Patent Publication Number: US-11377248-B2

Title: System and method for packaging of nested products

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a division of U.S. patent application Ser. No. 14/810,878, filed on Jul. 28, 2015, which is a continuation-in-part of U.S. patent application Ser. No. 14/254,028, filed on Apr. 16, 2014, now U.S. Pat. No. 10,071,828, which claims the benefit of U.S. Provisional Patent Application No. 61/854,154, filed on Apr. 17, 2013. 
     INCORPORATION BY REFERENCE 
     The disclosures of U.S. patent application Ser. No. 14/810,878, filed on Jul. 28, 2015, U.S. patent application Ser. No. 14/254,028, filed on Apr. 16, 2014, now U.S. Pat. No. 10,071,828, and U.S. Provisional Patent Application No. 61/854,154, filed on Apr. 17, 2013, are hereby incorporated by reference for all purposes as if presented herein in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention generally relates to packaging of various articles such as bottles, cans or other products within cartons, and in particular to the selection and loading of nested groups of products into a carton with the nested groups of products being controlled as they are loaded into the cartons and the ends of the cartons are folded and sealed. 
     BACKGROUND OF THE INVENTION 
     It is common for products, such as bottles, cans, bags, etc., to be selected into predefined product groupings and loaded into cartons for packaging of such products in sets or “packs” for transport and sale. For example, it is commonplace for soft drinks, beer and other food or drink products contained within cans or bottles to be packaged in paperboard cartons such as in 6, 12, 20 and/or 24 packs for sale to the end consumers. Typically, the bottles or cans will be fed into a packaging machine where they will be grouped into the desired sets or product packs, i.e., groups of 6, 12, 20, 24, etc., after which each group of bottles or cans will be loaded into or onto a carton. The cartons can comprise paperboard sleeves, although flat blank style cartons also can be used, with the selected product groupings generally being urged or otherwise moved into the interior of such carton sleeves through one open end thereof. Thereafter, the ends of the cartons will be folded and glued in place to create a sealed package. 
     Traditionally, products such as soft drinks and beer have been sold in packs of 6, 12 and 24 bottles or cans, thus providing consumers limited choices in the number of pre-packaged products available for purchase. Recently, as consumer tastes and preferences have changed, consumer demand for more variety in available package sizes has increased. In response to consumer demands for more and/or different sized product offerings, manufacturers are now developing and offering a wider variety of portion size containers, such as 6, 8, or 20 bottles or cans and/or half liter and 1 liter sizes as well. As a result, there is a growing need and demand for a much wider variety of package options than the traditional 6, 12 and 24 pack packages. 
     While consumers are looking for more options in terms of product pack sizes, it is, however, still desirable that such product packages remain as compact as possible so as to fit within refrigerators or on shelves with a minimal amount of space required or being taken up by such packages. In addition, such non-traditional size packages often require new, non-uniform size/shape carton constructions that can create a variety of issues in the selection, loading and packaging of such differing size groups of products therein. While attempts have been made to form packages having non-traditional product groupings, for example, groupings of 8 or 16 bottles, such systems generally have been forced to operate at slower production rates and have been inflexible in terms of the sizes and configurations of the cartons that can be packaged therein, typically being limited to use with a specific package size. 
     Accordingly, it can be seen that a need exists for a system and method for packaging products in a variety of different, non-traditional product groupings which addresses the foregoing and other related and unrelated problems in the art. 
     SUMMARY OF THE INVENTION 
     Briefly described, the present invention generally relates to a packaging system and method of operation of such packaging system adapted to enable the selection and grouping of nested product groupings of varying sizes and/or configurations and for loading such product groups or packs into a series of cartons moving along a carton path through the packaging system, after which the cartons can be enclosed and sealed. The present system provides flexibility in its operation so as to accommodate the selection and packaging of a variety of different size and/or configuration product groupings, including non-traditional pack sizes and “nested” or staggered product groups or packs. For example, the packaging system of the present invention can be adapted to package bottles, cans or other, similar products/articles in configurations ranging from conventional 2×3-6 packs, 2×6-12 packs, 3×4-12 packs, 4×5-20 packs, and 4×6-24 packs to more non-traditional packs such as 2×5-10 packs, 3×5-15 packs, 4×8-32, and larger packs, as well as enabling the selection, grouping and packaging of nested product groupings or staggered product arrangements, including the formation of 8, 10, 14, 18, 22 and 26 packs and other, varying sizes and/or configurations of packages and/or product groupings. 
     In one embodiment, the packaging system will include an infeed area upstream from a product selection and grouping area at which the products, for example cans or bottles, will be formed into product groups or packs of a desired size and configuration. The products can be fed along a first path of travel into the product selection and grouping area by a product conveyor, with an initial or first series of the products being separated into lines or lanes by a first or primary selector. If needed, any remaining products can be engaged by a secondary selector located downstream from the first or primary selector. To form a staggered or nested pack configuration, the first series of products, i.e., 2-7 rows of products will be selected and fed via the lanes of the primary selector to a product selector conveyor to form an initial product grouping within a pack reducing flight of the selector conveyor. An additional series of products, i.e., one, two, three, four or more products, can be fed through the lanes of the downstream secondary selector into a position abutting and engaging the initial product grouping to form the product pack. For example, in one embodiment, a secondary selector having a series of spaced lanes can be provided along at least one, or along both sides of the product selection and grouping area and can selectively feed or apply products to one or both sides of the initial product grouping. Alternatively, product feeding lanes or other selector devices for feeding 1 or 2 individual products or sets of products (or potentially more products) into positions adjacent and/or in engagement with one or both ends or sides of an initial group of products (e.g., in abutment with a selected row or series of products or aligned with gaps therebetween) also can be used to form a desired size and/or configuration product pack, including varying size and/or configuration nested packs. The resultant formed product pack is thereafter carried by the pack reducing flight into the loading area or station whereupon the product pack is engaged from a loading side thereof by a loader arm of a first or primary loading assembly. 
     As the loader arm of the primary loading assembly urges the product pack across its pack reducing flight of the selector conveyor, the product pack can be engaged by a movable compression plate. The compression plate can be positioned along an upstream or downstream edge of the pack reducing flight and is moved toward an opposed plate of the pack reducing flight to apply a compression or urging force against the product pack. This movement/compression force applied by the compression plate against the nested product pack helps reduce and tighten the spacing between the products of the nested product pack, and at the same time can help stabilize and guide the product pack as it is inserted into the open end of a corresponding carton. 
     As the product packs are being formed, the cartons generally are fed by a carton feeder onto a carton conveyor extending through the packaging system. The cartons will be placed within flights or between lugs of the carton conveyor and further can be engaged by an overhead lug conveyor for erecting the cartons into open ended sleeves. The carton sleeves thereafter will be moved in timed relation with an associated or corresponding selector conveyor flights for receiving a nested product pack therein. 
     As the product packs are moved into their respective cartons from the loading side of the packaging system, a secondary or stabilizer side loader arm can be moved through the opposite open end of the carton into engagement with the product pack so that the product pack is engaged and stably held between the loader arms of the primary and secondary loading assemblies. For loading nested product packs, the pusher faces of the loader arms can have a substantially U- or C-shaped configuration whereby the additional, nested products added to the product pack by the secondary selector will be held in a stabilized alignment as the nested product packs are inserted into the cartons. Additional, alternative pusher face configurations such as a substantially cross-shaped, A-shaped, generally flat, or other pusher face designs, also can be used. Still further, the selector wedges of the secondary selector can be changed to provide for varying selector wedge configurations as needed for selecting an additional series of one, two, three, four, or more products for feeding to the cartons as needed to form the desired size and/or configuration of nested product packs or other staggered product arrangements. 
     In further embodiments, additional and/or other, alternative secondary product selection or feeding mechanisms such as metering wheels and/or other types of selectors, can be provided to selectively present or feed one or more additional products to the product packs or product groups before, or upon loading or insertion of the product packs into their cartons to form the nested product packs therein. For example, individual products or sets of products can be selected and fed or placed into engagement with the product groups after an initial product grouping or pack is formed by the primary selector, with the selected products or sets of products being fed or supplied from secondary selectors arranged along one or along both sides of the product grouping and selection area, so that products can be added to and/or nested with the initial product grouping from one or both sides thereof as needed to form the desired nested product pack. Further product selectors also can be provided downstream from the primary and/or secondary selectors, such as, at locations along or adjacent the loading area, to enable additional selected products to be applied or nested with the product packs, including being moved into engagement therewith during loading, or potentially after the product packs have been loaded into their cartons. 
     The opposing loader arms of the primary and secondary loading assemblies generally are moved into and out of the cartons along a pitched or phased path of movement whereby the loader arms initially are moved toward each other as the nested product pack is moved into a loaded position within a carton and thereafter are moved in a generally synchronized movement across the carton with the nested product pack engaged therebetween so as to stably and securely convey the product pack into a loaded position within its associated carton. As the product pack is loaded or seated within its carton, the cartons will be moved toward/into a folding/sealing zone or area of the packaging system wherein the end flaps of the cartons will be tucked and/or folded to a closed position and an adhesive applied to seal the cartons. 
     As the cartons enter the folding/sealing area of the packaging system, lower end flap portions of the carton along the stabilizing side thereof can be engaged by a first or upstream folding/tucking mechanism, which folds the lower end flaps of the cartons toward their closed positions. The loader arm of the secondary loading assembly can be maintained in engaging contact with the product pack within the carton as the lower end flaps are folded. The leading lower end flap along the upstream side of the carton can be engaged and urged toward their closed position by a series of lower guide rails mounted adjacent to the path of travel of the cartons. At substantially the same time, a gusset between the leading lower end flaps can be engaged and moved to an inward, tucked position by a rotating tucking device, while the trailing gusset and lower end flap can be similarly engaged and moved to their tucked and folded positions. 
     As the loaded cartons continue along their path of travel, the loader arms of the primary and secondary loading assemblies are fully retracted from the cartons, after which the cartons can be engaged by downstream folding and tucking mechanisms on both sides of the cartons. The top, upper and/or side end flaps on both sides of the cartons and the lower end flaps on the loading side of the cartons thus will be folded into their closed positions, with the bottom end flaps of the cartons further being folded over or beneath the top end flaps. An adhesive, glue or other sealing material further can be applied to seal the end flaps of the cartons in their closed positions. The upper surfaces of the cartons also can be engaged by a control belt adjacent their loading ends, which belt can apply a desired compression force thereto to help provide additional stability to the products of the product packs adjacent the loading ends of the cartons as the loader arm of the primary or loading side loading assembly is moved out of engagement therewith, until the end flaps along the loading side of the carton can be folded/closed. 
     The enclosed cartons then can be moved through a compression section in which the cartons are engaged by compression belts to help seal the ends of the cartons in their closed configuration. The cartons also can be engaged by punches or other actuators to activate the series of article protection features that further can be provided along the bottom panels of the cartons. For example, if a series of bottles are being packaged within the cartons, fins, tongues or other projections can be formed within the cartons as needed to define article protection features separating the bottles or other fragile articles sufficient to reduce the amount of direct physical contact therebetween and assist in avoidance of breakage during handling and transport of the cartons. Thereafter, the cartons can be removed from the packaging system for collection for storage and/or transport. 
     In addition, for larger product packages, such as, for example, 20, 22, 24, 26, 28, 30, 32, and/or 34-36 packs, or larger packages, for which it may be desirable to provide additional product protection features along a center line thereof, the product packages can be fed into a turner/divider station, in which the product packages can be rotated, for example by approximately 90°, and/or also divided into multiple lanes for ease of storage of collection. The turner/divider station can be mounted at the end of the packaging system for receiving the cartons directly, or can be provided as a stand-alone, separate system in which the carton can be fed individually, as needed or desired. 
     As the cartons are fed into the turner/divider station, they can be engaged by an overhead turning mechanism. The overhead turning mechanism can include a series of turning arms that engage the upper surface of each carton. The turning arms generally can include the downwardly projecting portions or lugs to engage in upstream or downstream side surfaces of the cartons, respectively, and generally will be mounted to a support plate having a cam follower linked thereto. The cam followers engage and move along a cam track, causing the turning arms to be rotated, which correspondingly causes rotation of the cartons by approximately 90°. Once the cartons have been rotated, they can be engaged by a series of punches or other actuators for activating the article protection features extending along the center line of the cartons as needed. The cartons thereafter can be turned again and can be divided into multiple lanes or lines for collection and storage. 
     Various features, objects, advantages and aspects of the present invention further may be set forth or will become apparent to those skilled in the art upon consideration of the following detailed description, when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective illustration of an embodiment of a packaging system for packaging nested product packs and other, varying product pack configurations according to the principles of the present invention. 
         FIGS. 2A-2B  are perspective views of the packaging system of  FIG. 1 . 
         FIGS. 3A-3B  are exploded perspective views illustrating the various operative assemblies of the packaging system of  FIGS. 1-2B . 
         FIG. 4  is a perspective view illustrating example embodiments of cartons that can be used with the packaging system according to the principles of the present invention. 
         FIGS. 5A-5E  illustrate various example embodiments of carton blanks, and/or nested product pack configurations adapted to be received therein, which can be packaged by the packaging system of the present invention. 
         FIGS. 6A-6B  are perspective illustrations of new product selection and grouping areas of the product packaging system of  FIGS. 1-3B . 
         FIG. 7A  is a perspective illustration schematically illustrating the formation of a nested product group for feeding into a carton according to one example embodiment of the present invention. 
         FIG. 7B  is a plan view illustrating the formation an alternative nested product group for feeding into a carton using the packaging system according to the principles of the present invention. 
         FIGS. 8A-8B  are perspective illustrations of top and bottom sides of one embodiment of the pack reducing flight of the selector conveyor of the present invention according to one example embodiment. 
         FIGS. 9A-9C  are perspective illustrations of the loading and folding/sealing area of the packaging system of  FIGS. 1-3B . 
         FIG. 10  is a plan view illustrating the product selection and grouping, and loading areas of the packaging system of  FIGS. 1-3B . 
         FIGS. 11A-11G  are schematic views illustrating the selection and grouping of various example configuration nested product packs and their subsequent loading into a carton. 
         FIGS. 12A-12C  are schematic illustrations of alternative embodiments for product selection and grouping operations according to the principles of the present invention. 
         FIGS. 13A-13E  are schematic illustrations showing the progressive tucking and folding of the lower end flaps of the stabilizing side of the carton by the upstream folding and tucking mechanism. 
         FIGS. 14A-14D  are schematic illustrations of an example embodiment of the folding and tucking mechanisms of the folding/sealing area of the packaging system. 
         FIG. 15  is a perspective illustration of one example embodiment of a turner/divider station for use with the packaging system according to the principles of the present invention. 
         FIG. 16  is a bottom view of the turner/divider station of  FIG. 15 . 
         FIG. 17  is a side elevational view, with parts removed, illustrating the turning of the cartons and their engagement by a rotating punch assembly for activating a series of article protection features within the cartons. 
         FIG. 18  is a schematic illustration of the turning of the cartons for engagement and activation of the article protection features within the turner/divider station of  FIG. 15 . 
     
    
    
     It will be understood that the drawings accompanying the present disclosure, which are included to provide a further understanding of the present disclosure, incorporated in and constitute a part of this specification, illustrate various aspects, features, advantages and benefits of the present disclosure and invention, and together with the following detailed description, serve to explain the principals of the present invention. In addition, those skilled in the art will understand that, according, in practice, various features of the drawings discussed herein are not necessarily drawn to scale, and that dimensions of various features and elements shown or illustrated in the drawings and/or discussed in the following Detailed Description, may be expanded reduced or moved to an exploded position in order to more clearly illustrate the principles and embodiments of the present invention as set forth in the present disclosure. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now in greater detail to the drawings in which like numerals indicate like parts throughout the several views,  FIGS. 1A-2B  schematically illustrate an example embodiment of a packaging system  10  and method of operation according to the principles of the present invention for the selection and grouping of a series of products or articles P, arranged in product packs  11  of varying sizes and/or configurations for loading into cartons C for packaging. While the present invention generally is illustrated for use with packaging of bottles or cans, it will be understood by those skilled in the art that other, varying shapes products or articles also can be packaged by the packaging system and method of operation of the present invention. The present packaging system further is flexible so as to be able to accommodate the selection, grouping and packaging of a wide variety of different size and configuration product packs. For example, the packaging system can be adapted to receive, select, group and package bottles, cans or other products P in various traditional and non-traditional pack sizes or configurations ranging from 4, 6, 8, 9, 10, 12, 15, 16, 20, 21, 22 and 24 groupings or packs to larger pack sizes of 30, 32, 34, 36, 38, 40 or more, arranged in multiple rows of 2, 3, 4, 5, 6, 7 or more products, respectively, i.e., arrangements of 2×3, 2×4, 2×5, 2×6, 3×3, 3×4, 3×5, 3×6, 3×7, 4×4, 4×5, 4×6, 4×7, 4×8, 5×8, etc. . . . products, as indicated in  FIGS. 5A-5E . Other varying product pack sizes and configurations also can be used. 
     In addition, the present invention is particularly adapted to enable the selection, grouping, and packaging of nested or staggered product pack configurations as well as more conventional product pack arrangements. For example, alternative size nested or staggered product pack configurations such as 10 packs, 14 packs ( FIG. 5A ), 18 packs, 22 packs, 26 packs ( FIGS. 5B-5D ), 40 packs ( FIG. 5E ), or other, larger or smaller size nested or staggered packs, can be packaged utilizing the packaging system  10  of the present invention. Such nested or staggered packs can be formed in a substantially rectangular or square arrangement ( FIG. 5E ) or with a generally convex ( FIGS. 5A-5C ) or concave ( FIG. 5D ) configuration. It further will be understood by those skilled in the art of the foregoing pack descriptions are provided simply as examples, and are not to be taken as limiting the packaging system of the present invention solely to packaging such example configurations, but rather a wide variety of different pack sizes and/or configurations including greater or lesser pack sizes and/or configurations can be packaged utilizing the packaging system and method of operation thereof according to the principles of the present invention. 
       FIGS. 4 and 5A-5C  illustrate example cartons C and carton blanks B for forming such cartons, for the packaging of various size and/or configurations of nested product packs  11  ( FIGS. 5A-5E ) of varying sizes and/or configurations using the packaging system and method of operation thereof according to the principles of the present invention. Each of the carton blanks B shown in  FIGS. 5A-5C  generally will include side panels  14  and  15 , a base panel  16 , and further can include top panels  17 A/ 17 B that can be folded over and glued together to define the top or upper surface  18  of each carton C, as indicated in  FIG. 4 . Alternatively, the cartons can be formed with substantially solid or unitary top panels or in other configurations as needed or desired. As also shown in  FIGS. 5C-5D , the cartons further can include a series of article protection features  19  such as fins, tabs, or other projections formed into the base or bottom panel  16 . For example, as shown in  FIG. 5C , a first series of protection features  19 ′ can be arranged in a first orientation and location adjacent the side panels  14 / 15 , while a second series of article protection features  19 ″ can be formed in a second orientation arranged along a longitudinal axis or center-line  20  of the cartons, which second series of article protection features can be activated after loading of the product pack  11  therein to provide a desired separation and protection to the bottles or other fragile articles of the product pack within the carton. 
     Each of the cartons C ( FIGS. 2A-3B and 4 ) further generally will include first and second or loading and stabilizing side ends  21  and  22 , respectively, defining openings  23  ( FIGS. 2B and 7A-7B ) through which the product packs can be received following folding or erection of the cartons into an open ended carton sleeve. The open ends  23  of the first and second sides of the cartons  21  and  22  generally will be defined by a series of end flaps  25  ( FIGS. 5A-5C ), generally including top, bottom and side flaps. In one embodiment, the cartons can be provided with a configuration substantially matching the configuration of the product pack received therein. For example,  FIGS. 5A-5C  illustrate product packs with an extended or generally convex profile or configuration, about which their cartons can be formed. In such an embodiment, the end flaps of the cartons can include lower end flaps  26  formed at each end of the base panel  16  of each carton, and separated from the base panel by fold lines  26 A; bottom flaps  27  separated from the base panel  16  by fold lines  27 A, top or upper end flaps  28  separated from their respective top panels  17 A/ 17 B by fold lines  28 A, side flaps  29  ( FIGS. 5A-5B ) and  29 ′ ( FIG. 5C ) generally separated from the side panels  14 / 15  along fold lines  29 A. Lower gussets  31  also can be formed along/between the lower end flaps  26 , as indicated at dashed lines  31  in  FIGS. 5A-5C , while additional, upper gussets  32  further can be formed between the upper side and/or upper end flaps  29  and the top panels  17 A/ 17 B. 
     It additionally will be understood from  FIGS. 5A-5C  that other, varying arrangements of end flaps, side, top and base panels, and gussets also can be provided as needed to accommodate variations in the sizes and/or configurations of product packs, including nested product packs as shown, as well as to accommodate the packaging of different types of products forming such product packs. For example, as indicated in  FIG. 5C , where bottles are used as the products P of the product pack  11 , the side panels and side flaps  29 / 29 ′ of the cartons can be provided with additional fold lines extending across their width, indicated at lines  33 , as well as additional fold lines  34 A-B between the upper side panels and side or upper end flaps, defining an angled or substantially diamond shaped shoulder configuration shown at  36  in  FIG. 5C , adapted to help conform the side panels to the neck shape of the bottles of the product pack as needed or desired. As also shown in  FIG. 5C , the side or upper end flaps  29  also can be split or separated substantially along fold line  33  as indicated at  29 A/ 29 B to further facilitate the configuring/folding of the upper end flaps about the bottles at the ends of the nested product pack  11  to help ensure a tight, close fit package. 
     Still further, the cartons can be formed with substantially square or rectangular configurations, without the need for gussets, additional side and/or end flaps, or other features adapted to more closely approximate the configuration of a product pack received therein, which can result in reduction in the amount of paperboard or other materials used to form the cartons. For example, as shown in  FIGS. 5D-5E , for nested product packs  11  having a recessed or concave configuration or a generally rectangular or similar arrangement with staggered or offset rows, substantially rectangular or square shaped cartons can be used. The open spaces or recessed areas between the ends of the rows of products, such as indicated at  37  in  FIGS. 5D-5E , can provide additional space at the ends of the cartons for handles or hand grips to be formed in the cartons, and/or to provide space for inserts or other features if needed or desired. 
     As shown in  FIGS. 1A-3B , the packaging system  10  can generally be constructed in similar fashion to and/or incorporate the features of a packaging machine, such as a QUICKFLEX® 2100 style packaging machine as manufactured by Graphic Packaging International, Inc. The packaging system  10  thus can be adapted to operate in a conventional manner or fashion for packaging traditional style/configuration product packages, while further providing the additional flexibility and capability of accommodating a wider variety of package sizes and/or configurations, including the packaging of nested product pack configurations or other non-traditional pack sizes or configurations without requiring additional equipment or substantial reconstruction thereof. 
     As indicated in the figures, the packaging system  10  generally will include a frame  39 , defining a first, loading side  40 A and a second, stabilizing side  40 B of the packaging system, and which can include a housing or guards (not shown) and which frame supports the various operative systems and assemblies of the packaging system  10 . The packaging system further generally will include an infeed area  41  at which the cartons C and products P ( FIG. 1 ), respectively, are introduced into the packaging system, a downstream selection and grouping area or zone  42  in which the products are selected and formed into product packs, after which they are passed into a loading zone or area  43  for loading for loading into their associated or corresponding cartons, a folding/sealing area or zone  44 , and a compression area  46  at the downstream end of the packaging system to complete the packaging of the product packs within their associated cartons. 
     The infeed area or section  41  of the packaging system  10  generally will include an infeed conveyor  50  for conveying a series of cartons C, typically arranged in a stacked series as they are conveyed along the infeed conveyor  50 , as indicated in  FIG. 1 . The cartons are fed in stacked series along the infeed conveyor  50  to a carton loader  51 , which feeds individual cartons C onto a carton conveyor  52  ( FIGS. 2A, 3A-3B, 6A-6B ). An example of such a carton loader and carton infeed conveyor  50  generally is shown in U.S. Pat. No. 8,246,290, the disclosure of which is incorporated herein by reference as if set forth in its entirety. The carton conveyor  52  generally will include a lugged or flighted conveyor having a series of pusher lugs  53  ( FIGS. 2B, 3B and 6B ) carried by belts or chains  54  in between which each of the cartons will be received from the carton loader  51  and conveyed along a path of travel as indicated by arrow  56 . As additionally indicated in  FIGS. 2A-3B , an overhead flight or lug conveyor system/assembly  57  for erecting the cartons C, such as for example, shown in U.S. Pat. No. 5,809,746, the disclosure of which is incorporated by reference as if fully set forth herein, will be provided along the path of travel  56  of the cartons for engaging and erecting the cartons into an open ended sleeve configuration for loading of products therein, such as indicated in  FIGS. 7A-7B . 
     As further shown in  FIGS. 2A, 3A-3B and 6A , the infeed section or area  41  of the packaging system  10  further includes a product infeed conveyor  60 , which will feed a series of products, such as bottles or cans, along an initial path of travel, indicated by arrow  61  into the packaging system  10 . The product infeed conveyor  60  generally will include a substantially flat belt having an expanded width of a size to accommodate a desired number of products thereacross. The product infeed conveyor will feed the products to the selection and grouping station or area  42  where the products can be selected/separated into discrete by a series of guides  62 , of a primary selector  63 . The guides  62  can be moved into desired positions across the width of the product infeed conveyor as needed to accommodate or separate the products into a desired number of lanes  64  of product lines. For example, in  FIGS. 2A and 6B , six guides  62  are shown in use in the primary selector  63 , although it will be understood that greater or fewer number of guides  62 , defining greater or fewer product lanes  64 , also can be provided. The product lanes  64  of the primary selector  63  will separate the incoming products into discrete lines of products, which will be engaged by a series of selector wedges  65  that select and/or capture a desired number of products therebetween for guiding an initial or first series of products into the flights  66  of a product selector conveyor  67  moving along a path of travel substantially parallel to the path of travel  56  of the cartons moving along the carton conveyor. 
     As indicated in  FIGS. 6A-7B , a desired number of products from each of the product lanes are engaged and urged by the selector wedges  65  into associated flights  66  of the selector conveyor  67  in order to form an initial product pack or grouping  11 A moving substantially parallel to the cartons for loading therein. As further illustrated in  FIGS. 7A-8A , each of the flights  66  of the flighted product selection conveyor  67  generally can be constructed as a pack reducing flight which, in one embodiment, can include a substantially flat base plate  68  on which the packs are loaded an upstream wall  69 , which can be fixed in place, and a moveable downstream wall  71 . The downstream wall  71  can be mounted on rotary members  72  ( FIGS. 8A-8B ), such by bearings or pivot pins  73  ( FIG. 8B ), and thus can be moveable across the upper surface  74  of its associated base plate  68 , as indicated by arrows  76  and  76 ′, upon rotation of the rotary members  72 , as indicated by arrows  77  and  77 ′ in  FIG. 8B . A cam roller  78  or similar guide pin can be mounted to a lower surface of at least one of the rotary members  72 , and can engage a cam track or guide  79  ( FIGS. 6A-6B ) extending along the selector conveyor so as to cause the rotation of the rotary members as the cam roller follows along its associated cam track or guide. 
     As a result, the wall  71  of each flight generally will be urged toward and away from the product pack being formed within its associated flight as the selector conveyor is moved along its path of travel, thus applying a compressive force against the product pack. This compressive force generally results in tightening or collapsing of the spacing between the products within the product pack being formed as the product pack is engaged between the upstream and downstream walls of the flight, and further can assist in helping to guide and stabilize the upstream and downstream rows of the products of the product pack as it is loaded into a carton, as indicated in  FIG. 7A . The shape and/or position of the cam track  79  further can be varied and/or changed as needed to control the collapse and/or the amount of compression provided to the product pack. Where such compression is not needed, such as for running more conventional or standard product packs and cartons, the cam track can be moved out of engagement with the cam rollers and/or removed, or can be otherwise reconfigured as needed. 
     As additionally indicated in  FIG. 11G , in one embodiment, a series of funnels or guides  81  further can be provided for assisting with the guiding of the nested product packs or groups  11  into their cartons. The funnels  81  can include upstream and downstream plates  82 A- 82 B that are mounted in spaced series on a conveyor  83 . The funnels can be moved in time with the product packs  11 , and the positions or spacing between their upstream and downstream plates can be adjusted or varied, depending on the size and/or configuration of the product packs, as needed to facilitate movement of the product packs  11 . 
     As further illustrated in  FIGS. 6A-7B , a secondary selector  85  generally can be located adjacent the downstream end of the selection and grouping area  42  of the packaging system  10 , in a position to receive any additional remaining products not previously selected and loaded into a flight of the selector conveyor by the primary selector  63 . Thus, for running more conventional size packs, the secondary selector  85  does not necessarily have to be used. However, for the formation of more non-traditional pack sizes, including nested product packs  11  as illustrated in  FIGS. 7A-7B , the secondary selector can receive and select and guide additional series or numbers of products  11 B into an engaged or nested relationship with the initial product pack  11 A formed on each flight by the primary selector. As further illustrated in  FIGS. 12A-12B , one or more secondary selectors  85  can be provided and additionally can be mounted on one or both sides of the selector conveyor. 
     In one embodiment, as illustrated in  FIGS. 6A-6B and 9A-9C , the secondary selector (or secondary selectors as shown in  FIG. 12A ), can include a construction similar to that of the primary selector including one or more guides or rails  86  defining at least one lane or passage  87  therebetween, and along which the additional products  11 B ( FIGS. 9A-9C ) are received and guided into a desired nested engagement with the initial product packs  11 A formed within the flights of the selector conveyor. As further indicated in  FIGS. 7A-7B and 9A-9C , a series of selector wedges  88  can engage the additional series of products being fed by the secondary selector  85  to select and guide or direct the additional products into their nested relationship with the initial product groupings within the flights, as shown in  FIGS. 11A-11C . The selector wedges  88  ( FIG. 7A ) can be mounted on an endless moving belt or conveyor chain, at a desired spacing so as to define guide channels or passages  89  therebetween, and generally will be moved in timed relation with the incoming products moving along the at least one lane  87  of the secondary selector  85  for selecting and metering the products moving therealong. The products will be received within the channels  89  defined between the selection wedges, which will guide such products into nested engagement with their associated initial product groupings  11 A to form nested product packs  11 . Alternatively, other types of product selection mechanisms, including metering wheels or devices, individual product feeders, etc., also can be used as a secondary selector or selectors to select and direct or feed one or more products or sets of products into an engaging or nested relationship with the initial product groupings formed by the primary selector as needed to form the desired product packs. 
     The resultant product packs  11  can be formed with various numbers and arrangements of rows and of products, arranged in a variety of nested and/or staggered or other configurations. For example, the product packs can have a substantially square or rectangular arrangement with or without gaps at the ends thereof such as shown in  FIG. 5E ; a generally convex arrangement having additional products at the ends of one or more central or inner rows of products, as shown in  FIGS. 5A-5C and 7A ; a generally concave arrangement with additional products arranged at the outermost, front and rear, or other rows of products, such as shown in  FIGS. 5D and 7B ; either aligned or engaging with other products of such rows, or at gaps or other areas defined between such rows, and/or other varying package configurations. 
     In addition, as shown in  FIGS. 12A-12C , various size and/or configuration product packs  11  can be formed using other, alternative methods of product selection and presentation, whereby a series of additional individual products or groups of products can be added to a product grouping to form a desired product pack, including formation of a nested product pack. For example,  FIGS. 12A and 12B  illustrate formation of example nested product packs, wherein outside rows of products are added to an initial product grouping or pack, here shown as having a substantially rectangular pattern or configuration, although other patterns such as substantially square or other configurations also can be used. 
     In  FIG. 12A , a pair of secondary selectors  85 A/ 85 B generally are shown, mounted on opposite sides of the product grouping and selection area and the product conveyor (e.g., a first secondary selector  85 A being mounted along a first or the same side of the product selection and grouping area as the primary selector  60 , and a second or additional secondary selector  85 B mounted on a second or opposite side of the product selection and grouping area). As a result, products can be selectively fed from one or both sides of the initial product groupings or packs formed by the primary selector, into an engaging, nested relationship along outer portions or sides of each initial product grouping. Alternatively,  FIG. 12B  shows the selected application of individual products to a preformed product grouping by a secondary selector, which can be located on either the loading or stabilizing side  40 A/ 40 B of the product conveyor. As illustrated in  FIG. 12B , individual products or selected groups of products can be fed selectively into abutting or engaging relationship with selected rows or lines of products (e.g. the first or foremost and last or rearmost lines of products as shown in  FIG. 12B ) as needed to form different, varying configuration or size and shape nested product packs. In addition, upon engagement therewith by a loader arm  91 , the rows of products can be shifted or otherwise adjusted into an offset or nested configuration as needed. 
     Still further, as shown in  FIG. 12C , other, alternative product pack configurations also can be formed, such as by pulling different numbers of products from each lane of a primary selector and/or from one or more secondary selectors. For example, an underside pin or overhead pin style product selector mechanism can be used and can engage the series of incoming products  11 C moving along the conveyor so as to speed up or vary the rate at which the selected products or groups of products are fed along the product conveyor  67  to create a separation of these groups from the incoming group or mass  11 C of products. As a further alternative, or in addition, the product selection and grouping area  42  also can be divided into multiple zones, which can be operated at varying rates. By way of example, the product selection grouping area could be divided into at least three zones, and possibly more, that can be run at varying rates including inner and spaced outer zones, with the outer zones being run at a rate sufficient to select and pull different numbers of products from the group or mass  11 C of products being fed per machine cycle than a number of products being selected and pulled or transported by the inner or central zone. As shown in one example embodiment illustrated by  FIG. 12C , each of the outer zones or lanes can be configured to pull two or separate products, while the central zone or lanes can pull 4-6 products from the group or mass  11 C of products being fed so as to thus create a desired configuration of a nested product pack. 
     Other, varying package formations also can be utilized, for example, the use of metering wheels or other selectors provide products individually or in selected groups to various portions of a preformed product pack. The product packs also can be formed with the additional layers or outer layers of products engaging the primary product pack at gapped or intersecting areas between the products of the primary product grouping as generally illustrated in, for example,  FIGS. 7A, 12A and 12C , or alternatively can be moved into engagement with a particular line or row of products, as generally illustrated in  FIGS. 11A-11G, and 12B . 
     As further indicated in  FIGS. 6A, 7 and 9A-11F , after each product pack  11  has been formed within a flight  66  of the selector conveyor  67 , it will be moved into the loading area or zone  43  of the packaging system  10  for loading into a corresponding carton C. As the product packs  11  move into the loading area, they initially can be engaged by a loader arm  91  of a first, primary or loading assembly  92  mounted along the loading side  40 A of the packaging system. The primary loading assembly  92  ( FIGS. 9A-10 ) generally can include two or more drive chains, belts or other conveyors that are moved about an elliptical path of travel in the direction of arrow  94  and which will carry a series of loader arms  91  therealong. The number of loader arms  91  can be varied depending upon the size and/or spacing of the flights of the selector conveyor, with each arm typically moving in timed relation with an associated one of the selector conveyor flights. 
     Each loader arm  91  generally can include an elongated body or base  96 , which also can be formed as a pair of spaced arms or rods  97 , attached to a carriage  98  that is slidably mounted on a series of supports  99 , such as bars, rods, etc., which in turn are attached to the drive chains or belts  93  of the primary loading assembly. A cam follower  101  ( FIG. 9C ) can be mounted to the carriage  98  of each loader arm  91  and can engage and ride along a guide track  102 , the position of which can be adjusted by an actuator  103 , such as a hydraulic or pneumatic actuator or servomotor, or other, similar actuator. This causes the carriage to be urged transversely across the width of the primary loading assembly toward a corresponding product pack being conveyed by the selector conveyor. The position of track  102  thus can be varied to control the transverse movement of the loader arms  91  in the direction of arrows  104 / 104 ′, into and out of engagement with the product packs as needed for loading the product packs into the cartons, as indicated in  FIGS. 7A and 11A-12C . 
     A second or stabilizing loading assembly  106  also can be mounted on the opposite stabilizing side  40 B of the carton conveyor of the packaging system  10  from the primary loading assembly  92 . The secondary loading assembly can have a similar construction to that of the primary loading assembly, typically including a conveyor mechanism  107  ( FIGS. 9A-9B ) that can include one or more belts, chains, etc., and which carries a series of carriages  108  to which loader arms  109  are mounted. A movable guide track  111  can be moved laterally across the path of travel  112  of the carriages and loading arms for controlling the transverse movement of the stabilizing side loader arms  109  toward and away from their associated cartons moving along the carton conveyor. 
     An example of a loading system that can be used for the primary and/or secondary loading assemblies  92  and  106  of the packaging system  10  can include a split pitch barrel loader such as illustrated and described in U.S. Pat. Pub. No. 2010/0162668 A1, the disclosure of which is incorporated by reference as if fully set forth herein. 
     As further illustrated in  FIGS. 7A and 11A-11F , in one embodiment, the loader arms  91  and  109  each typically will include a forward, pusher face or plate, indicated at  115  and  116 , respectively. In one embodiment each pusher face  115 / 116  of each of the loader arms  91 / 109  can be formed as a substantially unitary plate, such as indicated in  FIGS. 7A and 11A-11F , or alternatively in another example embodiment, can be formed from a pair of side-by-side plates, each attached to a separate arm or rod forming their loader arm. Each pusher face further typically can be configured for engaging various sizes or configurations of product packs  11 , including nested product packs. By way of example, in one embodiment, such as for forming a generally concave product pack configuration or arrangement  11  as shown in  FIGS. 7A and 11A-11F and 12A , the pusher plates or faces  115  and  116  can have substantially U- or C-shaped configurations each with a recessed area  117  defined between a pair of forwardly extending projections or fingers  118 , or can form a generally convex pack configuration such as by including a generally A-shaped or forwardly projecting configuration as shown in  FIGS. 7B  and  11 G. The additional products  11 B selected by the secondary selector  85  can be received within this recessed area  117  for supporting the additional products  11 B as they are urged into their nested position against the initial group of products  11 A as the nested product pack  11  is loaded in the carton. 
     As also indicated in  FIG. 7A , the pusher faces  115  of the loader arms  91  of the primary loading assembly generally can have a lower portion or base  119  which projects downwardly and which is adapted to move over or in close proximity with the upper surface  74  of the base plates  68  of the flights  66  of the selector conveyor as the loader arms  91  move transversely thereacross, in order to engage and substantially stabilize a lower or bottom portion of the products (e.g., bottles as shown in the figures) of the product packs as the product packs are inserted into their corresponding cartons. Conversely, the pusher face  116  of the loader arm  109  of the secondary loading assembly  106  may not require a downwardly extending base or lower portion instead generally engaging an upper or mid portion of the portions, as indicated in  FIG. 7A . Still further, the pusher faces of the loader arms can be provided as change-parts to enable quick and easy change out of such pusher faces or plates as needed to accommodate differing size or configuration product packs (such as shown in  FIG. 7B ) and/or for running more conventional product pack arrangements which do not include a series of additional, staggered or nested products as a part of such product packs. 
     As schematically illustrated in  FIGS. 11A-11F , as the product packs  11  are urged toward and into their corresponding cartons C (in the direction of arrow  104 ), by the loader arms  91  of the primary loading assembly, the corresponding or associated loader arms  109  of the secondary loading assembly  106  generally will be moved into and through the open interior cavity or passage of the cartons, as indicated by arrow  121  in  FIGS. 11A-11C . As a result, as each product pack is inserted into its corresponding carton, it will be engaged from opposite sides thereof to help stabilize and prevent tipping or misalignment of the products as the product packs are seated within their cartons. With the product packs engaged by both loader arms  91 / 109 , movement of the loader arms  109  thereafter can be reversed so as to move in an opposite direction, as indicated by arrow  121 ′ as the loader arms  91  continue their forward movement in the direction of arrow  104  for loading the product packs into their cartons, with the product packs maintained in a stabilized arrangement during loading, as indicated in  FIGS. 11D-11E . Thereafter, as indicated in  FIG. 11F , once each product pack has been fully seated within its carton, the loader arms of the primary and secondary loading assemblies can be retracted (as indicated by arrows  104 ′ and  121 ′) as the cartons move into the downstream folding/sealing area or zone  44  of the packaging system ( FIGS. 1, 2B, 9A-10 and 13A-13B ). 
     In a further, alternative embodiment illustrated in  FIGS. 7B and 11G , the secondary selector  85  further can be reconfigured as needed to provide for the selection and feeding of additional, different arrangements of products  11 B as needed to form other, varying product pack configurations. For example, as indicated in  FIGS. 7B and 11G , the secondary selector can be configured to feed additional product groups  11 B in spaced or staggered arrangements into alignment with selected spaced apart rows of the initial product pack  11 A, such as being fed into engagement with the outermost or upstream and downstream rows of products. In such an embodiment as shown in  FIGS. 7B and 11G , the pusher faces  115 ′ and  116 ′ of the loader arms  91  and  109  of the primary and secondary loading assemblies can be changed and/or configured with a generally A-, E- or substantially T-shaped configuration; for example having a central projecting portion  122  that extends toward the product packs and is bordered by upstream and downstream lateral sections  123 A and  123 B. The pusher faces  115 ′ and  116 ′ can be provided as change parts so as to replace the pusher faces  115  and  116  of the loader arms  91  and  109 , or alternatively, the loader arms themselves can be replaced as needed. 
     Accordingly, while the secondary selector  85  is being shown in the illustrated embodiments as generally feeding two additional products into engagement with, for example, center rows of the initial product pack, as shown in  FIG. 7A , or into engagement with front and rear or foremost and endmost rows of products as shown in  FIG. 7B , it will be understood by those skilled in the art that greater or lesser numbers of products also can be fed into engagement or alignment with various selected rows of the initial product pack so as to form substantially rectangular, substantially square, or generally concave and/or generally convex product arrangements. For example, as shown in  FIG. 5E , three additional products, such as three additional cans, can be fed into engagement with the first or front row of products, the third or center row of products, and the fifth or last row of products to form a product pack of a desired size and/or shape that can be packaged using a substantially rectangular carton that does not require gussets and additional flaps to substantially conform the carton about the shape of the product pack, such as shown in  FIGS. 5A-5C . 
     In addition, as further illustrated in  FIG. 11G , the selector wedges of the secondary selector  85  can be replaced with additional, various configuration selector wedges, such as indicated at  88 A and  88 B. The selector wedges can be provided with angled guide surfaces  90 A- 90 C, which define an angled or redirecting upstream guide passage  89 A, which further can include substantially flat guide surfaces  90 D defining a downstream guide passage  89 B. It will also be understood by those skilled in the art that other, varying configurations of the selector wedges  88 A and  88 B, thus defining different and/or additional configuration guide channels  89 A and  89 B (including additional guide channels as needed) also can be used. The selector wedges  88 A and  88 B thus will engage the additional products being fed through the secondary selector, and will guide the additional products into a desired nested or staggered, convex or gapped product configuration such as shown in  FIGS. 5B, 5E, 7B and 11G . 
     As discussed above, the loader arms  91  ( FIGS. 7B and 11G ) of the primary loading assembly will engage and urge the additional products along the guide channels  89 A and  89 B, into engagement/alignment with selected rows (i.e., the upstream and downstream rows), while at substantially the same time, the downstream wall  71  of each pack reducing flight  66  can be moved toward its upstream wall  79  so as to collapse or reduce the pack size, with the amount of collapse and/or compression of the product pack  11  generally being controlled by the movement of the cam rollers  78  ( FIGS. 6A-6B ) along the cam track or guide  79 . In addition, as also illustrated in  FIGS. 7B and 11G , a funnel conveyor  83  can be provided between the flights  66  of the product selector conveyor  67  and the carton conveyor, for moving a series of funnels or guides  81  in timed movement with the product pack  11  across the flights and toward their corresponding or associated cartons. The funnels can further facilitate the compression and guiding each of the product packs  11  into their associated cartons, as needed or desired. 
     As the product packs are moved by the loader arms  91  of the primary loading assembly toward their cartons, the product packs further can be engaged on the opposite end or side by the loader arms  109  of the second or stabilizing loading assembly  106 , the pusher faces  116 , of which will generally have a similar configuration so as to matingly engage the product packs from the opposite side to help hold the product packs in their desired nested or staggered arrangement or configuration as the product packs are fed into the openings of their cartons. As noted above, as the product packs enter their associated cartons, the loader arms  109  of the second or stabilizing loading assembly  106  can be retracted as the loader arms  91  of the primary loading assembly  92  continue their forward movement, thus guiding the product packs into their cartons, as discussed above. Thereafter, the cartons, with their product packs loaded therein, will continue along their path of travel into the folding and sealing area of the packaging machine. 
     The selection and packaging of nested product packs having a substantially concave and/or staggered or gapped arrangements or configurations, such as illustrated in  FIGS. 5D, 5E, 7B and 11G , enables the packaging of a variety of different size or number of products in the product packs, i.e., 18, 20, 28, 32, 40 or other differing size pack configurations, which packs further can be packaged using more conventional rectangular or substantially square cartons. Such cartons may not necessarily require additional features such as gussets and/or additional folding flaps at the ends and/or sides thereof in order to more closely configure the carton about concave, oblong or other, similar extended shape product packs such as shown in  FIGS. 7A and 11A-11F . As a result, the use of such substantially rectangular or square packages can provide a potential cost savings in the amount of board material required to form the cartons, and can potentially enable increased production/packaging rates. 
     In addition, as noted, the packaging system  10  ( FIGS. 1-3B ) and method of operation thereof according to the principles of the present invention further has the flexibility to enable the packaging of more standard or conventional size product packs and/or cartons, for example 12 packs in 2×6, 3×4 configurations, 24 packs in 4×6 configuration, etc. To run such standard or more conventional product packs and cartons, the secondary selector can be disengaged and/or bypassed such that the products being fed on the product infeed conveyor are fed solely to the lanes of the primary selector, and the pusher faces and/or loader arms of the primary and stabilizing loading assemblies can be replaced or changed out with substantially flat front pusher faces for engaging the product packs and urging the product packs into their associated cartons. In addition, in running such generally standard or more conventional size product packages or cartons, if it is not needed or desired to compress or reduce the size of the product packs, the cam track guiding the cam rollers of the pack reducing flights  66  of the selector conveyor can be removed or moved or shifted to a position or location out of engagement with the cam rollers to avoid compression or reduction in size of the product packs. As a further alternative, the secondary selector can be maintained in operation, and can be used to selectively feed additional products in conjunction with the primary selector. For example, if the primary selector is feeding four to six rows, such as for forming a 12 or 24 pack, the secondary selector can be operated in conjunction with the primary selector to feed an additional row or rows as needed to form additional, larger size product packages. 
     As illustrated in  FIGS. 11E-11F , with the product packs seated in their cartons, the loader arms of each of the loading assemblies thereafter can be retracted or removed from the cartons and out of engagement with the product packs therein, after which, or in conjunction with which, the open ends of the cartons can be closed and sealed as the cartons continue along their path of travel into the holding/sorting area  44 . As indicated in  FIG. 14A , as the cartons enter the folding/sealing area  44 , they typically will be engaged by a first, upstream folding/tucking mechanism  125 . The upstream folding/tucking mechanism  125  generally can be located adjacent a downstream end of the secondary loading assembly  106  so as to engage the lower end flaps  26  and lower gussets  31  of the cartons C along the second or stabilizing side  40 B of the packaging system to initiate the closing of the cartons along the stabilizing sides thereof, while the loader arm  109  of the secondary loading assembly  106  generally can remain in contact or stabilizing engagement with the end most products P of the product pack  11  loaded thereon, as indicated in  FIGS. 13A, 14A and 14B . Thus, the closing of each carton for sealing its product pack therein can be initiated while the product packs are maintained in their stabilized engagement between the loading arms of the primary and secondary loading assemblies. 
     As noted above, the pusher plate  116  of the secondary loader arm  109  generally can be formed or configured so as to engage intermediate and/or upper portions of a product pack so as to enable the secondary loader arm  109  to remain in its stabilizing contact with the products during folding and closing of the lower end flaps of the cartons along their secondary or stabilizing sides, after which the secondary loader arm  109  can be fully retracted from the carton without interfering with the closing of the lower end flaps of the carton. Once closed, the lower end flaps of the carton thereafter can provide the desired or necessary stability for the product packs contained within their cartons as the remaining end flaps along both sides of the cartons are closed and sealed. 
       FIGS. 13A-13E  schematically illustrate the operation of the upstream folding/tucking mechanism  125  for folding and tucking the lower end flaps and lower gussets of the cartons along their secondary or stabilizing side. As indicated in  FIGS. 13A-14B , the initial folding/tucking mechanism  125  generally will include a tucking wheel  126  mounted on a driveshaft  127  and including a radial projection or tucking finger  128  located along the circumference thereof. The tucking wheel  126  generally will be rotated, such as under the control of a drive motor or by being linked to the drive system for the carton conveyor or other operative conveying elements of the packaging system so as to be rotated into engagement with the leading lower gusset  31 ′ of each carton, as indicated in  FIGS. 13A and 13B . The rotation of the tucking wheel causes the leading lower gusset to bend or fold inwardly, as indicated in  FIGS. 13B-13E , while at the same time the leading lower end flap  26 ′ of each carton will be engaged by one or more guide rods  129 , as indicated in  FIGS. 13A-14B , to cause the movement of the leading lower end flap of such a carton to its folded or closed position as shown in  FIGS. 13D and 13E . 
     At approximately the same time, an upstream tuck and fold member  131  can similarly engage the trailing lower end flap  26 ″ and gusset  31 ″ of the carton, as indicated in  FIGS. 13C-13E . The tuck and fold member  131  generally is mounted on a driveshaft  132 , which rotates the tuck and fold member into engagement with the downstream or trailing lower gusset and end and/or side flaps of each carton, and can include an elongated tucking finger or projection  133  that helps urge the trailing lower gusset inwardly, and hooked upper engaging end  134  that engages and urges the trailing lower end and/or side flaps toward their folded configuration shown in  FIG. 13D . As the tuck wheel  126  and tuck and fold member  131  of the upstream or initial fold/tuck mechanism  125  are rotated out of engagement with the gussets and end flaps of the cartons, the end flaps of the cartons thereafter will continue along the guide rods  129  will maintain the lower end flaps of the cartons in their folded/closed position as indicated in  FIG. 13E . Such engagement further helps provide stability to that end of the product pack within the carton. 
     While the guide rods  129  provide stability and support to the end of the product packs along the stabilizing or second side  40 B of the packaging system, the cartons also can be engaged by a control belt  136  along the loading side  40 A thereof, as indicated in  FIGS. 12A, 14C and 14D , to help provide additional stability to the product packs within the cartons as the first or primary loader arms are fully retracted therefrom. The control belt  136  can be a foam belt or similar cushioned belt formed from a non-stick or non-marring material so as to avoid damaging the cartons as the cartons are moved therealong. The control belt can be driven or moved at a speed commensurate with the movement of the cartons along their path of travel, and can apply a downward compression force against the upper surfaces of the cartons. This downward compression force can help create a frictional engagement between the top surfaces of the cartons and the products of the product pack contained therein to help provide additional stability to the product packs adjacent the loading ends of the cartons until the loading ends of the cartons can be closed and sealed. 
     As the cartons proceed through the folding/sealing area  44 , as indicated in  FIGS. 14A-14C , the side flaps along the ends of the cartons and lower end flaps along the loading sides of the cartons generally can be engaged by a folding mechanism, such as folding wheels  137 , mounted on each side of the path of travel of the cartons, as well as by a series of guide rails  138  to maintain the folded side and upper end flaps of the cartons in their folded and closed positions. Thereafter, the cartons typically will be engaged on each side thereof by a pair of downstream folding/tucking mechanisms  141 A and  141 B ( FIGS. 14C and 14D ). Each of the downstream folding/tucking mechanisms  141 A and  141 B can include a rotating folding wheel  142  mounted to a driveshaft  143  and rotated with the movement of the cartons thereby by an actuator such as a servomotor, stepper motor or other, similar drive  144 . A series of tucking fingers  146  are extensibly mounted within brackets  147  along a rear side surface of each folding wheel  142 . Each of the tucking fingers generally will be biased toward a retracted position by a spring or similar biasing mechanism  148 , with the lower or interior ends  149  of the tucking fingers  146  generally being rotated over or moving about a cam surface  151  mounted along the driveshaft  143  so as to cause the tucking fingers to be moved between extended and retracted positions. 
     In their extended positions, the tucking fingers will engage the upper gussets of the cartons so as to urge the upper gussets toward an inwardly folded position as an additional set of folding wheels  152  engage and urge the upper end and side flaps toward a folded, closed position and the top end flaps are engaged by the folding wheels and urged to their folded, closed position. Additionally, the lower or bottom end flaps of each of the cartons likewise can be engaged and urged toward folded and closed position by lower folding/tucking mechanisms  141 ′. Each lower folding/tucking mechanism can have a similar construction to the upper to folding/tucking mechanisms  141 A/ 141 B but will be positioned below the path of travel of the cartons in a position to engage and fold the bottom end panels. 
     Thereafter, as indicated in  FIGS. 1, 2B and 3A-3B , the cartons, with their end flaps folded to a closed position, can be moved through a series of glue or adhesive applicators  155 , which will apply an adhesive material thereto, for sealing the ends of the cartons. The cartons can be sealed with their bottom end flaps overlapping their top end flaps, or alternatively with their top end flaps overlapping the bottom end flaps thereof as needed or desired depending upon the configuration of the cartons and additional concerns, such as whether a handle or strap is provided therewith. The cartons are then received within the compression section  46  of the packaging system  10 , passing between compression belts  156  that generally will engage and apply a compressive force against the ends of the cartons to complete the closure and sealing of the cartons. 
     In addition, if the cartons are provided with a series of article protection features  19  formed integrally therein, as shown in  FIG. 5C , the cartons can be engaged by one or more actuators for activating such article protection features as the cartons are fed along the compression section of the packaging system between the compression belts  156 . Such actuators can include rotating punches or similar systems or devices such as disclosed in U.S. patent application Ser. No. 13/655,527, the disclosure of which is incorporated by reference as if fully set forth herein. 
     After the product packs  11  (including nested product packs) have been formed, loaded and sealed within their cartons, in one embodiment, the finished cartons can be offloaded for storage and/or transport. In another embodiment, as illustrated in  FIGS. 15-18 , the cartons C alternatively can be fed into a downstream turner/divider station  200 . For example, with some carton constructions, it may not be practical to engage and form any or all of the article protection  19 ″ features provided therein within the compression section of the packaging system, i.e., for larger packages as shown in  FIG. 5C , it may be desirable to include a row of article protection features formed along the center-line or longitudinal axis  20  thereof. Such cartons accordingly can be fed into the turner/divider station  200  ( FIG. 15 ) wherein the cartons can be rotated in order to enable the activation of such article protection features oriented along their longitudinal/center-line axis. 
     As further indicated in  FIGS. 15-18 , the turner/divider station  200  can be mounted to the packaging system  10  as a downstream section or station thereof, or alternatively, can be formed as a separate, stand-alone station. As  FIG. 15  indicates, the turner/divider station  200  can be positioned inline with the compression belts  156  of the compression section  46  of the packaging system  10  so as to receive the loaded/enclosed cartons C directly therefrom. The turner/divider system generally will include a framework or housing  201  having a turning section  202  and a dividing section  203  defined therealong. The turning section  202  generally can include a conveyor  206 , which can include a pair of spaced conveyor belts  207  ( FIG. 16 ) or other, similar conveying mechanism having non-stick surfaces to facilitate the rotation or turning of the cartons thereon as indicated in  FIGS. 17 and 18 . 
     An overhead turning mechanism  208  can be mounted to the frame  201  of the turner/divider station  200 , supported above the conveyor  206 . The overhead turning mechanism  208  can include a series of plates  209  mounted along a series of guide rods  210  that are driven by conveyor belts or chains  211  about an elliptical path of travel into engagement with the cartons and which move the cartons through the turning section  202  as indicated by arrows  212 . Turning arms  213  generally will be mounted to the plates  209  and will be carried thereby into engagement with the top or upper surfaces  18  of the cartons C, as indicated in  FIGS. 17 and 18 . Each of the turning arms also generally can include downwardly projecting portions or lugs  214 , which can be adjustably spaced so as to be adapted to fit varying size cartons and which will engage upstream and downstream side walls  15 / 14  of the cartons, respectively. 
     The turning arms  213  further can be connected via a rotating shaft or pin  216  to a linkage  217  having a cam roller or follower  218  mounted to a distal end thereof. The cam follower  218  of each linkage  217  generally will engage a cam track  219  formed about the overhead turning mechanism as the plates  209  are rotated along their path of travel. As the cam followers of the turning arms move along the cam track, the responsive movement of the linkage  217  causes the turning arms  213  to be rotated, which rotational movement correspondingly is transmitted to the cartons, causing rotation of the cartons to a desired orientation as indicated in  FIGS. 17 and 18 . In one embodiment, the cartons can be rotated approximately 90° so as to realign the longitudinal axis  20  thereof in order to position or locate the cartons as needed for engagement of the article protection features thereof by a rotating punch mechanism  221 , or similar actuator, as discussed above, for activating the article protection features extending along the longitudinal/centerline axes of the cartons. Other, greater or lesser rotations also can be provided as needed or desired. 
     As additionally indicated in  FIG. 18 , as the cartons enter the turner/divider station  200 , the cartons can be engaged on either side thereof by a series of lugs  225  carried by belts or chains of an initial conveying mechanism  226 . The lugs  225  help urge or move the cartons C along their path of travel onto and along the belts  207  of the turning section conveyor  206 . As the clamp arms begin to rotate or reorient the cartons, the lugs  225  can be moved away from engagement therewith. After the cartons have been rotated by a desired amount, the cartons can further be engaged by a series of downstream lugs or pushers  227  mounted long belts, chains or other conveying mechanisms of a secondary conveyor  228 . The downstream lugs  227  of the secondary conveyor  228  will engage and urge the cartons along the belts  207  of turning section conveyor  206  as the punch mechanism  221  engages the cartons. 
     While  FIGS. 17 and 18  illustrate the punch mechanism  221  as generally including a rotating wheel  231  having a series of fingers, punches or other projections  232  mounted in spaced series about the circumference of the wheel  231 , it will be understood that other, varying mechanisms for engaging the cartons and activating the article protection features therein also can be used. Once the centerline row of article protection features of the cartons has been activated or formed therein, the cartons can be reoriented or rotated back to their initial orientation, or can be rotated into another orientation as needed or desired, as shown in  FIGS. 17 and 18 . 
     Thereafter, the cartons will be passed to the dividing section  203  of the turner/divider station  200  as the turning arms of the overhead turning mechanism are rotated out of engagement with the cartons. As  FIGS. 16 and 18  illustrate, the dividing section  203  generally will include a conveying mechanism  235  that can comprise a series of slats or carrier plates  236  slidably mounted along rails  237 , the ends of which are mounted to belts, chains or other similar conveying elements, as indicated at  238 . As shown in  FIG. 16 , the dividing section  203  can be separated or arranged with two or more lanes  239  formed therealong. As the cartons are conveyed forwardly through the dividing section, the cartons can be divided and directed into multiple lanes as needed or desired. To divide the cartons into the lanes, the groups of slats supporting each of the cartons can be controlled so as to be moved laterally along their support rails  237 , resulting in the cartons being separated and divided into the two or more lanes  239  provided along the dividing section. The cartons thereafter can be collected for storage and/or transport as will be understood by those skilled in the art. 
     It will be understood by those skilled in the art that the invention is not limited to the particular methodology, devices, apparatus, materials, applications, etc., described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. 
     Unless defined otherwise, all technical and scientific terms used herein have the same invention is directed, and it will be understood that any methods and materials similar or equivalent to those described herein can be used in the practice or construction of the invention. 
     The foregoing description generally illustrates and describes various embodiments of the present invention. However, it will be understood by those skilled in the art that various changes can be made to the above-discussed construction without departing from the spirit and scope of the present invention as disclosed herein, and that it is further intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative, and not in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, alterations, etc., of the above-described embodiments, which shall be considered to be within the scope of the present invention. Accordingly, various features and characteristics of the present invention as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the present invention.