The Zipbox combines the attributes of folding carton and pouch packaging to create an easy-opening package that also recloses securely.
As the story goes, some 130 years ago, the folding carton was created accidentally, when in 1879, an employee of a printing shop mistakenly positioned a cutting die upside down in a press. When the dull flat face of the bottom edge of the rule creased the sheet, the cut-and-creased folding paper box was born.
Some 80 years later the French inventor Louis Doyen designed the, what he called, the Doypack, an abbreviation from DOYen and PACKaging. The Doyen design consists of two flat sheets seamed together along their sides, with a “W” fold running along the bottom. When the pouch is filled, the “W” opens and provides a base on which the pouch can stand. The original Doyen design showed the top being sealed straight across, but subsequent modifications include fitments to allow the pouch to be reclosed after opening. In these days this packaging format goes under the category name: ‘stand-up pouch’ (SUP).
Both packaging formats have seen a tremendous evolution mainly due to glamorous new materials available and the so important closures for the convenience of the consumer. Part of this evolution was the pre-lined carton and later the plain, utilitarian flexible bag in a paperboard carton.
And now the next step in this evolution is set, as T.H.E.M combined both the folding carton and the pouch into one packaging format, baptizing it ZipBox. The ZipBox of T.H.E.M. (Technical Help in Engineering and Marketing), based in Marlton, New Jersey/USA, is a pouch/folding carton hybrid combining the best features of traditional paperboard cartons (the cube efficiency and stable, upright stance) with the convenience and functionality of zippered pouch packaging (the easy-open, reclose and freshness-preserving features).
The coated carton bottom and resealable top provide the perfect solution to the long-standing consumer need for easier package reclosure and maintaining product freshness after opening.
The packaging can be made with a variety of materials including poly-coated paperboard and poly/foil/paperboard laminations for the carton and heat-sealable film with zippers for the pouch portion. The press-to-close zipper on top allows easy opening and closing. An airtight seal configuration on the package bottom of the package eliminates the need for a liner to maintain freshness, but, in stead, side flaps for the zippered pouch are constructed so that the zippered pouch folds down after filling for efficient sealing and shipping, and is easily opened when the top flaps are lifted up by the consumer and the tear-top zipper appears.
The Zipbox also offers sustainability benefits. The liner-less design provides a minimum of 10% additional content when compared to traditional bag-in-box packaging. And while stand-up pouches have met some needs for lightweight containers in shipping, the rectangular-shaped cartons offer more space efficiency. Its rectangular or square shape fills gaps found between canister or pouch packs to allow some 30% more product on a pallet than those formats.