Method of forming primary package tube for tampons

A method of packaging a tampon comprising the steps of:

• a) providing a packaging film on a mandrel in the form of a hollow tube, wherein:
• i) the packaging film material comprises at least one thermoplastic surface;
• ii) the mandrel has a first end extending from a revolving platform and a second end, distal the first end, and a length extending from the first end to the second end, and is capable of rotating with respect to the revolving platform,
• iii) the hollow tube of packaging film material has an overlapping longitudinal seam area having two plies of the packaging film and has a first end corresponding to the first end of the mandrel and a second end distal thereof, the second end extending beyond the second end of the mandrel to define a protruding tube portion, and a length extending from the first end to the second end;
• wherein the protruding tube portion has a length approximately equal to the radius of the hollow tube of packaging film material;
• b) forming a folded surface by rotating the hollow tube of packaging film material and mandrel with respect to the revolving platform while counter-rotating a plate having a plurality of folding blades extending outwardly therefrom, distal an axis of rotation thereof to form a plurality of folds that define the folded surface, substantially perpendicular to the longitudinal axis of the hollow tube of packaging film material, each folding blade engaging a portion of the protruding tube portion;
• c) applying heat and pressure to the folded surface to form a closed end of the hollow tube of packaging film material;
• d) inserting the tampon into the hollow tube of packaging film material;
• and
• e) closing the first end of the tube hollow tube of packaging film material.