Patent Publication Number: US-2023138404-A1

Title: Systems and methods for forming openings in water soluble packet

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. Nonprovisional application Ser. No. 17/329,067, filed May 24, 2021 which is a continuation of U.S. Nonprovisional application Ser. No. 14/179,878, filed Feb. 13, 2014, which claims the benefit of U.S. Provisional Patent Application 61/764,196 filed Feb. 13, 2013, and which is hereby incorporated by reference. 
    
    
     FIELD OF INVENTION 
     The present invention relates to systems and methods for forming openings in water soluble packets involving the use of a laser. 
     BACKGROUND OF INVENTION 
     Water soluble packets, also commonly referred to as pouches or sachets, provide a single dose of a product in one convenient unit. The water soluble packets include a water soluble film sealed around a pre-measured amount of the product. During exposure or contact with water, the film dissolves and the product mixes with the water. The water soluble packets provide many benefits to the consumer. The water soluble packets arc pre-measured, and thus avoid any measuring by the consumer. The product is contained by the film, and it not prone to spilling. 
     The water soluble packets are commonly used with dishwasher and laundry detergents. During a wash cycle, the water soluble film dissolves when exposed to the wash liquid allowing the detergent to mix with the wash liquid. The water soluble packets may also be used in any of a variety of different applications and contain any of a variety of different products. For example, herbicides, fertilizers, lawn chemicals, rinse-aids, cleaners, etc. may all be sealed within the water soluble packets. 
     Conventional water soluble packets are formed by using a drum having rows of cavities on its exterior surface. A base or bottom layer of film, such as a polyvinyl alcohol (PVA) film, is applied over the cavities. A vacuum from inside of the drum draws the base layer of film into the cavities to form a receptacle to receive the product. A specified amount of the product is next metered onto the base layer of film. A lid or an upper layer of film, such as additional PVA film, is then sealed over the base layer of the film. The product is now sealed inside of a combination of the base layer and the lid layer of films. Rows and rows of water soluble packets are formed as part of a continuous process. As the drum rotates, individual water soluble packets arc cut from the rows of water soluble packets. Such processes and equipment are described in U.S. Pat. No. 3,218,776, which is hereby incorporated by reference. 
     During the filling and sealing process, air becomes trapped inside of the packet with the product. The air forms an air bubble or an air pocket inside of the sealed water soluble packet. The air bubble or air pocket may cause inadvertent rupture of the water soluble packet and is not desirable from an aesthetic or packaging perspective. 
     In order to get the air out of packet, a water mist is typically sprayed onto the sealed water soluble packet by a mister. The water mist creates passages in the film of the water soluble packet to allow air trapped in the laundry packet to escape. Unfortunately, the water may also cause much of the film to discolor, which may not be cosmetically desirable from a consumer&#39;s or a retailer&#39;s perspective. Further, the water soluble packets may also become sticky and adhere to one another after being sprayed with the water mist. This causes problems in automated filling processes, which direct the water soluble packets into containers for retail sale. In these automated filling processes, the containers may be filled by weight, and multiple water soluble packets sticking together may interfere with such automated filling processes. 
     SUMMARY OF INVENTION 
     Systems and methods for forming openings in water soluble packets involving the use of a laser are herein described. The laser forms the openings to vent the water soluble packets. The openings provide for the escape or release of air trapped in the water soluble packets. The laser also forms the openings to assist in the filling of the water soluble packet with detergent or other product. The laser burns openings into the water soluble film that forms the water soluble packet. 
     The openings provide a number of improvements in the manufacturing process for water soluble packets and the resulting water soluble packets. First, the laser openings do not discolor the entire film of the water soluble packet. Second, the laser openings do not make the water soluble packets sticky, which is a problem associated with the use of a conventional water mister. Further, the laser openings, when applied in a pre-fill stage, assist in forming the water soluble packet with several beneficial aesthetic features that may be more desirable to consumer. The product in such water soluble packets is more tightly packed with fewer wrinkles in the film as compared to conventional packets. Further, the water soluble packets formed using the laser processes described herein are not generally pliable and do not exhibit a loose feel common to conventional water soluble packets. 
     The openings may include holes, perforations, voids, vents, etc. in the film. The laser burns the openings in the films. The openings permit air to escape from the packets. During the manufacturing process, air may be trapped inside of the packet with the product. The openings provide for the trapped air to escape or vent. The air trapped in the water soluble packet is generally under pressure, and the openings allow the interior of the water soluble packet to equilibrate in pressure with the atmosphere. By allowing air to escape, the water soluble packet has improved packaging characteristics. The water soluble packets are packed more tightly with product. Further, the film does not have bubbles or loose folds of the film. Also, the packets arc not sticky or mostly discolored. Further, the packets tend to have a uniform and consistent appearance. These characteristics may be desirable to a consumer or retailer. 
     The laser may be configured to form the openings at any of a variety of stages during the industrial manufacture of the water soluble packets. During the manufacturing process, the product is filled into cavities which are lined with a base layer of the film. The cavities are in the exterior surface of a rotating drum. After the filling, a lid layer of film is sealed to the base layer over the product. 
     The laser may form the openings at a pre-fill stage or at a post-fill stage in the manufacturing process of the water soluble packets. In a first pre-fill process, the laser forms the openings after the base film is positioned over or drawn into the cavities of the drum and before adding the product to the cavities. In a second pre-fill process, the laser forms the openings before the base film is positioned over the cavities. For example, the laser forms the openings in the base film as the base film is unrolled. In a third pre-fill process, the laser forms the openings in the lid film before the lid film is sealed to the base film. For example, the laser forms the openings in the lid film as the lid film is unrolled. 
     The laser may also form openings in the sealed packets of product, i.e., at a post-fill stage. For example, the laser may be positioned over an output or take away conveyor and direct pulses to the sealed packets. 
     The laser forms the openings as part of a continuous manufacturing process, i.e., the laser forms the openings while the film or water soluble packets are moving. Typically, the films or water soluble packets are not intermittently slowed or stopped in order to form the openings with the laser. As such, the use of the laser does not slow down production rates of the water soluble packets. 
     The laser may also be used with or integrated into both horizontal and vertical form fill seal machines. 
     In one aspect, a system to form openings in water soluble packets is described. The system includes a packet forming assembly to form water soluble packets. The packet forming assembly includes one or more cavities, a base film supply roll that supplies a base film to cover the one or more cavities, a feed hopper meters an amount of a product into the one or more cavities over the base film, and a lid film supply roll supplies a lid film that is sealed to the base film. A laser forms one or more openings in the water soluble packets. 
     In another aspect, a method of forming openings in water soluble packets is described. The method includes providing a packet forming assembly to form water soluble packets. The packet forming assembly comprises one or more cavities. The method includes covering the one or more cavities with a base film. The method includes feeding an amount of a product into the one or more cavities over the base film. The method includes sealing a lid film to the base film to form the water soluble packets. The method includes forming openings in the water soluble packets with a laser. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG.  1    is a schematic view of multiple configurations of the laser-assisted water soluble packet forming system. 
         FIG.  2    is a perspective view of the packet forming assembly. 
         FIG.  3    is a perspective view of the first configuration of the laser-assisted water soluble packet forming system. 
         FIG.  4    is a perspective view of the second configuration of the laser-assisted water soluble packet forming system. 
         FIG.  5    is a perspective view of the third configuration of the laser-assisted water soluble packet forming system. 
         FIG.  6    is a perspective view of the fourth configuration of the laser-assisted water soluble packet forming system. 
         FIG.  7    is a perspective view of the water soluble packet. 
         FIG.  8    is close-up view of the drum and its cavities. 
         FIG.  9    is a schematic view of the laser with a horizontal form fill seal machine. 
         FIG.  10    is a perspective view of the laser with a vertical form fill seal machine. 
     
    
    
     DETAILED DESCRIPTION OF INVENTION 
       FIG.  1    is a schematic view of multiple configurations of a laser-assisted water soluble packet forming system  10 , which is used to form water soluble packets  50 . An example of the water soluble packet  50  is shown in  FIG.  7   . The system  10  forms openings  90  in the water soluble packets  50 . The openings  90  are formed by a laser  410 . As shown in  FIG.  1   , the laser  410  may be positioned at any of a number of different alternate positions about the system  10 . 
     The water soluble packets  50  include a product  60  scaled between a base layer  70  and a lid layer  80 . The base layer  70  is formed from a base film  200 , while the lid layer  80  is formed from a lid film  300 . The openings  90  include holes, perforations, voids, vents, etc. in either or both of the base layer  70  and the lid layer  80 . As described below, the laser  410  may direct its pulses at any of the base film  200 , the lid film  300 , and/or the sealed water soluble packets  50 . Depending upon the set-up, the laser  410  burns the openings  90  in any or all of the base layer  70 , lid layer  80 , base film  200 , or lid film  300 . 
       FIG.  2    is a perspective view of a packet forming assembly  100 , which includes a rotating drum  110  operatively engaged to a motor  120  for rotation of the drum  110 . The packet forming assembly  100  forms the water soluble packets  50 . The drum  110  includes a plurality of cavities  130 . A bulk amount of the product  60  is placed in a feed hopper  150 , which is generally positioned above the drum  110 . As the drum  110  rotates, the feed hopper  150  meters an amount of the product  60  into the cavities  130  on top of the base film  200 . The lid film  300  is sealed to the base film  200 , and the water soluble packets  50  are separated. 
     The base film  200  is directed to the drum  110  from the base film supply roll  220 . A base film roller  230  presses the base film  200  against a surface  115  of the drum  110 . The base film  200  generally covers a plurality of the cavities  130 . Guide rollers  240  and  242  assist in directing and transferring the base film  200  to the drum  110 . 
     The lid film  300  is directed to the drum  110  from the lid film supply roll  320 . A lid film roller  330  presses the lid film  300  against the base film  200 . A guide roller  340  assists in directing and transferring the lid film  300  to the drum  110 . 
     The drum  110  includes multiple rows  142  of the cavities  130 . Generally, the surface  115  of the drum  110  is covered with the cavities  130 . The laser  410  may simultaneously pulse groups  144  of the cavities  130 . The groups  144  may cover multiple rows  142  of the cavities  130 . 
     With reference to  FIGS.  1  and  8   , each of the cavities  130  includes a vacuum opening  133  that is in fluidic communication with a vacuum passage  136 . The packet forming assembly  100  draws a vacuum through the vacuum passage  136  and the vacuum opening  133 . 
     With reference to  FIG.  1   , the packet forming assembly  100  includes a cutting assembly  180  to separate the water soluble packets  50  from each other. The cutting assembly  180  may include a vertical cutter  183  to make vertical separation cuts and a horizontal cutter  186  to make horizontal separation cuts. After the water soluble packets  50  are separated, the drum  110  drops the water soluble packets  50  onto a take away conveyor  190 . 
     With continued reference to  FIG.  1   , a laser assembly  400  includes the laser  410  to form the openings  90  in the water soluble packets  50 . The laser assembly  400  also includes a controller  420  and an encoder  430 . The controller  420  and the encoder  430  register and time the pulses from the laser  410  to strike the base layer  70 , lid layer  80 , base film  200 , and/or the lid film  300  at the appropriate interval and time. 
     The laser  410  may be integrated with the packet forming assembly  100  in any of a variety of configurations or positions. As described below in greater detail, the laser  410  may form the openings  90 , shown in  FIG.  7   , at a pre-fill stage or a post-fill stage in the packet forming process. Four exemplary configurations of the system  10  are described below and are referred to herein as configurations  10   a ,  10   b ,  10   c , and  10   d . Of course, one or more lasers  410  may be simultaneously employed at any of the configurations or positions. In summary,  FIG.  3    shows a perspective view of the first configuration  10   a  of the system  10 , which forms the openings  90  when the base film  200  is over or drawn into the cavities  130 .  FIG.  4    shows a perspective view of the second configuration  10   b , which forms the openings  90  in the sealed water soluble packets  50  after the water soluble packets  50  are formed on the drum  110  and separated by the cutting assembly  180 .  FIG.  5    shows a perspective view of the third configuration  10   c , which forms the openings  90  in the lid film  300  before the lid film  300  is sealed to the base film  200 .  FIG.  6    shows a perspective view of the fourth configuration  10   d , which forms the openings  90  in the base film  200  before base film  200  reaches the drum  110 . 
     With reference to  FIG.  3   , the first configuration  10   a  forms the openings  90  when the base film  200  is over or drawn into the cavities  130 . The first configuration  10   a  forms the openings  90  at a pre-fill stage. The laser  410  may form openings  90  in the base film  200 , while the base film  200  is positioned over the drum  110  or after the base film  200  has been drawn into the cavities  130  by the vacuum. In this aspect, the openings  90  are formed before the product  60  is added to the base film  200 . The laser  410  is positioned proximate to the drum  110 , and the laser  410  is focused toward the individual cavities  130  of the drum  110 . The drum  110  provides the vacuum through the vacuum passage  136  that conforms the base film  200  to the drum  110  and into the individual cavities  130 . Air is drawn into the vacuum passage  136  through the vacuum opening  133  in the bottom of the cavity  130 . The vacuum draws and stretches the base film  200  into the individual cavities  130 . The base film  200  forms a receptacle shape in the individual cavities  130  to receive the product  60 . Before the product  60  is added to the base film  200  positioned in the cavities  130 , the laser  410  forms the openings  90  in the base film  200 . Notably, the openings  90  are formed by the laser  410  after the base film  200  has been stretched into the cavities  130  by the vacuum of the drum  110 . The openings  90  are formed in the base film  200  after the base film  200  has been stretched, so the openings  90  will generally maintain their dimension as the base film  200  is not generally further stretched during the formation of the water soluble packet  50 . 
     In this aspect, the vacuum is also drawing air through the openings  90  in the film, which sucks the product  60  into the base film  200 . The product  60  may be deposited on the base film  200  in the cavities  130  while the vacuum force is drawing the base film  200  into the cavity  130  and air is passing through the openings  90  and into the vacuum opening  133 . This assists in increasing the density of the product  60  within the packet  50 . The product  60  in such water soluble packets  50  is more tightly packed with fewer wrinkles in the film as compared to conventional packets. Without the openings  90  and the drawing of air through the openings  90  by the vacuum, the water soluble packet  50  will have a softer feel and the product  60  will be more loosely contained in the water soluble packet  50 . 
     With reference to  FIG.  4   , the second configuration  10   b  forms the openings  90  in the sealed water soluble packets  50  after the water soluble packets  50  are formed on the drum  110  and separated by the cutting assembly  180 . The second configuration  10   b  forms the openings  90  at a post-fill stage. The laser  410  may be positioned to form openings  90  in the sealed water soluble packets  50  after the water soluble packets  50  are formed on the drum  110  and separated by a cutting assembly  180 . In this aspect, the openings  90  are formed after the lid film  300  and base film  200  are sealed together to contain the product  60 . The laser  410  may be positioned over the take away conveyor  190 . The laser  410  may be focused on any portion of the water soluble packet  50 . 
     With reference to  FIG.  5   , the third configuration  10   c  forms the openings  90  in the lid film  300  before the lid film  300  is sealed to the base film  200 . The third configuration  10   c  also forms the openings  90  at the pre-fill stage. The laser  410  may form the openings  90  in the lid film  300  that forms the packet  50 . The laser  410  may be positioned to form openings  90  in the lid film  300  before the lid film  300  reaches the drum  110 . The laser  410  is positioned proximate to the lid film supply roll  320 . As the sheet of the lid film  300  is unrolled and directed to the drum  110 , the laser  410  may form the openings  90 . One or more lasers may be configured to intermittently form openings  90  in the entire width of lid film  300  used to cover the cavities  130 . In this aspect, the openings  90  may be formed in portions of the lid film  300  which will become the sides or a periphery of the finished water soluble packet  50 . These areas of the lid film  300  are subjected to less stretching than the areas of the base film  200 , which will become the central portions of the water soluble packet  50 . By forming the openings  90  at the sides or periphery, the openings  90  are not generally stretched during the sealing process, and the openings  90  maintain their desired shape. 
     With reference to  FIG.  6   , the fourth configuration  10   d  forms the openings  90  in the base film  200  before base film  200  reaches the drum  110 . The fourth configuration  10   d  also forms the openings  90  at the pre-fill stage. The laser  410  may form openings  90  in the base film  200  that forms the packet  50 . The laser  410  may be positioned to form openings  90  in the base film  200  before the base film  200  reaches the drum  110 . The laser  410  is positioned proximate to the base film supply roll  220 . As the sheet of the base film  200  is unrolled and directed to the drum  110 , the laser  410  may form the openings  90 . One or more lasers  410  may be configured to intermittently form openings  90  in the entire width of the base film  200  used to cover the cavities  130 . In this aspect, the openings  90  are formed before the product  60  is added to the base film  200  and before the base film  200  and the lid film  300  arc scaled together. The openings  90  may be formed in portions of the base film  200  which will become the sides or a periphery of the finished water soluble packet  50 . These areas of the base film  200  are subjected to less stretching than the areas of the base film  200  film which will become the central portions of the water soluble packet  50 . By forming the openings  90  at the sides or periphery, the openings  90  are not generally stretched during the filling process, and the openings  90  maintain their desired shape. 
     The laser  410  will now be described. The laser  410  forms one or more openings  90  in the water soluble packet  50  or the portion of the films  200  and  300  forming the water soluble packet  50 . In some aspects, the laser  410  forms four openings  90  in each water soluble packet  50 . The openings  90  may have various sizes and shapes. For example, the openings  90  may have a size up to approximately 1000 um. 
     The system  10 , laser assembly  400 , and/or the processes described herein may be incorporated into water soluble packet forming systems and equipment from Cloud Packaging Solutions of Des Plaines, Ill. Such equipment is commercially available under the tradename HYDRO-FORMA. 
     The laser  410  may be configured to provide enough power to generally only burn the openings  90  into the film, and, in post-fill applications, not to burn a significant amount of the product  60  therein. The pulses will not damage the cavities  130 , belts, rollers, or other components of the water soluble packet forming system  10 . Although the laser  410  will not hurt a worker with incidental, momentary exposure to the laser  410 , the system  10  and its equipment may be provided with a protective shield and/or barriers to prevent accidental exposure of workers to the laser  410 . 
     With reference to  FIG.  1   , the laser assembly  400  includes the laser  410  to form the openings  90  in the water soluble packets  50 . The laser assembly  400  also includes the controller  420  and the encoder  430 . Existing water soluble packet forming systems may be retrofitted to include the laser assembly  400 . The laser  410  may be electronically linked to the controller  420 , which registers the pulses from the laser  410  with the moving films  200  and/or  300  or moving water soluble packets  50 . The encoder  430  may measure the speed of the take away conveyor  190 , the drum  120 , or any of the films  200  and  300 . The encoder  430  is in electrical communication with the controller  420  to provide the controller  420  with data regarding the speed. The laser  410  may be positioned stationary with respect to the moving films  200  and/or  300  or the belts carrying the water soluble packets  50 . The controller  420  may time the laser  410  to intermittently pulse the laser  410  as the films  200  and/or  300  or the water soluble packets  50  move past a focus point of the laser  410 . The controller  420  may be electronically linked to sensors or additional encoders that monitor the movement of the film or the belt carrying the water soluble packets  50 . The controller  420  times the pulses from the laser  410  to impact the films or water soluble packets  50  at the appropriate interval. 
     Any of a variety of lasers may be used with the system  10  and the processes described herein. One suitable laser for the laser  410  is a commercially available laser as Model  3320  from Videojet Technologies, Inc. of Wood Dale, Ill. This laser is a 30 watt CO2 laser. 
     The laser  410  and/or the controller  420  may be programmed to modulate any of a number of parameters and attributes of the laser pulses, for example, the timing of the laser pulses, the frequency of the laser pulses, the shape of the laser pulse, the pattern of the laser pulses, the area of coverage of the laser pulses, etc. The laser  410  and/or the controller  420  may include user-input controls, such as a touch screen, keyboard, etc. 
     The laser  410  may simultaneously emit an array of pulses that simultaneously forms multiple openings  90 . For example, the laser  410  may be configured to simultaneously form openings  90  in the base film  200  covering multiple rows  142  and groups  144  of the cavities  130  of the drum  110 . The laser  410  may be configured to simultaneously form openings  90  in multiple packets  50 , multiple rows of packets  50 , and/or or multiple groups  144  of packets  50 . Likewise, the laser  410  may be configured to simultaneously form openings  90  across a web of the films  200  and  300  in multiple columns and rows. For example, in a post-fill process, the laser  410  may be configured to simultaneously form openings  90  in approximately 12 water soluble packets  50 . For example, in a pre-fill process, the laser  410  may be configured to simultaneously form openings  90  across a portion of the films  200  and/or  300  of approximately 24 inches wide by approximately 0.25 to 1 inches deep. For example, in a pre-fill process, the laser  410  may be configured to simultaneously form openings  90  in a base film  200  covering approximately 12 cavities of the drum  110 . Further, multiple lasers  410  may be used together to fully cover a width of the drum  110 , films  200  and/or  300 , or the take away conveyor  190 . 
     The lid film  300  and base film  200  may be a water soluble film, such as a polyvinyl alcohol (PVA) film. The films dissolve with contact of water or other fluids. The films may have a thickness of approximately 1 millimeter to approximately 5 millimeter. Such films are commercially available from Monosol of Merrillville, Indiana. Other water soluble films for forming the water soluble packets  50  may include any water-soluble, film-forming polymer, copolymer, or mixtures of such polymers. The polymers may include vinyl polymers, including homopolymers and copolymers, having functionality rendering the polymers water-soluble, such as hydroxyl and carboxyl groups. Typical water-soluble polymers include at least one of polyvinyl alcohol, partially hydrolyzed polyvinyl acetate, polyvinyl pyrrolidone, alkyl celluloses such as methylcellulose, ethylcellulose, propylcellulose and derivatives thereof, such as the ethers and esters of alkyl celluloses, and acrylic polymers such as water-soluble polyacrylates, polyacrylamides, and acrylic maleic anhydride copolymers. Suitable water-soluble polymers further include copolymers of hydrolyzed vinyl alcohol and a nonhydrolyzable anionic comonomer. 
     Although the methods, systems, and assemblies described above are described with respect to laundry and dishwashing water soluble packets, the methods, the system  10 , and/or the laser assembly  400  may be used to form water soluble packets  50  containing any of a variety of products  60  such as, for example, powders, granules, or other solid compositions for any application, such as, for example, herbicides, fertilizers, lawn chemicals, rinse-aids, cleaners, etc. Generally, the water soluble packets  50  will contain a dry product  60 . 
     In addition to the packet forming assembly  100 , one or more lasers may also be used with or integrated into horizontal form fill seal machines and/or vertical form fill seal machines in order form openings to vent the water soluble packets. Horizontal form fill seal machines and vertical form fill seal machines are also used to make water soluble packets. As with other aspects, the openings provide for the escape or release of air trapped in the water soluble packets. The laser also forms the openings to assist in the filling of the water soluble packet with detergent or other product. These aspects are shown in  FIGS.  9  and  10   . 
       FIG.  9    is a schematic view of a laser-assisted water soluble packet forming system  500  using one or more of lasers  505   a ,  505   b ,  505   c ,  505   d , and  505   e  with a horizontal form fill seal machine  510 . The system  500  includes an endless belt  515  operatively engaged to a motor  517  for movement of the endless belt  515 . The packet forming assembly  500  also forms the water soluble packets  50 . The endless belt  515  includes a plurality of cavities  525 . A bulk amount of the product  60  is placed in a feed hopper  550 , which is generally positioned above the endless belt  515 . As the endless belt  515  moves, the feed hopper  550  meters an amount of the product  60  into the cavities  525  on top of a base film  520 . A lid film  530  is sealed to the base film  520 , and the water soluble packets  50  are separated. The base film  520  is directed to the endless belt  515  from a base film supply roll  560 . A base film roller  565  presses the base film  520  against the endless belt  515 . The lid film  530  is directed to the endless belt  515  from a lid film supply roll  570 . A lid film roller  575  presses the lid film  530  against the base film  520 . The endless belt  515  includes multiple rows of the cavities  525 . Generally, a surface  518  of the endless belt  515  is covered with the cavities  525 . The cavities  525  include a vacuum opening  533  that is in fluidic communication with a vacuum passage  536 . The packet forming assembly  500  includes a cutting assembly  580  to separate the water soluble packets  50  from each other. The cutting assembly  580  may include a vertical cutter  583  to make vertical separation cuts and a horizontal cutter  586  to make horizontal separation cuts. After the water soluble packets  50  are separated, the endless belt  515  drops the water soluble packets  50  onto a take away conveyor  590 . 
     The lasers  505   a ,  505   b ,  505   c ,  505   d , and  505   e  may be integrated with the packet forming assembly  500  in any of a variety of configurations or positions. Although  FIG.  9    shows the use of multiple lasers, only one of the lasers  505   a ,  505   b ,  505   c ,  505   d , and  505   e  needs to be employed. The lasers  505   a ,  505   b ,  505   c ,  505   d , and  505   e  may form the openings  90 , shown in  FIG.  7   , at a pre-fill stage or a post-fill stage in the packet forming process. Of course, one or more of the lasers  505   a ,  505   b ,  505   c ,  505   d , and  505   e  may be simultaneously employed at any of the configurations or positions. For example, the laser  505   a  may form the openings  90  in the base film  520  before the base film  520  reaches the endless belt  515 . The laser  505   b  may form the openings  90  when the base film  520  is over or drawn into the cavities  525 . The laser  505   c  may form the openings  90  in the lid film  530  before the lid film  530  is sealed to the base film  520 . The laser  505   d  may form the openings  90  after the water soluble packets  50  are formed on the endless belt  515  but before the packets  50  are separated by the cutting assembly  580 . The laser  505   e  may form the openings  90  after the water soluble packets  50  are formed on the endless belt  515 , separated by the cutting assembly  580 , and deposited on the take away conveyor  590 . The laser  505   e  may be positioned directly over the take away conveyor  590 . 
       FIG.  10    is a perspective view of a laser-assisted water soluble packet forming system  600  using one or both of lasers  605   a  and  605   b  with a vertical form fill seal machine  610 . The packet forming assembly  600  generally forms water soluble packets  55  from a single layer of a film  650 . A bulk amount of the product  60  is placed in a feed hopper  610 , which is generally positioned above a horn  620 . The horn  620  includes an entrance opening  623  and an exit opening  626 . The horn  620  also includes an exterior surface  630 . Drive rollers  640  pull the film  650  over the exterior surface  630  while the product  60  is metered into an interior of the horn  620  through the entrance opening  623 . The film  650  is provided by a supply roller  655 . A first sealing device  660  seals opposing vertical edges  652  and  654  of the film  650 . A second sealing device  670  seals the other seams. A cutting device  680  separates the individual packets  50  and drops the packets  50  onto a take-away conveyor  690 . 
     The lasers  605   a  and  605   b  may be integrated with the packet forming assembly  600  in any of a variety of configurations or positions. Although  FIG.  10    shows the use of multiple lasers, only one of the lasers  605   a  and  605   b  needs to be employed. The lasers  605   a  and  605   b  may form openings  91  in the packets  55  at a pre-fill stage or a post-fill stage in the packet forming process. For example, the laser  605   a  may form the openings  91  in the film  650  before the film  650  reaches the horn  620 . For example, the laser  605   b  may form the openings  91  in the packets  55  on the take-away conveyor  690 . The laser  605   b  may be positioned directly over the take-away conveyor  690 . 
     The systems  500  and  600  may also include the controller  420  to program and/or modulate any of a number of parameters and attributes of the laser pulses. The systems  500  and  600  may also include the encoder  430  to register and time the pulses from the lasers to strike the films or packets at the appropriate interval and time.