WO2023017274A1

WO2023017274A1 - Roll of packaging material, a apparatus and method for manufacturing of the packaging roll

Info

Publication number: WO2023017274A1
Application number: PCT/GB2022/052100
Authority: WO
Inventors: Mark A. KEMPSTER
Original assignee: Kempack Limited
Priority date: 2021-08-12
Filing date: 2022-08-11
Publication date: 2023-02-16
Also published as: GB202111620D0

Abstract

We describe below a roll of packaging as well as a method and an apparatus for producing a roll of packaging. The roll of packaging comprises an internal cavity which extends along a longitudinal axis of the roll and a plurality of discrete sheets of packaging material wound around the internal cavity in a sequential arrangement with each of the plurality of discrete sheets having an inner edge adjacent the internal cavity and being unbonded from each other. In use, the plurality of sheets are withdrawn from the internal cavity of the roll in a direction along an extent of the longitudinal axis of the roll, and separate from each other.

Description

.ROLL OF PACKAGING MATERIAL, A APPARATUS AND METHOD FOR MANUFACTURING OF THE PACKAGING ROLL

The present disclosure relates to a roll of packaging material, an apparatus for producing a roll of packaging material and a method of manufacturing a roll of packaging material.

Background

Paper-based packaging material may be crumpled and used as dunnage within a parcel. The dunnage effectively takes up space by filling voids within a container holding a product, so the product is less likely to move around within the container during transportation and delivery. Often containers go through numerous logistics channels and so the dunnage is important to reduce the likelihood of damage to the contents of the container.

EP1848314B discloses a packaging dispensing arrangement in which packaging is withdrawn from a roll of packaging formed of a single sheet of packaging material. The packaging, when withdrawn and out of the dispenser, may be arranged to be withdrawn with at least one winding of packaging overlapping at least one adjacent winding of packaging. EP1848314B describes the use of a core-less roll, in which packaging is withdrawn from the roll through a central hole of the roll. These traditional core-less rolls are manufactured using one sheet of single ply paper grade, traditionally at least 70 gsm and above. The use of stock rolls having a relatively high weight measurement, as set out above, creates a heavy duty “spiral” profile tube of packaging material offering good compression/recovery when packed into a box as a packaging medium.

US10618239 discloses an apparatus for assisting a user in tearing or otherwise breaking off or detaching a portion from a sheet of material at a desired point. The sheet of material in US10618239 may be obtained from an inside or outside surface of a roll of packaging material. The sheet of material may be made of single ply or multiple plies of material bonded together.

WO2019/064045 describes a coreless roll of absorbent sheet product such as napkins, toilet paper, towels etc. The continuous web of absorbent material is wound so as to define an axial hollow passageway which is centrally positioned relative to the roll and extends from one edge of the roll to the other edge. The axial hollow passageway enables the consumer to easily mount the roll on the spindle of a roll holder. When the roll is mounted on the spindle of a roll holder, the absorbent material is dispensed from a first end located at the outside of the roll. The second end of the absorbent material is located at the axial hollow passageway and comprises a coating which is designed to resist collapsing of the coreless roll when material is withdrawn from the roll.

However, the provision of a relatively heavy paper grade within the roll of packaging material means that a user’s hands may become damaged as the packaging is withdrawn from the roll. In other words, the relatively high stiffness and resistance to compression provided by the relatively heavy paper grade creates harsh conditions for a user required to withdraw packaging from the centre of a roll.

It is an aim of the present invention to overcome at least one of the above or other disadvantages.

Summary

According to the present disclosure there is provided a roll of packaging comprising: an internal cavity which extends along a longitudinal axis of the roll and a plurality of discrete sheets of packaging material wound around the internal cavity in a sequential arrangement with each of the plurality of discrete sheets having an inner edge adjacent the internal cavity, whereby, in use, the plurality of sheets are configured to be withdrawn from the internal cavity of the roll in a direction along an extent of the longitudinal axis of the roll, and wherein the plurality of sheets are unbonded from each other.

The use of a plurality of discrete unbonded sheets to form the roll of packaging means the sheets can be more ‘malleable’ compared with sheets from a roll of packaging formed of a single sheet. The use of a plurality of sheets should also result in less physical demand and fatigue on a packer’s hands.

For such rolls of packaging in which the sheets are arranged or configured to be withdrawn from the centre of the roll, the sheets that are drawn from the roll of packaging, in use, will typically crease as they are pulled from the internal cavity of the roll. The use of a plurality of sheets means that the packaging is likely to crease more readily than a heavier single sheet equivalent. The creases create additional air pockets offering better cushioning, crush and recovery properties of the sheets when used as packaging material.

When arranging rolls of packaging in which the sheets are arranged or configured to be withdrawn from the centre of the roll, the sheets need to be removable without tearing and optionally without causing the internal cavity to collapse. This may be achieved by appropriate selection of the dimensions of the roll. The roll has an inner diameter, namely a width of the inner cavity between the internal side walls of the roll. Similarly, the roll has an outer diameter, namely a width of the roll which is the width between the external side walls of the roll. When the inner diameter is too small, it is difficult to withdraw packaging from the centre of the roll and thus the sheets tend to rip or tear when being withdrawn. When the inner diameter is too large, the roll may have a tendency to collapse. The inner diameter may between 25% to 40% of the outer diameter, for example the inner diameter may be approximately one-third of the outer diameter.

When withdrawing the sheets of packaging material from the internal cavity, the sheets typically form a loose spiral (or a plurality of loose spirals) having overlapping sections. Each spiral and similarly each overlapping section of each spiral comprises each of the plurality of discrete sheets. The relationship between the inner diameter and the overall length of the roll (i.e. width of each sheet which is wound on the roll or length of the longitudinal axis) is also likely to affect the ability to form such spiral(s). The longer the length of the roll, it is typically more difficult to withdraw the sheets from the internal cavity. The inner diameter may be between 15% and 30% of the length of the roll, for example the inner diameter may be approximately one-quarter of the length of the roll.

The dimensions of the roll may have a defined relationship between the inner diameter, the outer diameter and the length of the roll. For example, the ratio of the inner diameter to the outer diameter to the length of the roll may be approximately 1 :3:4.

The plurality of discrete sheets are unbonded and thus are configured to separate from each other as they are withdrawn from the internal cavity of the roll. The separation enables the sheets to be handled more easily by a user. The separation of the sheets may further improve the cushioning, crush and recovery properties of the sheets by creating additional air pockets within the packaging material. The plurality of discrete sheets may comprise sheets having the same or different properties (e.g. weight - typically grams per square metre (gsm), thickness, texture, material etc.). The provision of different types of sheets within a single roll of packaging means that the uses of the roll of packaging may be more versatile.

The plurality of discrete sheets may comprise a first sheet having a first gsm weight and a second sheet having a second gsm weight, wherein the first gsm weight and the second gsm weight are the same or different. In other words, each of the plurality of discrete sheets may have a matching or a different weight. Each of the plurality of discrete sheets may have a weight of between 35 to 50 gsm. The provision of a plurality of lightweight sheets means that the sheets may be more malleable and less abrasive for a user when compared to the known rolls of packaging formed from a single sheet. The sum of the weights of the plurality of discrete sheets may be between 70 to 120 gsm. In other words, the weight of the roll may be similar to the weight of an equivalent heavier single sheet. In this way, the strength of roll of packaging material formed from a plurality of unbonded discrete sheets is maintained when compared with a roll of packaging formed from a single sheet. However, the proposed roll of packaging is typically a more user friendly, malleable packing medium.

One or more of the plurality of discrete sheets may comprise paper. One or more of the plurality of discrete sheets may comprise tissue paper.

At least one of the plurality of discrete sheets may comprise a single ply material. At least one of the plurality of discrete sheets comprises a material having two or more plies. In some arrangements, all of the plurality of discrete sheets may comprise a single ply material so that the benefits of using unbonded sheets are maximised.

The number of sheets within the plurality of discrete sheets may be selected based on the intended use. For example, the plurality of discrete sheets may comprise at least two sheets. In another example, the plurality of discrete sheets may comprise between two and four sheets.

According to the present disclosure there is provided an apparatus for producing a roll of packaging such as the roll described above. The apparatus comprises: a collapsible spindle; and a plurality of feeds rolls, wherein each feed roll comprises a discrete sheet of packaging material. The apparatus is configured to: simultaneously transport each of the plurality of discrete sheets under tension to the spindle, simultaneously wind each of the plurality of discrete sheets around the spindle to form a roll and collapse the spindle once the winding step is complete. A roll of packaging as described above is thus formed.

The plurality of feed rolls may comprise at least four feed rolls. When transporting each of the discrete sheets from the feed rolls to the spindle and/or winding each sheet around the spindle, tension is required to ensure that the sheets are flat, free from wrinkles and creases whereby a consistent roll of packaging can be created. The tension which is applied during transport (and optionally during winding) may be set up and fixed before producing the roll so that a consistent tension is applied throughout the process. When forming traditional rolls which have a central core to support the roll, the tension which is applied is typically set at a fixed value which is lower than 25% of the tensile strength of the material (e.g. paper) on the feed roll. When producing a roll of packaging such as that described above, the tension which is applied may be lower than when producing a roll with a central core whereby it is easier to withdraw the packaging from the produced roll of packaging. The tension applied during transport may affect the ability of the withdrawn packaging to form spirals. The tension which is applied may be between 8 to 15% of the tensile strength of the material on the feed roll.

The tension on each sheet may be determined by torque divided by radius. The tension may be applied using a control system which may be closed loop. The control system may comprise a torque device, load cell and tension controller such as a brake or a clutch. For example, the tension may be set to the pre-determined value setting an appropriate air pressure level within the brake on each feed roll.

According to the present disclosure there is provided a method of manufacturing a roll of packaging comprising: receiving a plurality of discrete sheets of packaging material from a plurality of feed rolls; and winding the plurality of discrete sheets around a spindle in a sequential arrangement to form a roll of discrete sheets which are unbonded from each other.

The above referenced features may be combined together in various combinations.

Brief Description of the Drawings Examples of the present disclosure will now be described with reference to the accompanying drawings.

Figure 1 shows a perspective view of packaging dispensing machine;

Figure 2 shows an example of a roll of packaging which can be used in the dispensing machine of Figure 1;

Figure 3A shows a schematical cross sectional view of a roll such as that shown in Figure 2;

Figure 3B shows a cross sectional view of a known roll of packaging formed of one sheet of packaging material;

Figure 4A shows a cross sectional view of a sheet formed of a singly ply of material;

Figure 4B shows a cross sectional view of a sheet formed of two plies of material;

Figure 5 shows a schematic of an apparatus for producing a roll of packaging; and

Figure 6 shows a flow chart of method steps for manufacturing a roll of packaging.

Detailed Description

We describe below a roll of packaging as well as a method and an apparatus for producing a roll of packaging.

Figure 1 shows a perspective view of packaging dispensing machine 100. The packaging dispensing machine 100 is configured to dispense sheets of packaging material from a roll of packaging 104. As explained in more detail below, the roll of packaging 104 comprises a plurality of discrete sheets of packaging material which have been wound together in an overlapping or sequential arrangement. The sheets of packaging material are drawn from an internal cavity of the roll of packaging 104.

As shown in this example, the roll of packaging 104 may be at least partially stored in a container 106 of the packaging dispensing machine 100. The roll of packaging 104 is initially entirely stored within the container 106, but as the sheets are dispensed (or drawn) from the roll, a portion of the roll of packaging 104 extends through an opening 108 in the container 106. The sheets of packaging material that pass through the opening 108 form a loose spiral (or a plurality of loose spirals) having overlapping sections. Each spiral and similarly each overlapping section of each spiral comprises each of the plurality of discrete sheets.

The sheets may be pulled by a user or a machine until a desired length has been withdrawn. A cutting implement (not shown) may then be used to severe the desired length of sheets from the roll of packaging 104. In other examples, a user may simply tear of the desired length of sheet without using a cutting implement.

The packaging dispensing machine 100 may include a stand (not shown) to support the packaging dispensing machine 100 and hold it in place. In this arrangement, the packaging dispensing machine 100 is set with its base at an angle of approximately 30 degrees to the horizontal. It will be appreciated that the stand may be adjustable so that the packaging dispensing machine 100 can be set at different angles or with the base horizontal. Alternatively, the packaging dispensing machine may sit directly on a supporting surface, such as a table.

The packaging dispensing machine 100 may also include a tray 112 arranged to couple with or hold the container 106. The tray 112 may be positioned under the sheets of packaging withdrawn from the roll of packaging 104 and catch the severed length of sheets.

Figure 2 shows an example of a roll of packaging 104. A longitudinal axis 156 of the roll of packaging 104 has been superimposed upon the roll of packaging 104 in this Figure. The height (h) of the roll is also indicated. A typical height for such rolls is 400mm. The height may also be termed the length of the roll.

The roll of packaging 104 is formed of two discrete sheets 122A, 122B of packaging material. The sheets 122A, 122B are shown being withdrawn from the internal cavity of the roll of packaging 104 in a direction along an extent of the longitudinal axis 156 of the roll of packaging 104. The sheets 122A, 122B form a loose spiral having overlapping sections of each of the plurality of discrete sheets as they are withdrawn. The overlap is caused by friction between adjacent sheets. The number of overlapping windings is dependent on the size of the internal cavity 124 and the speed at which the sheets 122A, 122 B are withdrawn.

At the exposed edge 126A, 126B of the withdrawn sheets 122A, 122B, the plurality of discrete sheets 122A, 122B separate from each other because they are not bonded to each other. These exposed edges 126A, 126B are at an angle of approximately 45 degrees to the longitudinal axis as they are withdrawn.

In this arrangement, one or more securing devices 158 hold an outer winding of the roll of packaging 104 in place. The one or more securing devices 158 may take the form of adhesive strips, such as a label. In other examples, one or more securing devices 158 may comprise rubber band. In contrast to other arrangements in which the sheets are wound from the outside of the roll (e.g. WO2019/064045), the sheets are withdrawn from the inner cavity as explained above and thus it is possible to secure the outer winding of the roll of packaging to prevent undesired unravelling of the roll.

In one example, the roll of packaging 104 may be dispensed using the packaging dispensing machine 100 as shown in Figure 1. Alternatively, the roll of packaging 104 may be used without a packaging dispensing machine 100.

Figure 3A shows an illustrative example of a cross section of a roll of packaging 104 such as that shown in Figure 2. The roll of packaging 104 is formed from plurality of discrete sheets 122A, 122B of packaging material. In the example shown in Figure 3A, the roll of packaging 104 is formed from a first sheet 122A and a second sheet 122B of packaging, but in other examples the roll of packaging 104 may include several discrete sheets wound together. The plurality of discrete sheets 122A, 122B are unbonded from each other. That is to say that in the event of the roll of packaging 104 being unravelled, the plurality of discrete sheets 122A, 122B would separate from each other and not be coupled together. This is in contrast to known rolls of material, such as tissue paper, in which a plurality of sheets are wound together and coupled together by means of embossing or adhesion.

The roll of packaging material 104 shown in Figure 3A includes an internal cavity 124 which extends along the longitudinal axis of the roll of packaging 104. The internal cavity 124 may be located centrally within the roll of packaging 104. That is to say that a centre point of the internal cavity 124 is on the longitudinal axis of the roll of packaging 104. The diameter of the internal cavity 124 is labelled ID (inner diameter) and similarly the diameter of the complete roll is labelled OD (outer diameter). The inner diameter is smaller than the outer diameter and may be approximately one-third the size of the outer diameter. Illustrative sizes are 100mm for the inner diameter and 300mm for the outer diameter. The height of the roll also has a relationship to the inner and outer diameters of the roll. A particularly suitable ratio of inner diameter to outer diameter to height of the roll may be expressed as 1 :3:4 (for example with the illustrative values above of 100mm, 300mm and 400mm). In other words, the inner diameter is approximately one-quarter the height of the roll.

Each of the discrete sheets 122A, 122B of packaging material are wound around the longitudinal axis to form the roll of packaging 104. In the illustrative example shown, the roll of packaging 104 only includes 1.5 windings, but in practice the roll of packaging 104 may be formed of upwards of thousands of windings. A winding may be considered to be a 360-degree region of packaging material around said longitudinal axis. In this arrangement, each winding of the packaging material comprises a winding of each of the discrete sheets 122A, 122B. In other words, the plurality of discrete sheets 122A, 122B form a sequential arrangement in the roll of packaging 104. In this example, there are only two sheets and thus the first sheet 122A and second sheet 122B are arranged in an alternating arrangement. That is to say that a winding of the first sheet 122A is sandwiched between two windings of the second sheet 122B and vice-versa. In other words, the windings of the first sheet 122A do not contact each other and similarly the windings of the second sheet 122B do not contact each other.

The plurality of discrete sheets 122A, 122B may comprise more than two discrete sheets. In such an arrangement, the sequential arrangement may be considered to be a substantially repeating arrangement (e.g. 1 , 2, 3, 1 , 2, 3 or 1 , 2, 3, 4, 1 , 2, 3, 4, etc.). That is to say that starting from the outermost winding of the roll of packaging 104 and working inwards (or vice versa), then there would be a repeating arrangement of the order of the sheets of packaging material. In other words, the windings of each sheet are only in contact with other sheets and each sheet is never in contact with itself.

The inner most windings of the roll of packaging 104 are withdrawn from the roll of packaging 104 in a direction along an extent of the longitudinal axis of the roll of packaging 104 (i.e. into or out of the page when looking at the cross sectional view shown in Figure 3A). Thus, as shown in Figure 3A, an inner edge 126A, 126B of each of the first sheet 122A and second sheet 122B is adjacent the inner cavity. The inner edges 126A, 126B extend along the length of the roll. Figure 3A shows the position of the first sheet 122A and second sheet 122B before the sheets are withdrawn from the roll and as shown both of the inner edges 126A, 126B initially are generally parallel to the longitudinal axis of the roll. As shown in Figure 2, the orientation of these inner edges changes as the packaging is withdrawn from the roll.

At the opposed end of each of the first sheet 122A and second sheet 122B, there is an outer edge 128A, 128B. These outer edges 128A, 128B are also generally parallel to the longitudinal axis of the roll and remain in this orientation as the packaging is withdrawn from the roll. A tape or adhesive (not shown) may be applied to an outer surface of the roll of packaging (which in this example is the first sheet 122A) over the outer edges 128A, 128B of both sheets to prevent the sheets unravelling from the roll.

Although the first sheet 122A and the second sheet 122B are adjacent to one another within the roll, they are unbonded from one another. This allows an air gap or separation to form between the first sheet 122A and the second sheet 122B as they are withdrawn from the roll of packaging 104.

Each sheet within the roll of packaging 104 may be formed of a single layer (1 -ply) of material, or multiple bonded layers of material (e.g. 2-ply, 3-ply, 4-ply etc.). Different sheets may be formed from different ply. For example, in the arrangement shown in Figure 3A, the first sheet 122A may be formed of a 1 -ply material (one layer) and the second sheet 122B may be formed of a 2-ply material (i.e. two bonded layers). In practice, a user can increase the number of discrete sheets of single ply (1 -ply) to avoid using multi-ply material. In other words, a 2-ply sheet of material could be replaced by two 1 -ply sheets of material.

Each of the plurality of discrete sheets may have the same or different properties (e.g. weights, material, thickness (which is effectively equivalent to weight with a material which is twice the thickness typically having twice the weight)). For example, each of the sheets of the plurality of discrete sheets of packaging material has a weight of between 30 to 60 gsm, more preferably 35gsm to 50gsm. The weight of each sheet may be selected so that the combined weight of the plurality of sheets sums to a desired weight, e.g. between 80 to 120gsm, more preferably 100gsm. The packaging material may take the form of paper. For example, the packaging material could be in the form of tissue paper

In the example shown, the roll of packaging 104 is generally cylindrical and has a circular, annular cross-section. Depending on the use of the roll of packaging 104, a different shape and/or cross-section may be used, for example, the roll of packaging 104 may have a generally oval or elliptical annular cross-section, i.e. may be a “squashed” circular roll. The shape of the internal cavity 124 typically matches the shape of the roll, i.e. the internal cavity has a circular or a non-circular cross section, such as an oval or ellipse depending on the use.

The roll of packaging has any size which is suitable for its use.

Typically, such rolls of packaging 104 have an outside diameter of between 240mm and 300mm, more preferably 270mm. Similarly, the diameter of the internal cavity 124 may be selected based on the use and/or manufacturing method described below. The diameter of the internal cavity 124 increases as the sheets 122A, 122B are withdrawn from the roll of packaging 104. Typically, the internal cavity 124 has a starting diameter of between 70mm and 130mm, more preferably 100mm. The diameter of the internal cavity 124 may also be referred to as an inside diameter of the roll of packaging 104.

Typically, the roll of packaging 104 may have a width (i.e. the extent of the roll of packaging along the longitudinal axis) of between 200 to 500 mm.

Merely for comparison, Figure 3B shows an illustrative example of a cross section of known roll of packaging 114 formed from a single sheet 116. As in Figure 3A and for simplicity, just 1.5 windings are shown. The roll of packaging 114 includes an internal cavity 118 and in use, the inner windings of the roll of packaging 114 may be withdrawn from the roll of packaging in a direction along the extent of the longitudinal axis of the roll of packaging 114. In contrast to the present disclosure, the roll of packaging 114 shown in Figure 3B is formed of a single, continuous, sheet 116 of material wound around a longitudinal axis to form the roll of packaging 114. The single sheet 116 of packaging material may be formed of a single ply or a multiple ply material but does not have a plurality of discrete sheets as described above in Figure 3B. As shown, each winding only contains the single sheet and although the windings may be considered to forms layers within the roll, each layer is formed from the same sheet. Forming a roll of packaging 104 having a plurality of discrete sheets 122A, 122B (such as the example shown in Figure 3A) enables the thickness of an individual sheet of packaging material to be reduced when compared with a roll of packaging 114 formed of a single sheet (such as the example shown in Figure 3B). In other words, a lighter weight of packaging material may be used for each of the plurality of sheets 122A, 122B when compared to the single sheet of the arrangement of Figure 3B. As such, an end user is able to work with individual, light, sheets of packaging to form the dunnage. Lighter sheets of packaging material will be more malleable for the packers which results in less physically demand and fatigue on the packer’s hands. The overall tear strength of the roll of packaging 104 formed of a plurality of discrete sheets 122A, 122B may be equivalent to a roll of packaging 114 formed of a single sheet of material by selecting material for each of the plurality of discrete sheets which have a combined weight which matches the weight of the single sheet.

In addition, as the discrete sheets 122A, 122B of packaging material are withdrawn from the roll of packaging 104, they crease more readily compared with a single sheet of heavier packaging material. Creases increase the number of air pockets ultimately offering better cushioning, crush and recovery properties of the sheets.

In addition, as the discrete sheets 122A, 122B are withdrawn from the roll of packaging 104, they will naturally separate because they are not bonded together. This will increase the number of air pockets to provide better cushioning. By contrast, even if 2 or 3 ply material was used in the single sheet example of Figure 2B, the layers within the sheet do not separate and would remain in contact with one another as they are withdrawn from the roll 114.

As explained above, the discrete sheets may be formed from single or multiple bonded layers of material. Figure 4A shows an example of a cross-section through a 1-ply sheet of material 126 which may be used to form one or more of the discrete sheets in the roll of packaging material. Similarly, Figure 4B shows an example of a crosssection through a 2-ply sheet of material formed of a first layer 128 and a second layer 130 which may be used to form one or more of the discrete sheets in the roll of packaging material. In the example shown in Figure 4B, the first layer 128 and second layer 130 are bonded together (e.g. embossed or adhered). In other words, an external force is required in order to separate the first layer 128 from the second layer 130. Figure 5 shows an example of an apparatus 150 for producing a roll of packaging 104 as described above.

In this example, the apparatus 150 includes a spindle 152 about which the roll of packaging 104 may be formed. The spindle 152 may be a collapsible spindle. That is to say that the width of the spindle may be adjustable as required to facilitate the removal of the roll of packaging 104 after it has been formed. In one example, the collapsible spindle comprises an air shaft, which includes an inflatable bladder that may be inflated to increase in size and deflated to decrease in size as required. Alternatively, the spindle may be mechanically collapsible.

The spindle 152 may be referred to as a wind up take up shaft. The spindle 152 may be substantially cylindrical. The apparatus 150 includes a plurality of feed rolls 154A, 154B. Each feed roll is controlled by a control system 160 (for ease only one control system is shown). It will be appreciated that there may be a single control system 160 controlling all the feed rolls as schematically shown in Figure 5 or a separate, dedicated control system 160 for each feed roll.

Each feed roll is configured to dispense a discrete sheet of packaging material under a certain pre-determined tension which may be set before production and which is modulated automatically through the production process of each roll by an air pressure on a brake on the feed roll. The control system comprises the typical components for controlling dispensing of the sheets. For example, as illustrated, the control system comprises a torque device 162, a load cell 164 and a tension controller 166 such as a brake or a clutch. The pre-determined tension which is applied to each roll may be between 8 to 15% of the tensile strength of the material on each feed roll. When the same material is used on each feed roll, the same tension may be applied to each roll. In the example shown in Figure 5, there is a first feed roll 154A that is configured to transport a first sheet 122A of packaging material to the spindle 152. In the example shown, there is also a second feed roll 154B configured to transport a second sheet 122B of packaging material to the spindle 152. The first feed roll 154A and the second feed roll 154B may each be configured to rotate about a respective axis. In this example, the first feed roll 154A is configured to rotate in a clockwise direction and the second feed roll 154B is configured to rotate in a clockwise direction. The spindle 152 is also configured to rotate. In this example, the spindle 152 is configured to rotate in a clockwise direction.

In an example in which there are just two feed rolls 154A, 154B, a first sheet 122A of packaging material 122A will be received on the spindle with an edge of the first sheet 122A adjacent the spindle and simultaneously (or momentarily later) a second sheet of packaging material 122B will be received on the spindle so that an edge of the second sheet 122B is also adjacent the spindle. The first sheet 122A and second sheet 122B of packaging material will then be configured to be wound around said spindle together in a sequential arrangement to produce the roll of packaging 104. The sequential arrangement in the case of just two sheets of packaging would be an alternating relationship.

Figure 5 also shows a third sheet 122C of packaging material and a fourth sheet 122D of packaging material being transported to the spindle 152 to form the roll of packaging material 104. A third feed roll configured to transport the third sheet 122C of packaging material and a fourth feed roll configured to transport the fourth sheet 122D of packaging material are not shown in Figure 5 for conciseness. The feed rolls each transport the discrete sheets simultaneously to the spindle. In this example, the roll of packaging 104 produced from the apparatus 140 would comprise four discrete sheets of packaging material wound together in a sequential arrangement.

In some examples, the apparatus 150 includes two feed rolls 154A, 154B to produce a roll of packaging 104 having two discrete sheets 122A, 122B, but in other examples, the apparatus 150 includes three, four or more feed rolls configured to produce a roll of packaging formed of three, four or more discrete sheets respectively.

Figure 6 shows an example of a flow chart representing method steps for manufacturing a roll of packaging 104 as described above.

At step 202, a plurality of discrete sheets of packaging material are received from a plurality of feed rolls. Each of the discrete sheets has an edge which touches the spindle. At step 204, the plurality of discrete sheets are simultaneously wound around a spindle in a sequential arrangement to form a roll of discrete sheets that are unbonded from each other. At step 206, the roll is removed from the spindle, for example by collapsing and withdrawing the spindle, leaving an internal cavity around which the discrete sheets are wound. The inner edge of each sheet is accessible from and can be withdrawn from the inner cavity of the roll to dispense packaging material comprising a plurality of discrete sheets. Optionally, tape or other securing device can be applied to prevent the roll from unravelling.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1 . A roll of packaging comprising: an internal cavity which extends along a longitudinal axis of the roll and a plurality of discrete sheets of packaging material wound around the internal cavity in a sequential arrangement with each of the plurality of discrete sheets having an inner edge adjacent the internal cavity, whereby the plurality of sheets are configured to be withdrawn from the internal cavity of the roll in a direction along an extent of the longitudinal axis of the roll, and wherein the plurality of sheets are unbonded from each other, whereby, in use, the plurality of discrete sheets separate from each other as they are withdrawn from the internal cavity of the roll.

2. The roll according to claim 1 , wherein the plurality of discrete sheets comprises a first sheet having a first gsm weight and a second sheet having a second gsm weight, wherein the first gsm weight and the second gsm weight are different.

3. The roll according to claim 1 or 2, wherein the plurality of discrete sheets comprises a first sheet and a second sheet of matching gsm weight.

4. The roll according to any one of the preceding claims, wherein each of the plurality of discrete sheets has a weight of between 35 to 50 gsm.

5. The roll according to any one of the preceding claims, wherein the plurality of discrete sheets has a combined weight of between 80 to 120 gsm.

6. The roll according to any one of the preceding claims, wherein the roll has an inner diameter which is the width of the inner cavity and an outer diameter which is the width of the roll and wherein the inner diameter has a value which is between 25% to 40% of a value of the outer diameter.

7. The roll according to claim 6, wherein the inner diameter is approximately one- third of the outer diameter.

8. The roll according to any one of the preceding claims, wherein the roll has an inner diameter which is the width of the inner cavity and a length of the roll which is the length of the longitudinal axis of the roll wherein the inner diameter has a value which is between 15% to 30% of a value of the length of the roll.

9. The roll according to claim 8, wherein the inner diameter is approximately one- quarter of the length of the roll.

10. The roll according to any one of the preceding claims, wherein at least one of the plurality of discrete sheets comprises a single ply material.

11. The roll according to any one of the preceding claims, wherein all of the plurality of discrete sheets comprise a single-ply material.

12. The roll according to any one of the preceding claims, wherein at least one of the plurality of discrete sheets comprises paper.

13. The roll according to any one of the preceding claims, wherein the plurality of discrete sheets comprises between two to four discrete sheets.

14. An apparatus for producing a roll of packaging according to any one of the preceding claims, the apparatus comprising: a spindle which is collapsible; and a plurality of feeds rolls, wherein each feed roll comprises a discrete sheet of packaging material, wherein the apparatus is configured to: simultaneously transport each of the plurality of discrete sheets under tension to the spindle; simultaneously wind each of the plurality of discrete sheets around the spindle, and collapse the spindle once the winding is complete to form a roll of packaging comprising an internal cavity which extends along a longitudinal axis of the roll and a plurality of discrete sheets of packaging material wound around the internal cavity in a sequential arrangement with each of the plurality of discrete sheets having an inner edge adjacent the internal cavity and being unbonded from each other.

15. The apparatus according to claim 14 wherein the plurality of feed rolls comprises at least four feed rolls. 18

16. The apparatus according to claim 14 or claim 15, wherein each of the plurality of discrete sheets has a tensile strength and the apparatus is configured to apply a predetermined tension to each of the plurality of discrete sheets during at least one of the transporting and winding stages and wherein the pre-determined tension is between 8% to 15% of the tensile strength.

17. A method of manufacturing a roll of packaging according to any one of claims 1 to 13, comprising: receiving a plurality of discrete sheets of packaging material from a plurality of feed rolls; winding the plurality of discrete sheets around a spindle in a sequential arrangement to form a roll of discrete sheets which are unbonded from each other, and collapsing the spindle to form an inner cavity around which the plurality of discrete sheets are wound.