Patent Publication Number: US-7213385-B2

Title: Vertical stand-up pouch with zipper seal quick change module

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a divisional of U.S. application Ser. No. 11/028,751, filed Jan. 4, 2005, now abandoned which is a divisional of U.S. application Ser. No. 10/695,339, filed Oct. 28, 2003 (now U.S. Pat. No. 6,860,084), which is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/135,329, filed on Apr. 30, 2002, (now U.S. Pat. 6,679,034), which, in turn, is a continuation-in-part of co-pending U.S. application Ser. No. 10/124,669 filed on Apr. 17, 2002, (now U.S. Pat. 6,729,109), and U.S. application No. 10/100,370 filed on Mar. 18, 2002, (now U.S. Pat. 6,722,106). 

   TECHNICAL FIELD 
   The present invention relates to a vertical stand-up pouch having vertical gussets and an integrated zipper seal constructed using a modified vertical form, fill, and seal packaging machine, and the method for making same, that provides for a single piece construction of a stand-up bag suitable for retail snack food distribution. The invention allows for use of existing film converter and packaging technology to produce a stand-up package having an integrated zipper seal with minimal increased costs and minimal modifications. 
   DESCRIPTION OF THE RELATED ART  
   Vertical form, fill, and seal packaging machines are commonly used in the snack food industry for forming, filling, and sealing bags of chips and other like products. Such packaging machines take a packaging film from a sheet roll and forms the film into a vertical tube around a product delivery cylinder. The vertical tube is vertically sealed along its length to form a back seal. The machine applies a pair of heat-sealing jaws or facings against the tube to form a horizontal transverse seal. This transverse seal acts as the top seal on the bag below and the bottom seal on the package being filled and formed above. The product to be packaged, such as potato chips, is dropped through the product delivery cylinder and formed tube and is held within the tube above the bottom transverse seal. After the package has been filled, the film tube is pushed downward to draw out another package length. A transverse seal is formed above the product, thus sealing it within the film tube and forming a package of product. The package below said transverse seal is separated from the rest of the film tube by cutting horizontally across the sealed area. 
   The packaging film used in such process is typically a composite polymer material produced by a film converter. For example, one prior art composite film used for packaging potato chips and like products is illustrated in  FIG. 1 , which is a schematic of a cross-section of the film illustrating each individual substantive layer.  FIG. 1  shows an inside, or product side, layer  16  which typically comprises metalized oriented polypropylene (“OPP”) or metalized polyethylene terephtalate (“PET”). This is followed by a laminate layer  14 , typically a polyethylene extrusion, and an ink or graphics layer  12 . The ink layer  12  is typically used for the presentation of graphics that can be viewed through a transparent outside layer  10 , which layer  10  is typically OPP or PET. 
   The prior art film composition shown in  FIG. 1  is ideally suited for use on vertical form and fill machines for the packaging of food products. The metalized inside layer  16 , which is usually metalized with a thin layer of aluminum, provides excellent barrier properties. The use of OPP or PET for the outside layer  10  and the inside layer  16  further makes it possible to heat seal any surface of the film to any other surface in forming either the transverse seals or back seal of a package. Alternatively, a material can be used on the outside layer  12  that will not seal on itself, such as a paper layer or a non-sealing polymer layer, so that only the inside layer  16  is used as a sealing surface. 
   Typical back seals formed using the film composition shown in  FIG. 1  are illustrated in  FIGS. 2   a  and  2   b .  FIG. 2   a  is a schematic of a “lap seal” embodiment of a back seal being formed on a tube of film, which can be used when the outside and inside layers are sealable together.  FIG. 2   b  illustrates a “fin seal” embodiment of a back seal being formed on a tube of film, which can be used when the outside layer is not suitable as a sealing surface. 
   With reference to  FIG. 2   a , a portion of the inside metalized layer  26  is mated with a portion of the outside layer  20  in the area indicated by the arrows to form a lap seal. The seal in this area is accomplished by applying heat and pressure to the film in such area. The lap seal design shown in  FIG. 2   a  insures that the product to be placed inside the formed package will be protected from the ink layer by the metalized inside layer  26 . 
   The fin seal variation shown in  FIG. 2   b  also provides that the product to be placed in the formed package will be protected from the ink layer by the metalized inside layer  26 . Again, the outside layer  20  does not contact any product. In the embodiment shown in  FIG. 2   b , however, the inside layer  26  is folded over and then sealed on itself in the area indicated by the arrows. Again, this seal is accomplished by the application of heat and pressure to the film in the area illustrated. 
   Regardless of whether a lap seal or fin seal is used for constructing a standard package using a vertical form, fill, and seal packaging machine, the end result is a package as shown in  FIG. 3a  with horizontally oriented top and bottom transverse seals  31 ,  33 . Such package is referred to in the art as a “vertical flex bag” or “pillow pouch,” and is commonly used for packaging snack foods such as potato chips, tortilla chips, and other various sheeted and extruded products. The back seal discussed with reference to  FIGS. 2   a  and  2   b  runs vertically along the bag and is typically centered on the back of the package shown in  FIG. 3   a , thus not visible in  FIG. 3   a . Because of the narrow, single edge base on the package shown in  FIG. 3   a  formed by the bottom transverse seal  33 , such prior art packages are not particularly stable when standing on one end. This shortcoming has been addressed in the packaging industry by the development of a horizontal stand-up pouch such as the embodiment illustrated in  FIGS. 4   a ,  4   b , and  4   c . As can be seen by reference to said Figures, such horizontal stand-up pouch has a relatively broad and flat base  47  having two contact edges. This allows for the pouch to rest on this base  47  in a vertical presentation. Manufacture of such horizontal stand-up pouches, however, does not involve the use of standard vertical form, fill, and seal machines but, rather, involves an expensive and relatively slow 3-piece construction using a pouch form, fill, and seal machine. 
   Referring to  FIGS. 4   b  and  4   c , the horizontal stand-up pouch of the prior art is constructed of three separate pieces of film that are mated together, namely, a front sheet  41 , a rear sheet  43 , and a base sheet  45 . The front sheet  41  and rear sheet  43  are sealed against each other around their edges, typically by heat sealing. The base sheet  45  is, however, first secured along its outer edges to the outer edges of the bottom of the front sheet  41  and rear sheet  43 , as is best illustrated in  FIG. 4   c . Likewise, the mating of the base sheet  45  to the front sheet  41  and the rear sheet  43  is also accomplished typically by a heat seal. The requirement that such horizontal stand-up pouch be constructed of three pieces results in a package that is significantly more expensive to construct than a standard form, fill, and seal vertical flex bag. 
   Further disadvantages of using horizontal stand-up pouches include the initial capital expense of the horizontal stand-up pouch machines, the additional gas flush volume required during packaging as compared to a vertical flex bag, increased down time to change the bag size, slower bag forming speed, and a decreased bag size range. For example, a Polaris model vertical form, fill, and seal machine manufactured by Klick Lock Woodman of Georgia, USA, with a volume capacity of 60–100 bags per minute costs in the range of $75,000.00 per machine. A typical horizontal stand-up pouch manufacturing machine manufactured by Roberts Packaging of Battle Creek, Mich., with a bag capacity of 40–60 bags per minute typically costs $500,000.00. The film cost for a standard vertical form, fill, and seal package is approximately $0.04 per bag with a comparable horizontal stand-up pouch costing roughly twice as much. Horizontal stand-up pouches further require more than twice the oxygen or nitrogen gas flush. Changing the bag size on a horizontal stand-up pouch further takes in excess of two hours, typically, while a vertical form and fill machine bag size can be changed in a matter of minutes. Also, the typical bag size range on a horizontal stand-up pouch machine is from 4 oz. to 10 oz., while a vertical form and fill machine can typically make bags in the size range of 1 oz. to 24 oz. 
   One current advantage of a horizontal stand-up pouch machine over a vertical form, fill, and seal machine, however, is the relatively simple additional step of adding a zipper seal at the top of the bag for reclosing of the bag. Vertical form, fill, and seal machines typically require substantial modification and/or the use of zipper seals premounted on the film oriented horizontally to the seal facings used to seal the horizontal transverse seals. 
   An alternative approach taken in the prior art to producing a bag with more of a stand-up presentation is the construction of a flat bottom bag such as illustrated in  FIG. 3   b . Such bag is constructed in a method very similar to that described above with regard to prior art pillow pouches. However, in order to form the vertical gussets  37  on either side of the bag, the vertical form, fill, and seal machine must be substantially modified by the addition of two movable devices on opposite sides of the sealing carriage that moves in and out to make contact with the packaging film tube in order to form the tuck that becomes the gussets  37  shown in  FIG. 3   b . Specifically, when a tube is pushed down to form the next bag, two triangular shaped devices are moved horizontally towards the packaging film tube until two vertical tucks are formed on the packaging film tube above the transverse seals by virtue of contact with these moving triangular shaped devices. While the two triangular shaped devices are thus in contact with the packaging tube, the bottom transverse seal  33  is formed. The package is constructed with an outer layer  30  that is non-sealable, such as paper. This causes the formation of a V-shaped gusset  37  along each vertical edge of the package when the transverse seals  31 ,  33  are formed. While the triangular shaped devices are still in contact with the tube of packaging material, the product is dropped through the forming tube into the tube of packaging film that is sealed at one end by virtue of the lower transverse seal  33 . The triangular shaped devices are then removed from contact with the tube of packaging film and the film is pushed down for the formation of the next package. The process is repeated such that the lower transverse seal  33  of the package above and upper transverse seal  31  of the package below are then formed. This transverse seal is then cut, thereby releasing a formed and filled package from the machine having the distinctive vertical gussets  37  shown in  FIG. 3   b.    
   The prior art method described above forms a package with a relatively broad base due to the V-shaped vertical gussets  37 . Consequently, it is commonly referred to in the art as a flat bottom bag. Such flat bottom bag is advantageous over the previously described horizontal stand-up pouch in that it is formed on a vertical form, fill, and seal machine, albeit with major modifications. However, the prior art method of making a flat bottom bag has a number of significant drawbacks. For example, the capital expense for modifying the vertical form, fill, and seal machine to include the moving triangular-shaped devices is approximately $30,000.00 per machine. The changeover time to convert a vertical form, fill, and seal machine from a standard pillow pouch configuration to a stand-up bag configuration can be substantial, and generally in the neighborhood of one-quarter man hours. The addition of all of the moving parts required for the triangular-shaped device to move in and out of position during each package formation cycle also adds complexity to the vertical form, fill, and seal machine, inevitably resulting in maintenance issues. Importantly, the vertical form, fill, and seal machine modified to include the moving triangular-shaped devices is significantly slower than a vertical form, fill, and seal machine without such devices because of these moving components that form the vertical gussets. For example, in the formation of a six inch by nine inch bag, the maximum run speed for a modified vertical form, fill, and seal machine using the triangular-shaped moving devices is in the range of 15 to 20 bags per minute. A standard vertical form, fill, and seal machine without such modification can construct a similarly sized pillow pouch at the rate of approximately 40 bags per minute. 
   Consequently, a need exists for a method to form a stand-up pouch, similar in appearance and functionality to the prior art horizontal stand-up pouches or prior art flat bottom bags, using vertical form, fill, and seal machine technology and a single sheet of packaging film. Moreover, a need also exists for a method of incorporating a zipper seal into such a formed stand-up pouch using the vertical form, fill, and seal machine technology. These methods should allow for reduced film cost per bag as compared to horizontal stand-up pouches, ease in size change, and little capital outlay, all while maintaining bag forming speeds typical of vertical form, fill, and seal machine pillow pouch production. Such methods should ideally produce a vertical stand-up pouch or a flat bottom bag having a zipper seal incorporated therein, and constructed of materials commonly used to form standard vertical flex bags without adding complexity or moving parts to a standard vertical form, fill, and seal machine. 
   SUMMARY OF THE INVENTION 
   The proposed invention involves producing a vertical stand-up pouch or package having a zipper seal mechanism incorporated therein constructed of a single sheet of material using a vertical form, fill, and seal machine. The vertical form, fill, and seal machine may be specifically constructed to produce such a package or comprise a standard vertical form, fill, and seal machine which is slightly modified with a quick change module comprising a tension insertion mechanism in line with a longitudinal channel formed adjacent to the form/fill tube and a pair of forming plates located below the forming/filling tube and at least one stationary tucker mechanism mounted to the frame of the machine. The tucker mechanism is positioned between a pair of forming plates, thereby creating a vertical tuck along the length of the package while it is being formed. 
   Conversely, a length of zipper seal mechanism may be inserted and attached along a longitudinal length of the package on an opposing side from the side into which the vertical tuck is formed. The zipper seal mechanism is typically comprised of two interlocking and opposing members, each of which include a profile portion, which interlocks with a complementary profile portion on the other member, and a tab portion extending away from the profile portion. 
   The zipper seal mechanism is typically supplied from a supply spool, which feeds the zipper seal mechanism to a longitudinal channel formed in or adjacent to the forming/filling tube of the vertical form, fill, and seal machine. The length of zipper seal mechanism may comprise either a continuous length of the zipper seal mechanism or separate segment lengths of zipper seal mechanism interspersed along an interconnecting webbing. 
   The length of zipper seal mechanism is attached to the packaging material while the material is being formed into a tubular shape. A reciprocating heat sealing mechanism attaches at least a portion of the tab portions of the each of the interlocked members comprising the zipper seal mechanism to an interior surface of the tubular shaped material prior to a longitudinal heat sealing mechanism applying a vertical back seal to the tubular shaped material. 
   A tension insertion mechanism located at the bottom of the forming/filling tube blouses the packaging film pushing the zipper seal mechanism into the interior of the package thereby creating a headspace between the film and the interlocked profiled portions of the zipper seal mechanism. The creation of the headspace improves the sealing qualities of the traverse sea subsequently applied to the package. 
   The graphics on the package are oriented 90° from a standard presentation when using the invention to make a vertical stand-up pouch. The transverse seals on such formed package are therefore oriented vertically when the bag is placed on display. Consequently, the vertical tuck is situated at the resulting package&#39;s base while the zipper seal mechanism is situated on the interior of the top of the resulting package. 
   The method disclosed and the package formed as a consequence is a substantial improvement over prior art horizontal stand-up pouches or packages. The method works on existing vertical form, fill, and seal machines requiring very little modification. There are no substantial moving parts or jaw carriage modifications involved. The vertical form, fill, and seal machines can be easily converted back to a pillow pouch configuration with a simple module change. The same metalized or clear laminations used as materials in pillow pouches can also be used with the invention therefore saving in per bag cost. 
   The invention may also include a quick change module comprising the forming plates and, when making vertical stand-up pouches, a tension insertion mechanism on the opposite side of the forming tube from the crease forming plates. The module easily attaches to the bottom of the forming tube, thereby making conversion back to a standard pillow bag manufacture simple and quick. 
   The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein: 
       FIG. 1  is a schematic cross-section views of prior art packaging films; 
       FIG. 2   a  is a schematic cross-section view of a tube of packaging film illustrating the formation of a prior art lap seal; 
       FIG. 2   b  is a schematic cross-section of a tube of packaging film illustrating the formation of a prior art fin seal; 
       FIG. 3   a  is a perspective view of a prior art vertical flex bag; 
       FIG. 3   b  is a perspective view of a prior art flat bottom bag; 
       FIGS. 4   a ,  4   b , and  4   c  are perspective views in elevation of a prior art horizontal stand-up pouch; 
       FIG. 5   a  is a schematic cross-section of a tube of packaging film formed by the vertical stand-up pouch embodiment of the present invention methods; 
       FIG. 5   b  is a schematic cross-section of a tube of packaging film formed by the flat bottom bag embodiment of the present invention methods; 
       FIG. 5   c  is a schematic cross-section of a tube of packaging film formed by the vertical stand-up pouch having a zipper seal incorporated therein embodiment of the present invention methods; 
       FIG. 5   d  is an enlarged view of the top of the schematic cross-section of a tube of packaging film formed by the vertical stand-up pouch having a zipper seal incorporated therein shown in  FIG. 5   c;    
       FIG. 6   a  is a perspective view of the tucker mechanism, forming plates, and tension bar in elevation of the vertical stand-up pouch embodiment of the present invention in relation to a forming tube and sealing jaws of a vertical form, fill, and seal machine; 
       FIG. 6   b  is a perspective view of the tucker mechanism and forming plates in elevation of the flat bottom bag embodiment of the present invention in relation to a forming tube and sealing jaws of a vertical form, fill, and seal machine; 
       FIG. 6   c  is a perspective view of the tucker mechanism, forming plates, and zipper seal insertion mechanism in elevation of the vertical stand-up pouch having a zipper seal incorporated therein embodiment of the present invention in relation to a forming tube and sealing jaws of a vertical form, fill, and seal machine; 
       FIGS. 7   a  and  7   b  are perspective views of the vertical stand-up pouch of the present invention; 
       FIGS. 7   c  and  7   d  are perspective views of the vertical stand-up pouch having a zipper seal incorporated therein of the present invention; 
       FIG. 8  is a perspective view of one embodiment of the tucker mechanism of the present invention; 
       FIG. 9   a  is a perspective view of one embodiment of the quick change module of the present invention in elevation below the bottom of a forming tube; 
       FIG. 9   b  is a sectional view of one embodiment of the quick change module attached to the bottom of a forming tube, said sectional view taken along lines  9   b — 9   b  of  FIG. 9   a;  and 
       FIG. 9   c  is a side view in elevation of one embodiment of the quick change module of the present invention. 
       FIG. 10  is a cross-sectional view of one embodiment of interlocking zipper elements comprising a zipper seal mechanism utilized in the form, fill, and seal packaging machine of the present invention; 
       FIG. 11  is a simplified perspective view of a form, fill, and seal packaging machine adapted to manufacture a stand-up pouch having a zipper seal incorporated therein in accordance with the present invention; 
       FIG. 12   a  is a simplified sectional view of a first embodiment of a zipper heat seal bar, said sectional view taken along lines  12 — 12  of  FIG. 11 ; 
       FIG. 12   b  is a simplified sectional view of a second embodiment of a zipper heat seal bar, said sectional view taken along lines  12 — 12  of  FIG. 11 ; 
       FIG. 13   a  is a perspective view of one embodiment of the zipper seal insert quick change module of the present invention in elevation below the bottom of a forming tube; 
       FIG. 13   b  is a sectional view of one embodiment of the zipper seal insert quick change module attached to the bottom of a forming tube, said sectional view taken along lines  13   b — 13   b  of  FIG. 13   a;    
       FIG. 13   c  is a reverse perspective view of a transition tension mechanism in the embodiment of the zipper seal insert quick change module of the present invention shown in  FIG. 13   a;  and 
       FIG. 13   d  is a simplified sectional view of the transition tension mechanism, said sectional view taken along lines  13   d — 13   d  of  FIG. 13   c.    
   

   Where used in the various figures of the drawing, the same numerals designate the same or similar parts. Furthermore, when the terms “top,” “bottom,” “first, ” “second,” “upper,” “lower,” “height,” “width,” “length,” “end,” “side,” “horizontal,” “vertical,” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the invention. 
   All figures are drawn for ease of explanation of the basic teachings of the present invention only; the extensions of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements will likewise be within the skill of the art after the following teachings of the present invention have been read and understood. 
   DETAILED DESCRIPTION OF THE INVENTION 
   A. Vertical Stand-Up Pouch 
     FIGS. 5   a  and  6   a  illustrate the basic components used with the method of the proposed invention as it relates to the manufacture of a vertical stand-up pouch. The same reference numbers are used to identify the same corresponding elements throughout all drawings unless otherwise noted.  FIG. 5   a  is a schematic cross-section of a tube of packaging material (film) formed by the present invention method. The tube of packaging film shown in  FIG. 5   a  is illustrated as a cross-sectional area immediately below the forming tube  101  of  FIG. 6   a . The tube of packaging film comprises an outer layer  116  and an inner layer  110 , and can comprise material typically used in the field of art for making a standard vertical flex bag, such as discussed in relation to  FIG. 1 . The tube in  FIG. 5   a  has been formed by sealing one sheet of film with a vertical back seal, as previously described with regard to discussions of prior art vertical form and fill machine methods. 
     FIG. 6   a  shows a forming tube  101  typical in most respects to those used with prior art vertical form, fill, and seal machines. This forming tube  101  can be a cylinder, have a rectangular cross section, or any number of shapes, but is preferably cylindrical as illustrated. The film illustrated in  FIG. 5   a  is initially formed around the forming tube  101  of  FIG. 6   a . This forming tube  101  is shown in elevation but would normally be integrally attached to the vertical form, fill, and seal machine. Also shown in  FIG. 6   a  are a pair of prior art sealing jaws  108  likewise illustrated in elevation. Not shown in  FIG. 6   a  is the sealing jaw carriage on which such sealing jaws  108  would be mounted below the forming tube  101 . 
   As previously described, the practice in the prior art in the manufacture of a vertical flex bag involves feeding a continuous packaging film directed around the forming tube  101 . A back seal is formed on a single layer of film in order to create a tube of film around the forming tube  101 . The seal jaws  108  close on the thus formed tube of packaging film, thereby forming a bottom transverse seal. Product is then dropped through the forming tube  101  into the tube of packaging film. The tube is then driven downward by friction against rotating belts (not shown), and the seal jaws  108  are used to form another transverse seal above the level of the product found inside the tube. This seal is subsequently cut horizontally such that a top transverse seal is formed at the top of the filled bag below and a bottom transverse seal is formed on the tube of packaging film above. The packaging film during the prior art operation described above is oriented perpendicular to the longitudinal translation of the film so as to be readable by an operator of the machine as the film travels down the forming tube  101 . This orientation provides graphics  39  on the formed prior art bag that are readable by a consumer when the formed bag is placed on a retail display shelf while resting on its bottom transverse seal  33  as seen in  FIG. 3   a . As will be described in further detail below, the orientation of the graphics on the film packaging for Applicants&#39; invention is 90° off of the prior art orientation, such that the graphics appear sideways as viewed by the operator of the vertical form and fill machine as the film is pulled down the forming tube  101  of  FIG. 6   a . In other words, the graphics on the packaging film are oriented perpendicular to the direction of film travel. 
   The invention adds three basic components to a prior art vertical form, fill, and seal machine. Two forming plates  104  and one tension bar  102  are used to hold the packaging film tube in tension from inside the tube, as indicated by the arrows illustrated on  FIG. 5   a . As shown in  FIG. 6   a , the forming plates  104  and tension bar  102  can be attached directly to the forming tube  101  or, alternatively, to any supporting structure on the vertical form, fill, and seal machine, as long as the forming plates  104  and tension bar  102  are positioned within the tube of packaging material, below the bottom of the forming tube  101 , and above the heat sealing jaws  108 . 
   Tension is applied on the outside of the film and in the opposite direction of the tension provided by the forming plates  104  by a fixed or stationary tucker mechanism  106 , alternatively referred to herein as a tucker bar  106 , positioned between said forming plates  104 . The tucker bar  106  is preferably attached to the sealing carriage for the vertical form, fill, and seal machine and is adjustable along all three axes (in/out, up/down, and front/back). Alternatively, the tucker bar  106  can be attached to the frame of the vertical form, fill, and seal machine or any other point that can supports its function outside the film tube. These adjustments in all three axes allow for the tucker bar  106  to be easily moved out of the way to convert the vertical form and fill machine back to standard operation and is accomplished, in the embodiment shown in  FIG. 6   a , by a tension screw  162  that can lock the tucker bar  106  in place when tightened. While the tucker bar  106  is adjustable, unlike in the prior art, it is fixed or stationary during operation. Therefore, the present invention is a substantial improvement over the art in that there are no moving parts to the tucker mechanism during bag making. This improvement is what Applicants intend to describe when referring to the tucker bar  106  as “stationary” or “fixed.” Because of this stationary tucker bar feature, bag making speeds can match typical pillow pouch manufacturing rates. 
   When moved forward into position (i.e., toward the forming plates  104 ), the tucker bar  106  provides a crease or fold in the tube of the packaging film between the two forming plates  104 . This crease is formed prior to formation of the transverse seal by the seal jaws  108 . Consequently, once the transverse seal is formed, the crease becomes an integral feature of one side of the package. The vertical form and fill machine thereafter operates basically as previously described in the prior art, with the sealing jaws  108  forming a lower transverse seal, product being introduced through the forming tube  101  into the sealed tube of packaging film (which now has a crease on one side), and the upper transverse seal being formed, thereby completing the package. The major differences between a prior art package and Applicants&#39; package, however, are that a crease is formed on one side (which later becomes the bottom of the formed package) using the fixed mechanism described and that the graphics on the packaging film used by the invention are oriented such that when the formed package is stood onto the end with the crease, the graphics are readable by a consumer. 
   An example of the formed package of the instant invention is shown in  FIGS. 7   a  and  7   b , which show the outside layer of the packaging film  116  with the graphics  179  oriented as previously described. As can be seen from  FIGS. 7   a  and  7   b , the construction of the invention&#39;s vertical stand-up pouch shares characteristics with the prior art vertical flex bags shown in  FIG. 3   a . However, the transverse seals  131 ,  133  of the vertical stand-up bag of the invention are oriented vertically once the bag stands up on one end, as shown in  FIG. 7   b .  FIG. 7   a  shows the crease  176  that was formed by the tucker bar  106  and forming plates  104  discussed in relation to  FIGS. 5   a  and  6   a.    
   Returning to  FIG. 6   a , another optional feature that can be incorporated into this invention is the use of a diversion plate  160  within the forming tube  101 . This diversion plate  160 , in the embodiment illustrated, is a flat plate welded vertically inside the forming tube  101  that extends from the bottom of the forming tube  101  to some distance above (for example, at least two or three inches) the bottom of the forming tube  101 , where it then is sealed against the inside of the forming tube  101 . 
   The diversion plate  160  in a preferred embodiment accomplishes two functions. First, the diversion plate  160  keeps product that is dropped down the forming tube  101  away from the area where the crease is being formed on the tube of packaging film. Second, the diversion plate  160 , can be used as a channel for a gas or nitrogen flush. In such instance, the diversion plate  160  at some point above the bottom of the forming tube  101  seals at the top of the plate  160  against the forming tube  101 . Below such seal (not shown) an orifice can be drilled into the forming tube  101  in order to provide gas communication between an exterior gas (for example, nitrogen or oxygen) source and the cavity formed between the diversion plate  160  and the interior of the forming tube  101 . The diversion plate  160  as shown in  FIG. 6   a  is a flat plate, but it should be understood that it can be of any variety of shapes, for example, having a curved surface, provided that it accomplishes the functionality of diverting the product away from the area where the tuck is formed on the tube of film. 
   By using the diversion plate  160  as a channel for the gas flush, the present invention eliminates the need for a separate gas tube to be placed inside the forming tube  101  that normally accomplishes the same function in the prior art. The added benefit of providing a relatively large volume channel formed by the diversion plate  160  and the interior of the forming tube  101  is that a relatively large volume of flushing gas can be introduced into a filled and partially formed package at a significantly lower gas velocity compared to prior art gas tubes. This allows for the filling of packages using this embodiment of the present invention that may contain low weight product that might otherwise be blown back into the forming tube by prior art flushing tubes. 
     FIG. 8  illustrates a preferred embodiment of the tucker bar  106 . This embodiment of the tucker bar  106  comprises a head  180  attached to a support  182 . Drilled within the support  182  and head  180  is a gas channel  184  shown in phantom on  FIG. 8 . This gas channel  184  provides a gas communication from an exterior gas source (not shown) through the support  182 , through the head  180 , and out three orifices  186 . The gas channel  184  allows for a metered burst of pressurized gas (typically air) that helps keep the tuck illustrated in  FIG. 5   a  taut throughout the forming and sealing operation without the necessity of moving the tucker bar in and out during bag formation. It should be noted that during operation (bag making) the tucker bar  106  is always stationary. It should further be noted that the head  180  necessarily cannot extend along the entire length of the crease formed by the tucker bar  106  and forming plates  104 . Further, it should be understood that when the sealing jaws  108  close onto the tube of film, the lateral dimensions of the tube of film change. All of these facts are compensated for by the use of the pressurized air bursting from the orifices  186 . The pressurized air keeps an even amount of pressure on the tuck as it is being formed in the various stages of the forming and sealing process. The air burst can be continuous, but is preferably metered to start as the film for the next bag is being pulled down through the completion of the transverse seal. 
   The head  180  can comprise any non-stick material but is preferably a fluoropolymer, such as Teflon®. In an alternative embodiment, the tucker bar  106  can comprise one integral piece of metal with the head portion  180  being coated with a fluoropolymer. The curved contact area of the head  180  allows for the continuous formation of the tuck illustrated in  FIG. 5   a  without tearing the packaging film as it is pushed down below the forming tube. While shown with three orifices  186 , the head  180  can comprise any number of orifices from one on. 
   To further compensate for the change in the width of the film tube as the transverse seal is formed by the seal jaws  108  of  FIG. 6   a , it should be noted that the tension bar  102  bends outwardly away from the center of said tube of film along the length of the tension bar  102  and the forming plates  104  are hinged by a horizontal hinge  165 . If the tension bar  102  is designed otherwise (e.g., strictly vertical) excess slack occurs in the area of the film tube near the transverse seal. The forming plates  104  comprise horizontal hinges  165  that allow the forming plates to fold inward (i.e., toward each other) slightly while the lower transverse seal is formed. Otherwise, the tube of packaging film would be ripped by the tips of the forming plates  104  during this step. 
   The present invention offers an economic method of producing a stand-up pouch with numerous advantages over prior art horizontal stand-up pouches and methods for making them. 
   Examples of these advantages are illustrated in Table 1 below. 
   
     
       
         
             
             
             
             
           
             
                 
               TABLE 1 
             
             
                 
                 
             
             
                 
                 
               Commercially 
                 
             
             
                 
                 
               Available 
               Applicants&#39; 
             
             
                 
               Current 
               Horizontal 
               Vertical 
             
             
                 
               Vertical 
               Stand-Up 
               Stand-Up 
             
             
                 
               Flex Bag 
               Pouches 
               Bag 
             
             
                 
                 
             
           
          
             
                 
             
          
         
         
             
             
             
             
          
             
               Machine Type 
               Standard 
               Pouch Form, 
               Standard 
             
             
                 
               Vertical FFS 
               Fill, Seal 
               Vertical FFS 
             
             
               Machine Cost 
               $75,000.00 
               $500,000.00 
               $75,000.00 
             
             
               Film Cost 
               $0.04/bag 
               $0.08/bag 
               $0.04/bag 
             
             
               Gas Flush 
               Less than 2% O 2   
               Only to 5% O 2   
               Less than 2% O 2   
             
             
               Size Change 
               Easy, 
               2 hours 
               Easy, 
             
             
                 
               change former 
                 
               change former 
             
             
               Format Change 
               Flex Bag Only 
               Stand-Up Pouch 
               Both, 
             
             
                 
                 
               Only 
               simple change 
             
             
               Continuous 
               No 
               Yes 
               Yes 
             
             
               Feed Zipper 
             
             
               Option 
             
             
               Bag Size 
               (Width/Height) 
               (Width/Height) 
               (Width/Height) 
             
             
               Range in 
               5/5 through 
               5/5 through 
               5/5 through 24/11 
             
             
               Inches 
               14/24 
               10/12 
             
             
                 
             
          
         
       
     
   
   As noted above and will be described in further detail below, a continuous feed zipper option is available on Applicants&#39; invention, which is not available using current vertical form, fill, and seal machine technology. This is because of the orientation of the film graphics used on the packaging film of the present invention. Since the graphics are oriented 90° from the prior art, a zipper seal can be run continuously in a vertical line down the forming tube along with the packaging film as it is being formed into a tube and subsequent package. This is not possible with the prior art, because such orientation of a continuous vertical strip of a zipper seal would place such seal in a vertical orientation once the package is formed and stood up for display. 
   The invention is further an improvement over methods for manufacturing prior art flat bottom bags. Since the tucker mechanism of Applicants&#39; invention is stationary during bag formation, the present invention eliminates the need for moving parts that push against the film tube for the formation of a gusset. This elimination of moving parts allows for increased bag production rates, significantly lower changeover times to pillow pouch production, and significantly fewer maintenance issues. 
   B. Flat Bottom Bag 
     FIGS. 5   b  and  6   b  illustrate the basic components used with the method of the proposed invention as it relates to the manufacture of a flat bottom bag.  FIG. 5   b  is a schematic cross-section of a tube of packaging material (film) formed by the present invention method. The tube of packaging film shown in  FIG. 5   b  is illustrated as a cross-sectional area immediately below the forming tube  101  of  FIG. 6   b  (shown in phantom in  FIG. 5   b ). The tube of packaging film comprises an outer layer  116  and an inner layer  110 , and can comprise material typically used in the field of art for making a standard vertical flex bag, such as discussed in relation to  FIG. 1 . However, for reasons that will become apparent from the discussion below, a preferred embodiment of the bag of the present invention comprises an outside layer  116  that is not sealable on itself, such as paper. The tube in  FIG. 5   b  has been formed by sealing one sheet of film with a vertical back seal, as previously described with regard to discussions of prior art vertical form and fill machine methods. 
     FIG. 6   b  shows a forming tube  101  typical in most respects to those used with prior art vertical form, fill, and seal machines. This forming tube  101  can be a cylinder, have a rectangular cross section, or any number of shapes, but is preferably cylindrical as illustrated. The film illustrated in  FIG. 5   b  is initially formed around the forming tube  101  of  FIG. 6   b . This forming tube  101  is shown in elevation but would normally be integrally attached to the vertical form, fill, and seal machine. Also shown in  FIG. 6   b  are a pair of prior art sealing jaws  108  likewise illustrated in elevation. Not shown in  FIG. 6   b  is the sealing jaw carriage on which such sealing jaws  108  would be mounted below the forming tube  101 . 
   As previously described, the practice in the prior art in the manufacture of a vertical flex bag involves feeding a continuous packaging film directed around the forming tube  101 . A back seal is formed on a single layer of film in order to create a tube of film around the forming tube  101 . The seal jaws  108  close on the thus formed tube of packaging film, thereby forming a bottom transverse seal. Product is then dropped through the forming tube  101  into the tube of packaging film. The tube is then driven downward by friction against rotating belts (not shown) and the seal jaws  108  are used to form another transverse seal above the level of the product found inside the tube. This seal is subsequently cut horizontally such that a top transverse seal is formed at the top of the filled bag below and a bottom transverse seal is formed on the tube of packaging film above. The packaging film during the prior art operation described above is oriented perpendicular to the longitudinal translation of the film so as to be readable by an operator of the machine as the film travels down the forming tube  101 . This orientation provides graphics  39  on the formed prior art bag that are readable by a consumer when the formed bag is placed on a retail display shelf while resting on its bottom transverse seal  33  as seen in  FIG. 3   a.    
   The invention adds two basic components to a prior art vertical form, fill, and seal machine. Two pair of stationary or fixed forming plates  104 ,  105  are used to hold the packaging film tube in tension from inside the tube, as indicated by the arrows illustrated on  FIG. 5   b . As shown in  FIG. 6   b , the forming plates  104 ,  105  can be attached directly to the forming tube  101  or, alternatively, to any supporting structure on the vertical form, fill, and seal machine, as long as the forming plates  104 ,  105  are positioned within the tube of packaging material, below the bottom of the forming tube  101 , and above the heat sealing jaws  108 . 
   Tension is applied on the outside of the film and in the opposite direction of the tension provided by the forming plates  104 ,  105  by two stationary or fixed tucker mechanisms  106 ,  107 , alternatively referred to herein as tucker bars  106 ,  107 , positioned between said forming plates  104 ,  105 . The tucker bars  106 ,  107  are preferably attached to the sealing carriage for the vertical form, fill, and seal machine and are adjustable along all three axes (in/out, up/down, and front/back). Alternatively, the tucker bars  106 ,  107  can be attached to the frame of the vertical form, fill, and seal machine or any other point that can supports their function outside the film tube. These adjustments in all three axes allow for the tucker bars  106 ,  107  to be easily moved out of the way to convert the vertical form and fill machine back to standard operation and is accomplished, in the embodiment shown in  FIG. 6   b , by a tension screw  162  that can lock the tucker bars  106 ,  107  in place when tightened. While the tucker bars  106 ,  107  are adjustable, unlike in the prior art, they are fixed or stationary during operation. Therefore, the present invention is a substantial improvement over the art in that there are no moving parts to the tucker mechanism during bag making. This improvement is what Applicants intend to describe when referring to the tucker bars  106 ,  107  as “stationary” or “fixed.” Because of this stationary tucker bar feature, bag making speeds can match typical pillow pouch manufacturing rates, modification costs are low (such as 3 to 4 thousand dollars per machine), and no additional maintenance issues are introduced. 
   When moved forward into position (i.e., toward the forming plates  104 ,  105 ), the tucker bars  106 ,  107  provide a crease or fold in the tube of the packaging film between the two forming plates  104 ,  105 . This crease is formed prior to formation of the transverse seal by the seal jaws  108 . Consequently, once the transverse seal is formed, the crease becomes an integral feature of two sides of the package, referred to as gussets. As shown in  FIG. 3   b , these gussets  37  form a “V” shape on each end of the horizontal transverse seals  31 ,  33  because the outer layer of packaging film used to form the bag comprises a material that does not seal on itself, such as paper. In an alternative embodiment, the outside layer  30  of the film comprises a material that seals on itself, thereby closing the ends of the “V” shaped gussets illustrated in  FIG. 3   b.    
   After the transverse seals are formed, the vertical form and fill machine thereafter operates basically as previously described in the prior art, with the sealing jaws  108  forming a lower transverse seal, product being introduced through the forming tube  101  into the sealed tube of packaging film (which now has a vertical crease on two opposite sides), and the upper transverse seal being formed, thereby completing the package. A major difference between a prior art package and Applicants&#39; package, however, is that a gusset is formed on each side of the package of the present invention using the fixed mechanism described. 
   An example of the formed package of the instant invention is shown in  FIG. 3   b , which shows the outside layer of the packaging film  30  with the graphics  38  oriented as previously described. As can be seen from  FIG. 3   b , the construction of the invention&#39;s flat bottom bag shares characteristics with the prior art vertical flex bags shown in  FIG. 3   a .  FIG. 3   b  shows the gussets  37  that were formed by the tucker bars  106 ,  107  and forming plates  104 ,  105  discussed in relation to  FIGS. 5   b  and  6   b.    
   Returning to  FIG. 6   b , another optional feature that can be incorporated into this invention is the use of one or two diversion plates  160  within the forming tube  101 . These diversion plates  160 , in the embodiment illustrated, comprise a flat plate welded vertically inside the forming tube  101  that extends from the bottom of the forming tube  101  to some distance above (for example, at least two or three inches) the bottom of the forming tube  101 , where it then is sealed against the inside of the forming tube  101 . 
   The diversion plates  160  in a preferred embodiment accomplish two functions. First, the diversion plates  160  keeps product that is dropped down the forming tube  101  away from the area where the crease is being formed on the tube of packaging film. Second, the diversion plates  160 , if properly sealed against the forming tube  101 , can be used as channels for a gas or nitrogen flush. In such instance, at least one, but preferably both diversion plates  160  at some point above the bottom of the forming tube  101  seal at the top of the plate  160  against the forming tube  101 . Below such seal (not shown) one or more orifices can be drilled into the forming tube  101  in order to provide gas communication between an exterior gas (for example, nitrogen or oxygen) source and the cavity formed between a diversion plate  160  and the interior of the forming tube  101 . The diversion plates  160  are shown in  FIG. 6   b  as a flat plate, but it should be understood that they could be of any variety of shapes, for example, having a curved surface, provided that they accomplish the functionality of diverting the product away from the area where the tucks are formed on the tube of film. 
   By using one or more of the diversion plates  160  as a channel for the gas flush, the present invention eliminates the need for a separate gas tube to be placed inside the forming tube  101  that normally accomplishes the same function in the prior art. The added benefit of providing a relatively large volume channel formed by a diversion plate  160  and the interior of the forming tube  101  is that a relatively large volume of flushing gas can be introduced into a filled and partially formed package at a significantly lower gas velocity compared to prior art gas tubes. This allows for the filling of packages using this embodiment of the present invention that may contain low weight product that might otherwise be blown back into the forming tube by prior art flushing tubes. 
     FIG. 8  illustrates a preferred embodiment of a tucker bar  106 . This embodiment of a tucker bar  106  comprises a head  180  attached to a support  182 . Drilled within the support  182  and head  180  is a gas channel  184  shown in phantom on  FIG. 8 . This gas channel  184  provides a gas communication from an exterior gas source (not shown) through the support  182 , the head  180 , and out three orifices  186 . The gas channel  184  allows for a metered burst of pressurized gas (typically air) that helps keep the tuck illustrated in  FIG. 5   b  taut throughout the forming and sealing operation without the necessity of moving the tucker bar in and out during bag formation. It should be noted that during operation (bag making) the tucker bar  106  is always stationary. It should further be noted that the head  180  necessarily cannot extend along the entire length of the crease formed by the tucker bar  106  and forming plates  104 . Further, it should be understood that when the sealing jaws  108  close onto the tube of film, the lateral dimensions of the tube of film change. All of these facts are compensated for by the use of the pressurized air bursting from the orifices  186 . The pressurized air keeps an even amount of pressure on the tuck as it is being formed in the various stages of the forming and sealing process. The air burst can be continuous, but is preferably metered to start as the film for the next bag is being pulled down through the completion of the transverse seal. 
   The head  180  can comprise any non-stick material but is preferably a fluoropolymer, such as Teflon®. In an alternative embodiment, the tucker bar  106  can comprise one integral piece of metal with the head portion  180  being coated with a fluoropolymer. The curved contact area of the head  180  allows for the continuous formation of the tuck illustrated in  FIG. 5   b  without tearing the packaging film as it is pushed down below the forming tube. While shown with three orifices  186 , the head  180  can comprise any number of orifices from one on. 
   To further compensate for the change in the width of the film tube as the transverse seal is formed by the seal jaws  108  of  FIG. 6   b , it should be noted that the forming plates  104 ,  105  are hinged by a horizontal hinge  165 . The forming plates  104 ,  105  comprise horizontal hinges  165  that allow the forming plates to fold inward (i.e., toward each other) slightly while the lower transverse seal is formed. Otherwise, the tube of packaging film would be ripped by the tips of the forming plates  104 ,  105  during this step. 
   The present invention offers an economic method of producing a flat bottom bag with numerous advantages over prior art horizontal stand-up pouches and methods for making them. 
   Examples of these advantages are illustrated in Table 2 below. 
   
     
       
         
             
             
             
             
           
             
                 
               TABLE 2 
             
             
                 
                 
             
             
                 
                 
               Commercially 
                 
             
             
                 
                 
               Available 
             
             
                 
               Current 
               Horizontal 
               Applicants&#39; 
             
             
                 
               Vertical 
               Stand-Up 
               Flat Bottom 
             
             
                 
               Flex Bag 
               Pouches 
               Bag 
             
             
                 
                 
             
           
          
             
                 
             
          
         
         
             
             
             
             
          
             
               Machine Type 
               Standard 
               Pouch Form, 
               Standard 
             
             
                 
               Vertical FFS 
               Fill, Seal 
               Vertical FFS 
             
             
               Machine Cost 
               $75,000.00 
               $500,000.00 
               $75,000.00 
             
             
               Film Cost 
               $0.04/bag 
               $0.08/bag 
               $0.04/bag 
             
             
               Gas Flush 
               Less than 2% O 2   
               Only to 5% O 2   
               Less than 2% O 2   
             
             
               Size Change 
               Easy, 
               2 hours 
               Easy, 
             
             
                 
               change former 
                 
               change former 
             
             
               Format 
               Flex Bag Only 
               Stand-Up Pouch 
               Both, 
             
             
               Change 
                 
               Only 
               simple change 
             
             
               Bag Size 
               (Width/Height) 
               (Width/Height) 
               (Width/Height) 
             
             
               Range in 
               5/5 through 
               5/5 through 
               5/5 through 
             
             
               Inches 
               14/24 
               10/12 
               11/24 
             
             
                 
             
          
         
       
     
   
   Further, the speed at which a form, fill, and seal machine modified by Applicants&#39; invention can run is not compromised by the modification, as is the case with the prior art method for making a flat bottom bag using a triangular-shaped device that is moved in and out during operation. In fact, Applicants&#39; invention allows bag production rates on the order of twice as fast as the prior art method for making the same style bag. 
   In addition, the lack of moving parts associated with the tucker mechanism of Applicants&#39; invention greatly reduces the cost of converting a vertical form, fill, and seal machine to manufacturing flat bottom bags, as well as reduces maintenance issues involved thereby. For example, converting a vertical form, fill, and seal machine to a flat bottom bag configuration using prior art devices that move in and out during operation costs in the range of $30,000.00 per machine. Applicants&#39; invention involves retrofitting existing vertical form, fill, and seal machines at a fraction, approximately 1/10th, of that cost. 
   C. Zipper Seal Insertion Mechanism 
   Another embodiment of the invention further includes an apparatus and method for producing a stand-up package having a zipper seal incorporated therein.  FIGS. 5   c  and  6   c  illustrate the basic components used with the method of the proposed invention as it relates to the manufacture of a stand-up package having a zipper seal incorporated therein. The same reference numbers are used to identify the same corresponding elements throughout all drawings unless otherwise noted.  FIG. 5   c  is a schematic cross-section of a tube of packaging material (film) formed by the present invention method. The tube of packaging film shown in  FIG. 5   c  is illustrated as a cross-sectional area immediately below the forming tube  101  of  FIG. 6   c . The tube of packaging film comprises an outer layer  116  and an inner layer  110 , and can comprise material typically used in the field of art for making a standard vertical flex bag, such as discussed in relation to  FIG. 1 . The tube in  FIG. 5   c  has been formed by sealing one sheet of film with a vertical back seal, as previously described with regard to discussions of prior art vertical form and fill machine methods. 
     FIG. 6   c  shows a forming tube  101  typical in most respects to those used with prior art vertical form, fill, and seal machines. This forming tube  101  can be a cylinder, have a rectangular cross section, or any number of shapes. This forming tube  101  includes a channel track  188  formed along one side for receiving a length of zipper seal mechanism  220 . The zipper seal mechanism  220  is typically supplied from a supply spool  218 , which feeds the zipper seal mechanism  220  to the longitudinal channel  188  formed in or adjacent to the forming tube  101  of the vertical form, fill, and seal machine. 
   The length of zipper seal mechanism  220  may comprise either a continuous length of zipper seal mechanism  220  or separate segments of zipper seal mechanism  220  interspersed along an interconnecting webbing. As shown in  FIG. 10 , the length of zipper seal mechanism  220  is comprised of two opposing and interlocking zipper elements or members  222 ,  226 . Each of the zipper members  222 ,  226  include a tab portion and an interlocking profile portion. For example, a first zipper element  222  includes a tab portion  223  and a male interlocking profile portion  224 ; while the second zipper element  226  includes a tab portion  227  and a female interlocking profile portion  228 . 
   The packaging film illustrated in  FIG. 5   c  is initially formed around the forming tube  101  of  FIG. 6   c . However, prior to sealing the one sheet of film with a vertical back seal, at least a portion of the zipper seal mechanism  220  is sealed to the surface of the packaging film which will subsequently comprise the inner layer  110  of the tube. This forming tube  101  is shown in elevation but would normally be integrally attached to the vertical form, fill, and seal machine. Also shown in  FIG. 6   c  are a pair of prior art sealing jaws  108  likewise illustrated in elevation. Not shown in  FIG. 6   c  is the sealing jaw carriage on which such sealing jaws  108  would be mounted below the forming tube  101 . 
   As previously described, the practice in the prior art in the manufacture of a vertical flex bag involves feeding a continuous packaging film directed around the forming tube  101 . A back seal is formed on a single layer of film in order to create a tube of film around the forming tube  101 . The seal jaws  108  close on the thus formed tube of packaging film, thereby forming a bottom transverse seal. Product is then dropped through the forming tube  101  into the tube of packaging film. The tube is then driven downward by friction against rotating belts (not shown), and the seal jaws  108  are used to form another transverse seal above the level of the product found inside the tube. This seal is subsequently cut horizontally such that a top transverse seal is formed at the top of the filled bag below and a bottom transverse seal is formed on the tube of packaging film above. The packaging film during the prior art operation described above is oriented perpendicular to the longitudinal translation of the film so as to be readable by an operator of the machine as the film travels down the forming tube  101 . This orientation provides graphics  39  on the formed prior art bag that are readable by a consumer when the formed bag is placed on a retail display shelf while resting on its bottom transverse seal  33  as seen in  FIG. 3   a . As described in the previous embodiments of the invention, the orientation of the graphics on the film packaging for Applicants&#39; present invention is 90° off of the prior art orientation, such that the graphics appear sideways as viewed by the operator of the vertical form, fill, and seal machine as the film is pulled down the forming tube  101  of  FIG. 6   c.    
   The present invention adds several basic components to a prior art vertical form, fill, and seal machine. Two forming plates  104  and a tension insertion mechanism  202  are used to hold the packaging film tube in tension from inside the tube, as indicated by the arrows illustrated on  FIG. 5   c . As shown in  FIG. 6   c , the forming plates  104  and tension insertion mechanism  202  can be attached directly to the forming tube  101  or, alternatively, to any supporting structure on the vertical form, fill, and seal machine, as long as the forming plates  104  and the tension insertion mechanism  202  are positioned within the tube of packaging material, below the bottom of the forming tube  101 , and above the heat sealing jaws  108 . 
   Tension is applied on the outside of the film and in the opposite direction of the tension provided by the forming plates  104  by a fixed or stationary tucker mechanism  106 , alternatively referred to herein as a tucker bar  106 , positioned between said forming plates  104 . The tucker bar  106  is preferably attached to the sealing carriage for the vertical form, fill, and seal machine and is adjustable along all three axes (in/out, up/down, and front/back). Alternatively, the tucker bar  106  can be attached to the frame of the vertical form, fill, and seal machine or any other point that can supports its function outside the film tube. These adjustments in all three axes allow for the tucker bar  106  to be easily moved out of the way to convert the vertical form and fill machine back to standard operation and is accomplished, in the embodiment shown in  FIG. 6   c , by a tension screw  162  that can lock the tucker bar  106  in place when tightened. While the tucker bar  106  is adjustable, unlike in the prior art, it is fixed or stationary during operation. Therefore, the present invention is a substantial improvement over the art in that there are no moving parts to the tucker mechanism during bag making. This improvement is what Applicants intend to describe when referring to the tucker bar  106  as “stationary” or “fixed.” Because of this stationary tucker bar feature, bag making speeds can match typical pillow pouch manufacturing rates. 
   When moved forward into position (i.e., toward the forming plates  104 ), the tucker bar  106  provides a crease or fold in the tube of the packaging film between the two forming plates  104 . This crease is formed prior to formation of the transverse seal by the seal jaws  108 . Consequently, once the transverse seal is formed, the crease becomes an integral feature of one side of the package. 
   The present invention further includes a channel track  188  formed along one side of the forming tube  101  and adapted for receiving a length of zipper seal mechanism  220  from a supply spool  218 . As will be subsequently explained, the channel track  188  may either be formed or fashioned into the sidewall of the forming tube  191  or comprise a longitudinal gap between two heat seal plates attached to the sidewall of the forming tube  191 . Regardless of the embodiment selected, the channel track  188  performs two critical functions. First, the channel track  188  effectively controls the positioning of the zipper seal mechanism  220  along the inner layer  110  of the tube. Second, the channel track  188  protects the interlocked profile portions  224 ,  228  of the zipper seal mechanism  220  from fusing together when the tab portions  223 ,  227  are heat sealed to the inner layer  110  of the formed tube. 
   Thus, in accordance with the present invention, a length of zipper seal mechanism  220  is directed to the top portion of the forming tube  101  such that the two interlocked zipper members  222 ,  226  are together threaded down the channel track  188  formed along one side of the forming tube  101 . The associated tab portions  223 ,  227  of zipper seal mechanism  220  are splayed out along the outer peripheral surface of the forming tube  101  so as not to overlap one another. Packaging film is initially formed around the forming tube  101  in a conventional manner. However, prior to sealing the one sheet of film with a vertical back seal, at least a portion of each of the tab portions  223 ,  227  of the zipper seal mechanism  220  is sealed to the surface of the packaging film which will subsequently comprise the inner layer  110  of the tube. Thus, as the formed tube is advanced down the forming tube  101  in a conventional manner, the length of zipper mechanism  220  that is sealed on the interior of the formed tube is also advanced. 
   Referring now  FIGS. 5   c ,  5   d  and  6   c , at the bottom of the forming tube  101 , the channel track  188  extends through the tension insertion mechanism  202  such that as tension is applied to the advancing formed tube, the associated tab portions  223 ,  227  of the zipper seal mechanism  220  are projected away from the surface of the forming tube  101  and bent around two projecting plates  192   a ,  192   b  of the tension insertion mechanism  202  thereby blousing the packaging film between the two portions of the associated tab portions  223 ,  227  sealed to the inner layer  110  of the formed tube. This blousing creates a headspace  201  between the film and the interlocked profile portions  224 ,  228  of the zipper seal mechanism  220 . The creation of the headspace  201  improves the sealing qualities of the traverse seal subsequently applied to the package. 
   The vertical form, fill, and seal machine of the present invention thereafter operates basically as previously described in the prior art, with the sealing jaws  108  forming a lower transverse seal, product being introduced through the forming tube  101  into the sealed tube of packaging film (which now has a crease on one side and a zipper seal on another side), and the upper transverse seal being formed, thereby completing the package. 
   The major differences between a prior art package and this embodiment of Applicants&#39; package, however, are that a crease is formed on one side (which later becomes the bottom of the formed package) using the fixed mechanism described, a length zipper seal mechanism  220  in sealed onto the inner layer  110  of another side (which later becomes the top of the formed package) using the channel track  188  and the fixed tension insertion mechanism  202  described, and that the graphics on the packaging film used by the invention are oriented such that when the formed package is stood onto its end with the creased end generally at the bottom and the zipper seal end generally at the top, the graphics are readable by a consumer. 
   An example of the formed package of the instant invention is shown in  FIGS. 7   c  and  7   d , which show the outside layer of the packaging film  116  with the graphics  179  oriented as previously described. As can be seen from  FIGS. 7   c  and  7   d , the construction of the invention&#39;s vertical stand-up pouch shares characteristics with the prior art vertical flex bags shown in  FIG. 3   a . However, the transverse seals  131 ,  133  of the vertical stand-up bag of the invention are oriented vertically and the vertical back seal  251  is oriented horizontally once the bag stands up on one end, as shown in  FIG. 7   d .  FIG. 7   c  shows the crease  176  that is formed by the tucker bar  106  and forming plates  104  and the zipper seal mechanism  220  positioned and sealed on the package interior as previously discussed in relation to  FIGS. 5   c  and  6   c.    
   As noted previously, the added ability to insert a zipper seal mechanism  220  enabled by Applicants&#39; invention, is not available using current vertical form, fill, and seal machine technology. This is due, in part, to the orientation of the film graphics used on the packaging film of the present invention. Since the graphics are oriented 90° from the prior art, a zipper seal mechanism  220  can be run longitudinally along the forming tube adjacent with the packaging film as it is being formed into a tube. This is not possible with the prior art because such an orientation of a vertical length of a zipper seal would place such seal in a vertical orientation once the package is formed and stood up for display. 
   Returning to  FIG. 6   c , another optional feature that can be incorporated into this invention is the use of a diversion plate  160  within the forming tube  101 . This diversion plate  160 , in the embodiment illustrated, is a flat plate welded vertically inside the forming tube  101  that extends from the bottom of the forming tube  101  to some distance above (for example, at least two or three inches) the bottom of the forming tube  101 , where it then is sealed against the inside of the forming tube  101 . 
   The diversion plate  160  in a preferred embodiment accomplishes two functions. First, the diversion plate  160  keeps product that is dropped down the forming tube  101  away from the area where the crease is being formed on the tube of packaging film. Second, the diversion plate  160 , can be used as a channel for a gas or nitrogen flush. In such instance, the diversion plate  160  at some point above the bottom of the forming tube  101  seals at the top of the plate  160  against the forming tube  101 . Below such seal (not shown) an orifice can be drilled into the forming tube  101  in order to provide gas communication between an exterior gas (e.g., nitrogen or oxygen) source and the cavity formed between the diversion plate  160  and the interior of the forming tube  101 . The diversion plate  160  as shown in  FIG. 6   c  is a flat plate, but it should be understood that it can be of any variety of shapes, for example, having a curved surface, provided that it accomplishes the functionality of diverting the product away from the area where the tuck is formed on the tube of film. 
   By using the diversion plate  160  as a channel for the gas flush, the present invention eliminates the need for a separate gas tube to be placed inside the forming tube  101  that normally accomplishes the same function in the prior art. The added benefit of providing a relatively large volume channel formed by the diversion plate  160  and the interior of the forming tube  101  is that a relatively large volume of flushing gas can be introduced into a filled and partially formed package at a significantly lower gas velocity compared to prior art gas tubes. This allows for the filling of packages using this embodiment of the present invention that may contain low weight product that might otherwise be blown back into the forming tube by prior art flushing tubes. 
     FIG. 8  illustrates a preferred embodiment of the tucker bar  106 . This embodiment of the tucker bar  106  comprises a head  180  attached to a support  182 . Drilled within the support  182  and head  180  is a gas channel  184  shown in phantom on  FIG. 8 . This gas channel  184  provides a gas communication from an exterior gas source (not shown) through the support  182 , through the head  180 , and out three orifices  186 . The gas channel  184  allows for a metered burst of pressurized gas (typically air) that helps keep the tuck illustrated in  FIG. 5   c  taut throughout the forming and sealing operation without the necessity of moving the tucker bar in and out during bag formation. It should be noted that during operation (bag making) the tucker bar  106  is always stationary. It should further be noted that the head  180  necessarily cannot extend along the entire length of the crease formed by the tucker bar  106  and forming plates  104 . Further, it should be understood that when the sealing jaws  108  close onto the tube of film, the lateral dimensions of the tube of film change. All of these facts are compensated for by the use of the pressurized air bursting from the orifices  186 . The pressurized air keeps an even amount of pressure on the tuck as it is being formed in the various stages of the forming and sealing process. The air burst can be continuous, but is preferably metered to start as the film for the next bag is being pulled down through the completion of the transverse seal. 
   The head  180  can comprise any non-stick material but is preferably a fluoropolymer, such as Teflon®. In an alternative embodiment, the tucker bar  106  can comprise one integral piece of metal with the head portion  180  being coated with a fluoropolymer. The curved contact area of the head  180  allows for the continuous formation of the tuck illustrated in  FIG. 5   c  without tearing the packaging film as it is pushed down below the forming tube. While shown with three orifices  186 , the head  180  can comprise any number of orifices from one on. 
   To further compensate for the change in the width of the film tube as the transverse seal is formed by the seal jaws  108  of  FIG. 6   c , it should be noted that the two projecting plates  192   a ,  192   b  of the tension insertion mechanism  202  project outwardly away from the center of said tube of film along the length of the tension insertion mechanism  202  and the forming plates  104  may be hinged by a horizontal hinge  165 . If the tension insertion mechanism  202  is designed otherwise (e.g., strictly vertical) excess slack occurs in the area of the film tube near the transverse seal. The forming plates  104  may include horizontal hinges  165  that allow the forming plates to fold inward (i.e., toward each other) slightly while the lower transverse seal is formed. Otherwise, the tube of packaging film would be ripped by the tips of the forming plates  104  during this step. 
   As noted with previously described embodiments, the instant invention is further an improvement over methods for manufacturing prior art flat bottom bags. Since the tucker mechanism of Applicants&#39; invention is stationary during bag formation, the present invention eliminates the need for moving parts that push against the film tube for the formation of a gusset. This elimination of moving parts allows for increased bag production rates, significantly lower changeover times to pillow pouch production, and significantly fewer maintenance issues. 
   D. Quick Change Module 
   Whether the vertical stand-up pouch embodiment or the flat bottom bag embodiment of the present invention is used, another embodiment of the invention incorporates a quick change module that can be installed on the bottom of a forming tube in order to quickly modify a vertical form, fill, and seal machine from pillow pouch production to the desired stand-up bag production of the present invention. One embodiment of this quick change module, as it relates particularly vertical stand-up pouches, is illustrated by  FIGS. 9   a ,  9   b , and  9   c .  FIG. 9   a  is a perspective view in elevation of the quick change module  94  suspended below the bottom of a forming tube  91  shown partially cut away in order to illustrate interior features.  FIG. 9   b  is a sectional view of the same embodiment of said quick change module  94  shown attached to the bottom of the forming tube  91 . The sectional view of  FIG. 9   b  is taken along reference lines  9   b — 9   b  of  FIG. 9   a .  FIG. 9   c  is a side view in elevation of the same quick change module embodiment. 
   With reference to  FIGS. 9   a ,  9   b , and  9   c , it can be seen that the embodiment illustrated shows that the quick change module  94  comprises one pair of forming plates  104  and one tension bar  92 , which must perform the same functions as similar elements described above with relation to the vertical stand-up pouch. The module  94  is attached to the bottom of a forming tube  91 , as will be described below. The forming tube  91  illustrated in  FIGS. 9   a  and  9   b  is shown as a rectangular shape. Consequently, the module  94  is likewise rectangularly shaped. It should be understood, however, that the shape of the forming tube  91  and corresponding shape of the module  94  can be any number of shapes, such as a circle, an oval, a square, or other shapes. 
   The module  94 , for the embodiment shown, attaches to the bottom of the forming tube  91  by first inserting one or more tabs  96  that are integral to the forming tube into corresponding holes  93  that are integral to the module  94 . The module  94  is thereafter secured by placing a tab  95  that is integral with a diverter plate  161  into a tab guide  97  that is integral with a diverter tongue  163 . As is evident from  FIG. 9   b , this diverter tongue  163  rotates about a pin  168  that extends through a collar  166 . When the diverter tongue  163  is rotated in the direction of the arrow illustrated in  FIG. 9   b , the tab guide  97  is lifted over the tab  95 . The tab guide  97  is biased in the opposite direction of the rotation indicated by the arrow in  FIG. 9   b  by a spring  170 . Pressure is maintained on the inside area of the forming tube  91  in the vicinity of the tabs  96  by virtue of one or more tongues  164  that fit on the inside opposite wall of the forming tube  91 . Consequently, once the module  94  is properly installed on the base of the forming plate  91 , the tabs  96  retain their position in their respective holes  93 . Likewise, the diverter plate tab  95  retains its position in the tab guide  97 . 
   As with the previous embodiments of the invention described above, the module embodiment illustrated also incorporates a diverter  161 . The diverter is used in combination with the diverter tongue  163  to keep product away from the vertical gusset areas. This diverter  161  can likewise be used as a gas flushing channel in addition to serving the purpose of keeping product away from the gussets formed by the forming plates  104 , as previously described above. 
   Also as with previous embodiments, the forming plates  104  can swing towards each other by rotating about a hinge  105 . This hinge  105  comprises a bolt  167  about which a shoulder  169  rotates. The shoulder  169  is in turn attached to the forming plates  104 . This arrangement allows for the forming plates  104  to rotate about the bolts  167  and avoid ripping of the packaging film when the transverse seals are being formed below the forming plates by the transverse seal jaws (not shown). 
   While the embodiment illustrated in  FIGS. 9   a ,  9   b , and  9   c  is used for constructing vertical stand-up pouches, it should be understood that a second embodiment of the module  94  having the forming plates  104 , diverter  161 , diverter tongue  163 , and all accompanying components being duplicated on the side of the module  94  presently illustrated with the tension bar  92 , can be used to manufacture flat bottom bags. In other words, the flat bottom bag embodiment of the module can be easily understood by drawing a vertical line down the center of  FIG. 9   b . All of the components on the right-hand side of such vertical line are then reproduced in mirror image on the left-hand side of the vertical line, thereby replacing the tension bar  92  elements with another pair of forming plates  104  and the diverter tongue  163 , etc . . . . 
   Another embodiment of the quick change module of the present invention comprises a module that can be installed on the bottom of a forming tube in order to quickly modify a vertical form, fill, and seal machine from the pillow pouch or the stand-up bag production to the production of stand-up packages having a zipper seal incorporated therein. 
   One embodiment of a vertical form, fill, and seal machine adapted for receiving this quick change module, as it relates particularly vertical stand-up pouches, is illustrated by  FIG. 11 . The forming tube  191  illustrated in  FIG. 11  is shown as having a rectangular shape. Consequently, the module  194  is likewise rectangularly shaped. It should be understood, however, that the shape of the forming tube  191  and corresponding shape of the module  194  can be any number of shapes, such as a circle, an oval, a square, or other shapes. This forming tube  191  also includes a channel track  188  formed along one side for receiving a length of zipper seal mechanism  220  from a supply spool  218 . As previously shown in  FIG. 10 , the length of zipper seal mechanism  220  is comprised of two interlocking zipper elements  222 ,  226 . Each of the zipper elements  222 ,  226  include a tab portion and an interlocking profile portion. For example, a first zipper element  222  includes a tab portion  223  and a male interlocking profile portion  224 ; while the second zipper element  226  includes a tab portion  227  and a female interlocking profile portion  228 . 
   In accordance with the present invention, a length of zipper seal mechanism  220  is directed to the top portion of the forming tube  191  having a channel track  188  formed along one side such that the two interlocked profile portions  224 ,  228  of the zipper seal mechanism  220  are threaded down through the channel track  188 . The associated tab portions  223 ,  227  of zipper seal mechanism  220  are splayed out along the outer peripheral surface of the forming tube  191  by a roller mechanism  190  so as not to overlap one another. 
   In one embodiment, the channel track  188  comprises a deep groove fashioned into the outer peripheral surface of the forming tube  191 . Thus, as shown in  FIG. 12   a , in cross section the channel track  188  is located on the interior of the forming tube  191 . In an alternative embodiment shown in  FIG. 12   b , the channel track  188 A is positioned on the exterior of the forming tube  191 . The channel track  188 A comprises a gap between two heat seal plates  246 ,  248  extending longitudinally along and attached to the outer peripheral surface of a side of the forming tube  191 . 
   The packaging film  120  (illustrated in phantom in  FIG. 11 ) is initially formed around the forming tube  191  in a conventional manner. However, prior to sealing the sheet of packaging film  120  with a vertical back seal  251  using a back heat seal bar  250 , at least a portion of each of the tab portions  223 ,  227  of the zipper seal mechanism  220  is sealed to the surface of the packaging film  120 . Thus, the tab portions  223 ,  227  are sealed to the inner layer  110  of the tube that is created subsequently by the vertical back seal  251 . As shown in  FIGS. 12   a  and  12   b , the zipper heat seal bar  240  typically comprises multiple individual heating surfaces (e.g.,  242 ,  244 ) for imparting a narrow heat seal on only a portion of each of the tab portions  223 ,  227  of the zipper seal mechanism  220 . 
   As shown in  FIG. 11 , the zipper heat seal bar  240  is positioned above and approximately 90° out of phase from the back heat seal bar  250 . The tube is driven downward by an advancing mechanism (e.g., friction against rotating belts  260 ,  262 ). Thus, as the formed tube is advanced down the forming tube  191  in a conventional manner, the length of zipper mechanism  220  sealed on the interior of the formed tube is also advanced. 
   In accordance with one embodiment of the present invention, the zipper heat seal bar  240  and the back heat seal bar  250  each reciprocate concurrently with one another and consecutively with the advancing means. That is to say, the advancing means advances a specific length of the tubular shaped material packaging film  120  and stops; whereupon, the zipper heat seal bar  240  and the back heat seal bar  250  each reciprocate into contact with the packaging film  120  imparting heat seals to the zipper seal mechanism  220  and vertical back seal  251 , respectively. However, as best illustrated in  FIG. 11 , due to the configuration of the zipper heat seal bar  240  and the back heat seal bar  250 , at least a portion of the zipper seal mechanism  220  is always attached to the packaging film  120  prior to the imparting of the vertical back seal  251 . 
   The forming tube  191  is shown in elevation but would normally be integrally attached to the vertical form, fill, and seal machine. Also shown in  FIG. 11  are a pair of prior art sealing jaws  108  likewise illustrated in elevation. Not shown in  FIG. 11  is the sealing jaw carriage on which such sealing jaws  108  would be mounted below the forming tube  191 . 
   At the bottom of the forming tube  191 , a quick change module  194  is installed which quickly modifies the vertical form, fill, and seal machine from the pillow pouch or the stand-up bag production to the production of stand-up packages having a zipper seal incorporated therein. As will be subsequently explained in greater detail, the quick change module  194  incorporates two forming plates  204  and a tension insertion mechanism  202  as previously described for producing stand-up packages having a zipper seal incorporated therein. 
   Additionally, as with previous embodiments, the module  194  also incorporates forming plates  204  that can swing towards each other by rotating about a hinge  205 . This hinge  205  comprises a bolt  267  about which a shoulder  269  rotates. The shoulder  269  is in turn attached to the forming plates  204 . This arrangement allows for the forming plates  204  to rotate about the bolts  267  and avoid ripping of the packaging film when the transverse seals are being formed below the forming plates by the transverse seal jaws  108  as shown in  FIG. 11 . 
   Referring now to  FIGS. 11 ,  13   c , and  13   d , the module  194  also includes a tension insertion mechanism  202  comprising two projecting plates  192   a ,  192   b  situated on opposing sides of a module channel track  189 . When the module  194  is attached to the bottom of the forming tube  191 , the module channel track  189  connects with and is co-aligned with the channel track  188  formed in the forming tube  191 . In accordance with the present invention, as the formed tube advances over the forming plates  204  and the tension insertion mechanism  202 , tension is applied such that the associated tab portions  223 ,  227  of the zipper seal mechanism  220  are projected away from the surface of the forming tube  191  and bent around the two projecting plates  192   a ,  192   b  of the tension insertion mechanism  202  thereby blousing the packaging film  120  between the two portions of the associated tab portions  223 ,  227  sealed to the inner layer  110  of the formed tube. As particularly shown in  FIG. 5   d , this blousing creates a headspace  201  between the film  120  and the interlocked profile portions  224 ,  228  of the zipper seal mechanism  220 . The creation of the headspace  201  improves the sealing qualities of the traverse seal subsequently applied to the package. 
   The embodiment of this quick change module  194 , as it relates particularly vertical stand-up pouches having a zipper seal incorporated therein, is illustrated by  FIGS. 13   a ,  13   b ,  13   c  and  13   d .  FIG. 13   a  is a perspective view in elevation of the zipper seal insertion quick change module  194  suspended below the bottom of a forming tube  191  shown partially cut away in order to illustrate interior features.  FIG. 13   b  is a sectional view of the same embodiment of said quick change module  194  shown attached to the bottom of the forming tube  191 . The sectional view of  FIG. 13   b  is taken along reference lines  13   b — 13   b  of  FIG. 13   a .  FIG. 13   c  is a side view in elevation of the tension insertion mechanism  202  incorporated into the quick change module  194 . The sectional view of  FIG. 13   d  is taken along reference lines  13   d — 13   d  of  FIG. 13   c.    
   With reference to  FIGS. 11 ,  13   a ,  13   b , and  13   c , it can be seen that the embodiment illustrated shows that the quick change module  194  comprises one pair of forming plates  204  and a tension insertion mechanism  202 , which must perform the same functions as similar elements described previously with relation to the vertical stand-up pouch. The module  194  is attached to the bottom of a forming tube  191 , as will be described below. 
   The module  194  for the embodiment shown, attaches to the bottom of the forming tube  191  by first inserting one or more tabs  196  that are integral to the forming tube into corresponding holes  193  that are integral to the module  194 . The module  194  is thereafter secured by placing another tab  195  that is integral with a diverter plate  261  into a tab guide  197  that is integral with a diverter tongue  263 . As is evident from  FIG. 13   b , this diverter tongue  263  rotates about a pin  268  that extends through a collar  266 . When the diverter tongue  263  is rotated in the direction of the arrow illustrated in  FIG. 13   b , the tab guide  197  slides along the tab  195 . The tab guide  197  is biased in the opposite direction of the rotation indicated by the arrow in  FIG. 13   b  by a spring  270 . Pressure is maintained on the inside area of the forming tube  191  in the vicinity of the tabs  196  by virtue of one or more tongues  264  that fit on the inside opposite wall of the forming tube  191 . Consequently, once the module  194  is properly installed on the base of the forming plate  191 , the tabs  196  retain their position in their respective holes  193 . Likewise, the diverter plate tab  195  retains its position in the tab guide  197 . 
   As with the previous embodiments of the invention described above, the module embodiment illustrated also incorporates a diverter  261 . The diverter is used in combination with the diverter tongue  263  o keep product away from the vertical gusset areas. This diverter  261  can likewise be used as a gas flushing channel in addition to serving the purpose of keeping product away from the gussets formed by the forming plates  204 , as previously described. 
   The vertical form, fill, and seal machine having the a quick change module  194  of the present invention shown in  FIG. 11 , thereafter operates basically as previously described in the prior art, with the sealing jaws  108  forming a lower transverse seal, product being introduced through the forming tube  191  into the sealed tube of packaging film (which now has a crease on one side and a zipper seal on another side), and the upper transverse seal being formed, thereby completing the package. 
   The major differences between a prior art package and this embodiment of Applicants&#39; package, however, are that a crease is formed on one side (which later becomes the bottom of the formed package) using the fixed mechanism described, a length zipper seal mechanism  220  in sealed onto the inner layer  110  of another side (which later becomes the top of the formed package) using the channel track  188  and fixed tension insertion mechanism  202  described, and that the graphics on the packaging film used by the invention are oriented such that when the formed package is stood onto the end with the crease, the graphics are readable by a consumer. 
   The quick change modules described herein, used in combination with the ability to move the tucker bar  106  away from the packaging film tube, as described with relation to  FIGS. 6   a ,  6   b ,  6   c  and  11 , and the use of the tension screw  162 , allows for the conversion of a vertical form, fill, and seal machine from a standard pillow pouch configuration to a vertical stand-up pouch configuration (or flat bottom bag configuration), or to a configuration for producing stand-up packages having a zipper seal incorporated therein, and back again in a matter of minutes with several simple steps. Yet, the invention described does not require the addition of any parts that move during bag manufacture. Consequently, the invention is an improvement over the prior art in providing a simple, efficient, and effective modification to a vertical form, fill, and seal machine, that allows the operator to manufacture a standard pillow pouch bag, vertical stand-up pouch, flat bottom bag, or stand-up packages having a zipper seal incorporated therein with an easy change over and few collateral maintenance issues. 
   While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made and other adaptations and modifications can be employed therein without departing from the spirit and scope of the invention.