique, the side seal is a two-step seal, as shown in  FIG. 20 . The two-step seal advantageously avoids the generation of ketones due to application of heat to the material. The first or inner seal is a low temperature seal. The second or outer seal is a high temperature seal. The second seal is spaced apart from the first seal by a predetermined distance, to create an air gap. The first seal is a tack seal, such as 6 mm wide, and is of a sufficient temperature so as to melt the layers of material and tack the edges together. The predetermined distance between the first and second seal is ½-1 mm. The second seal is applied at a higher temperature and pressure than the first seal. As a result, any gas, such as steam, ketones, aromatics or the like are pushed in an outwardly direction, out through the open edges of the panels, and not into the pouch. Thus, the first seal prevents entry of contaminates into the pouch to avoid organoleptic contamination.  
      The methodology advances to block  115 , and the section of pouches formed in the roll width of material are separated from each other in a cutting operation. For example, each section of material may be first separated along its width, i.e. along the side seam of the pouches. The section is then separated into individual pouches. In this example, the width of unrolling represents the side edges. The material is cut using a known cutting apparatus, such as a laser or punch or the like. The material is cut into a pouch  10  using a known cutting apparatus, such as a laser or punch or the like. The cutting apparatus forms a single cut in the material to separate the pouches. The length of the pouch  10  is controlled by the distance between the cuts.  
      Alternatively. two pouches  10  are cut out at one time by adding a double cut between two cuts, preferably in the center. Advantageously, forming two pouches during the cutting operation effectively doubles the assembly line speed.  
      It should be appreciated that the upper edge or lower edge may be further trimmed. For example, the end of the pouch may be trimmed to accommodate a fitment  86 . In another example, two legs are formed during the trimming operation, in order to recess the fitment. The fitment may be ultrasonically sealed to the pouch.  
      The methodology advances to  120 , and an edge is sealed, such as the lower edge  18 . The lower edge  18  may be sealed using a known sealing process, such as an ultrasonic sealing process. Another sealing technique is a heat weld that involves the application of heat and compression. As previously described, the seal bar may have a plasma coating. In addition, the flap  60  for a folded flat seam  62  may be tacked down to the outer wall of the pouch, such as at an upper or lower end of the center seam. The flap is held in place such as by using an adhesive, or sealed while applying the heat weld or ultrasonic seal. It should be appreciated that the outermost layer of the pouch material may be coated with a heat sealable material to assist in securing the flap to the outer wall of the pouch  10 .  
      The methodology advances to block  125  and an opening means  74  may also be applied to the pouch  10  at this time. For example, a fitment, as previously described, may be sealed within the walls of the pouch  10 , such as between the upper edges  16 . The fitment may be sealed using an ultrasonic seal, or a heat weld, or by a combination of ultrasonic seal and heat weld. For example, the base portion  487  of the fitment  472  is sealed between the walls of the pouch using an ultrasonic seal, a heat seal, and then a cool seal. The heat seal melts a layer of the pouch material, and the material flows around the sealing ribs  488  on the base portion  487 , and fills in any void between the base portion  487  and the wall of the pouch. The cool seal sets the seal and provides an attractive finish to the overall seal. Advantageously, fewer stations are required to seal the fitment between the walls of the pouch, since a tack seal is eliminated.  
      In addition, an insert  72  may be likewise applied to the pouch  10  at this time. The insert  72  may be positioned at a lower edge of the pouch, an upper edge, or both an upper and lower edge. The methodology advances to block  130 .  
      In block  130 , the individual pouches are finished. For example, a lower edge of the pouch  10  may be trimmed to shape, i.e. the corners may be angled. This operation may be performed using a cutter or a die cut or the like.  
      In another example of a finishing operation, a crease or guide pocket may be formed in a top portion of each wall  12 ,  14  in a creasing operation, in order to facilitate opening and filling of the pouch. An example of a method of forming a crease in a wall to facilitate opening the pouch is disclosed in commonly assigned U.S. patent application Ser. No. 10/310,221, which is incorporated herein by reference. It should be appreciated that the shape of the finished pouch is non-limiting, and may be round, square, oval, triangular or the like. In still another example of a finishing operation, the sleeve is applied over the individual pouch and shrunk to fit using an application of heat to the pouch.  
      The methodology advances to block  135  and the pre-made pouch  10  is then transported to the filling machine. The completed pouch may include any combination of the previously described features. Further, the completed pouch may be filled through an open edge, i.e. upper or lower, or through the fitment. The pouches may be loaded into a carrier and transferred to a filling machine. It should be appreciated that the filling machine may be integral with the pouch forming machine, or a separate machine. This portability increases the flexibility of the pouch and may result in a manufacturing cost savings.  
      The methodology advances to block  140 , and the pouch is unloaded from the carrier and placed in a holder for moving the pouch between stations. An example of a holder is a cup-shaped member, as disclosed in commonly assigned U.S. patent application Ser. No. 10/336,601, which is incorporated herein by reference. Alternatively, the pouch  10  may be held using grippers (not shown) as is known in the art. The methodology advances to block  145 .  
      In block  145 , the pouch  10  is opened in an opening operation. Various techniques are conventionally known in the art for opening the pouch  10 , and may depend on whether the pouch is filled through the fitment or the open edges of the pouch. For example, the guide pocket formed by the crease in the front wall  12  and back wall  14  facilitates opening of the pouch. A nozzle (not shown) may be mechanically lowered into the guide pocket to direct a stream of compressed gas into the guide pocket, to force the walls of the pouch  10  away from each other. An example of a gas is carbon dioxide or nitrogen, or the like. The blowing station may include a manifold, with a hood extending over the top of the edges of the pouch as known in the art. The manifold has rows of apertures (not shown) formed above the upper edges  16  of the pouch  10 . The hood is placed over the pouch  10  to assist in maintaining the air pressure in the pouch  10 . The supply of pressurized gas is directed through the aperture to form a plurality of jets of pressurized gas or air. The jets are directed downwardly at the diamond-shaped openings formed at the upper edges  16  to assist in overcoming the surface tension of the pouch and assist in separation of the walls  12 ,  14 . A diving rod (not shown) may then be used to make sure the pouch  10  is fully opened. If the pouch has a fitment, the gas is injected through the spout fitment. After the pouch is opened, it may be injected with super-saturated steam to eliminate any pathogens or the like. The methodology advances to block  150 .  
      In block  150 , the pouch  10  is filled with the product in a filling operation. For example, a fill tube (not shown) is lowered into the opened pouch  10  and the product is dispensed into the open pouch  10 .  
      If the product is naturally carbonated, such as beer or soda or the like, the pouch is preferably filled while immersed in a nitrogen atmosphere. If the product is not naturally carbonated and carbonation is desirable, it is immersed in a carbonator to introduce carbon dioxide into the product. For example, carbon dioxide is introduced into cold water or juice to provide a carbonated beverage. The product may contain a mixture of up to four volumes of carbon dioxide. It should be appreciated that the carbon dioxide masks any undesirable taste from ketones and other solvents released during the sealing process. The carbon dioxide also increases the pressure within the product so that the walls of the pouch are rigid after the top is sealed. The product is preferably filled at a temperature ranging from 29° F. to ambient temperature. The methodology advances to block  155 .  
      In block  155 , the filled pouch is sealed. For example, if the pouch is filled through open edges, the open edge of the pouch  10  is closed by applying a closing seal The closing seal may be an ultrasonic seal, or an ultra pulse seal, or a heat weld or the like. If the pouch holds a carbonated beverage, the pouch may be sealed as described in commonly owned PCT Patent Application No. PCT/US03/034396 which is incorporated herein by reference. In the example of a carbonated beverage, the first seal  94  is an ultrasonic seal or an ultra pulse seal. If desired, an end of the flap flat seam may be tacked down in this operation, or sealed with the cover strip  92 .  
      In block  160 , a second cosmetic seal  96  is applied above the first seal  94  for a carbonated product. The second seal may be a heat weld. Some of the product may be trapped between the first and second seals  94 ,  96 . This is advantageous since there is no gas in the head space, i.e. the region between the product and the heat seal, and less pouch material is required. As previously described, the closing seal may include a first closing seal. A cosmetic seal is applied above the first and second closing seals. The first closing seal is a tack seal, and the second closing seal is a high pressure, high temperature seal.  
      Alternatively, the pouch is filled through the spout fitment and the cap is applied to close the pouch. The cap may be a tamper-evident cap for a carbonated product, as previously described. The cap contains the product in the filled pouch, to prevent leakage of the product from the pouch. The complementary arrangement of threads and grooves in the cap and spout provides for the controlled release of pressure from the pouch.  
      The methodology advances to block  165  and the pouch  10  is finished in a finishing operation. For example, the edges  16 ,  18 ,  20  of the pouch  10  are trimmed to achieve a predetermined shape, In addition, the pouch  10  may be cooled at a cooling station, where the pouch  10  is cooled using a conventionally known cooling technique. Optionally, the sleeve may be placed over the filled pouch and shrunk to fit over the pouch by applying heat. The sleeve layer forms an outer layer of the pouch. The methodology advances to block  170 .  
      In block  170  the filled pouch  10  is discharged from the machine. A plurality of pouches may be placed in a package for sales or shipping purposes.  
      It should be appreciated that the pouch may undergo other processing steps, such as such as an upstream oxygen purging station, downstream oxygen purging station, pasteurization or the like. For example, the filled pouch  10  may be pasteurized in integral retort chamber (not shown) that heats and then cools the pouch  10 . The pouch  10  may be tested, such as burst testing or the like, prior to packaging for shipping. These additional processing steps may take place at a station on the form/fill/seal apparatus, or on another apparatus.  
      It should be appreciated that the order of steps may vary depending on the pouch and its features. Also, a particular manufacturing station may perform one or a plurality of operations, to enhance the efficiency of the methodology and apparatus.  
      Referring to  FIGS. 13-16 , an example of a fill-seal machine  30  for carrying out the method described with respect to  FIG. 12  is illustrated. The fill machines illustrated are by way of example, and other configurations may be utilized. It should be appreciated that a particular manufacturing station may perform one or more operations. It should also be appreciated that the order of operations may vary. The fill-seal machine  30  may be configured as a flat bed, a conveyor, a rotary turret or the like. An example of a flat bed form machine is manufactured by Nishibe, such as the model number SBM500, SMB600 or SMB700. It should be appreciated that the fill-seal machine may be integral with the form machine, or a separate machine.  
      In operation, the carrier with the pouch is loaded onto the machine  30  as shown at “ 1 ”. The pouches  10  are removed from the receptacle and placed in a holder as shown at “ 2 ”, such as by using a gripper.  
      The pouch  10  is transported along the conveyor belt to operation “ 3 ”, and the pouch  10  is opened in an opening operation. Various techniques are conventionally known in the art for further opening the pouch  10 . The guide pocket formed by the crease in the front panel and back panel facilitates opening the upper edges of the pouch. For example, a nozzle may be mechanically lowered into the pouch to direct a stream of compressed gas downwardly into the pouch to force the walls of the pouch away from each other to further open an upper edge of the pouch. An example of a gas is carbon dioxide or nitrogen. The lever arms assist in maintaining the pouch in an open position.  
      The pouch  10  is then fully opened. For example, a blowing station may include a manifold, with a hood extending over the top of the edges of the pouch. The manifold has rows of apertures (not shown) formed above the upper edges of the walls of the pouch. The hood is placed over the pouch to assist in maintaining the air pressure in the pouch. The supply of pressurized gas is directed through the aperture to form a plurality of jets of pressurized gas or air. The jets are directed downwardly at the diamond-shaped openings formed at the upper edges to assist in overcoming the surface tension of the walls and assist in separation of the walls. A diving rod may then be used to make sure the pouch is fully opened.  
      The opened pouch is transferred to a filling station as indicated at operation “ 4 ”, and the pouch is filled with the product. For example, a nozzle dispenses a predetermined amount of product into the opened pouch. The product may be dispensed into the opened edges of the pouch or through a fitment. In this example, the fill nozzle is lowered into the opened pouch, and the product is dispensed into the open pouch. Depending on the size of the pouch, there may be two fill stations.  
      If the product is naturally carbonated, such as beer or soda or the like, the pouch is preferably filled while immersed in a nitrogen or carbon dioxide atmosphere. The pouch may be flushed with nitrogen or carbon dioxide or a mixture of both. If the product is not naturally carbonated, it is immersed in a carbon dioxide process to introduce carbon dioxide into the product. For example, carbon dioxide is introduced into cold water or juice to provide a carbonated beverage. The product may contain a mixture of up to six volumes of carbon dioxide. It should be appreciated that the carbon dioxide masks any undesirable taste from ketones and other solvents released during the sealing process. The carbon dioxide also increases the pressure within the product so that the walls of the pouch  10  are rigid after the top is sealed. The product is preferably filled at a temperature ranging from 29° F. to ambient temperature. The carbonation is advantageous as a microbiocide which can enhance the flavor or prevent mold or contamination.  
      The pouch  10  is transferred to a station “ 5 ” for removing any oxygen from the pouch. The headspace of the pouch may be flushed with a gas. The pouch is then transferred to a sealing station and the open edges of the pouch are first sealed, as indicated at operation “ 6 ”. For example, at the sealing station “ 6 ”, the lifting surface ends, causing the lever arms to return to their original position, and the pouch to close. It should be noted that the filled pouch might return to a partially closed position due to the product contained therein. The first seal may be a thermal seal. For example, a heat-sealing member extends therethrough the slots in the sides of the cup, to seal the upper edge of pouch. As previously described the heat sealing member may have a plasma coating.  
      Another example of a first seal for a carbonated product utilizes an ultrasonic sealing process. Preferably the ultrasonic seal includes sound waves and is formed using a horn and anvil. A second seal is applied at a second sealing station “ 7 ”. The second seal may be applied using a heat seal means to form a second heat seal over the first seal. It should be appreciated that the second seal may be spaced slightly above the first seal. The second heat-sealing station is conventional and utilizes heat or a combination of heat and pressure to form the seal. The second seal may also be a cosmetic seal or another type of seal, such as ultrasonic, ultra pulse or the like. The first and second seals are applied for a carbonated product as disclosed in commonly assigned Patent Application No. PCT/US03/34396, which is incorporated herein by reference.  
      If the pouch is filled through the fitment, the pouch is closed by securing a cap to the fitment. The cap may have a temper-evident feature. The cap and fitment preferably have leak-proof features as previously described for a carbonated product.  
      The pouch is transferred to a finishing station as shown at “ 8 ” for finishing and removal from the filling machine. For example, the pasteurized pouch  10  may be cooled. A tear notch may be formed in the pocket portion of the pouch to facilitate opening the pouch to access the product in the pouch. In another finishing operation, the edges of the pouch are trimmed to achieve a desired shape. The finished pouches may be discharged into a package. For example, grippers may be utilized to place the pouch in a box for shipment.  
      If desired, the pouch may be transferred to a pasteurization station. Pasteurization enhances the shelf life of the product. The pouch is inserted into an enclosed retort chamber. Air is extracted from the chamber, such as using a vacuum source. The product inside the pouch is pasteurized. For example, a combination of steam and water is used to heat the pouch to a predetermined temperature for a predetermined period of time to pasteurize the product contained within the pouch. The package is Lhen cooled. In this example, recirculated water surrounds the pouch to cool the pouch. In certain instances, it may be desirable to apply steam to sterilize the pouch  10  and to wet the inner surface of the walls to facilitate handling.  
      Referring to  FIGS. 14-16 , another example of a machine for carrying out the above-described method is illustrated. As shown in  FIG. 16-17 , the machine  160  is of a turret-type having radially extending arms  162 . Each arm  162  carries a predetermined number of cuplike receptacles  164 . As shown in  FIG. 17 , the receptacles  164  have a cylindrical wall extending upwardly from a bottom, as disclosed in co-pending Patent Application No. 60/345,230. There may be up to ten receptacles  164  on each arm  162 . It should be appreciated that a particular manufacturing station may perform one or more operations. It should also be appreciated that the order of operations may vary.  
      The cups are delivered to a loading station by conveyor where empty pouches are loaded into the receptacles from magazines  166  onto a rotary turret  163 . The pouches  10  are fully formed but the upper edges  16  of the walls  12 ,  14  are unsealed. Each magazine  166  or turret segment holds a supply of empty flat pouches  10 . The same number of magazines or segments are needed as the number of receptacles  164 , which will be loaded onto the arm  162  of the turret. The magazines are positioned side by side with the receptacles  164  below. A linear cam servo feed-in device  168  moves to push an empty pouch  10  from the magazine  166  into a receptacle  162  positioned beneath the magazine  166 . The cam  170  engages the top pouch. The magazines are angled so that gravity pulls the pouches  10  downwardly to the cam  170  which pushes against the bottom pouch in the magazine and is rotated to slide the pouch from the magazine downwardly into the corresponding awaiting receptacle  164 . The cams  170  are mounted to a single rod  172  which is rotated to move the cams in unison. The rotary turret picks a pouch  10  horizontally from the magazine  166  and loads onto a segment which transfers the empty pouch into the receptacle  164 .  
      The group of receptacles  164  is then fed by the conveyor  174  sideways onto a radial arm  162  of the turret  163 . The arms  162  are sequentially indexed through a number of stations. The turret  163  is rotated to move the receptacles  164  containing the pouches  10  to an opening station  176  where the flat pouches  10  are opened by a group of nozzles positioned above the pouches  10 . The pouches  10  then are moved to a checking station where photocells or pressure is used to make sure the pouches have been opened,  178 . The pouches  10  then move to a first filling station  180  where pouches could be evacuated and diving nozzles are lowered into the pouch  10  to fill the pouch  10  with the product. In the case of larger pouches, it may be necessary to move the pouches to a second fill station  182  to complete the filling of the pouch. The pouches  10  then are moved to a station  184  where any oxygen in the pouch residing above the product is removed, if necessary. This can be done by providing a hood or diving nozzle where oxygen is either evacuated or replaced with carbon dioxide or nitrogen into the pouch to displace the oxygen. A diving nozzle is used to inject the gas.  
      The pouches  10  are then moved to a pouch closing station  186  to entirely seal the pouch. For example, an ultrasonic sealing apparatus pushes the upper edges  16  of the walls  12 ,  14  together over the product and seals the walls  12 ,  14  together. As previously described, the heat sealing means may have a plasma coating. For a carbonated product, a first seal may be an ultrasonic seal and a second seal is applied above the first seal. The second seal is a heat weld, and some of the product may be trapped between the first seal and the second seal. For a noncarbonated product, the seal may be a heat weld, ultrasonic seal or the like. The pouches are then moved to a finishing station  188 . The pouches  10  may be cooled. The pouches may undergo a secondary operation, such as pasteurization at a pasteurization station  190 .  
      The pouches are moved to a discharge station  192  where the receptacles  164  are moved from the arm  162  of the turret  163  outwardly onto the conveyor  174 . The receptacles  164  are then moved by the conveyor  174  under robotic arms  194  having grippers which are then lowered to grab the pouch  10  and lift the pouch  10  from the receptacles  164 . The receptacles  164  are then moved by the conveyor  174  through a rinsing station  196  and returned to the other side of the turret for use. The pouches  10  are placed by the grippers into cartons. At this point, the filled pouch is available for distribution. Alternatively, the filled pouch  10  may be placed onto another conveyor belt for additional processing, such as tunnel pasteurization for shelf stabilization. In certain instances, it may be desirable to apply steam to sterilize the pouch  10  and to wet the inner surface of the walls to facilitate handling.  
      As shown in  FIGS. 14-15 , the pouches  10  may be filled using an example of a continuous motion machine  210 . The continuous motion machine has rows  212  of receptacles  164  mounted to a conveyor which are moved in an elliptical path past the same stations as set forth for the rotary machine above. Up to ten receptacles may extend across a row. Preformed pouches are fed from magazines located above the receptacles.  
      The various operations such as opening, checking, filling and sealing are performed by apparatus which moves over the receptacles at the same speed as the receptacles. Two sets of identical equipment such as opening equipment are utilized. The first set travels with the belt performing the operation while a second set is lifted upwardly by a chain along a frame and then moved rearwardly and down to the start position where it meets the next row of receptacles. The pouches are loaded into the receptacles and then moved to the start of the opening station  214  where blowers are moved down and travel with the pouches while the alternate set of blowers are moved upwardly and rearwardly. At the end of the travel through the opening station, the pouches are fully opened by diving wands  216 . The pouches are then turned 180° to travel back down through the apparatus where they are moved sequentially through an evacuation station  218 , fill station  220 , closing station  222  and top seal station  226 . At the opposite end of the machine, the robotic arms  228  move downwardly, grab the pouches and move them to a conveyor for loading into packaging. The pouches then are rotated 180° to the start position and the receptacles may be washed as they move around to the start position.  
      The present invention has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.  
      Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, the present invention may be practiced other than as specifically described.