System and method for assembling a package with a flip-top

A mandrel for use with an automatic packaging machine in forming a package with a flip-top, comprising:

• a mounting block for coupling the mandrel to the automatic packaging machine,
• a package-holding assembly operatively connected to the mounting block, the package-holding assembly having a free end and a fixed end, the free end having a secured position and an unsecured position and being rotatable about a first axis between the secured position and the unsecured position;
• a lateral support member coupled to the mounting block, wherein the package-holding assembly is rotapanelly connected to the lateral support member;
• a latch coupled to the lateral support member for releasably connecting the free end of the package-holding assembly;
• and
• a flap holder assembly operatively connected to the mounting block, the flap holder assembly rotatable about a second axis substantially perpendicular to the first axis.

A method of forming a latching flip-top box having a flip-top portion hingedly connected to the box along a minor axis of the box, comprising the steps of:

• providing a box blank;
• placing the unitary box blank in a mandrel, the mandrel, coupled to a conveyor system and comprising:
• a package-holding assembly rotatable about a first axis from a first position to a second position;
• and
• a flap holder assembly operatively connected to the package-holding assembly, the flap holder assembly rotatable from a retracted position to an extended position about a second axis substantially perpendicular to the first axis,
• folding a first lower flap of the box blank with a first plow;
• folding a second lower flap of the box blank onto the first lower flap with a second plow;
• folding a third lower flap of the box blank onto the second lower flap with a third plow;
• applying an adhesive to the third lower flap;
• folding a fourth lower flap of the box blank onto the third lower flap with a fourth plow;
• rotating the package-holding assembly about the first axis from the first position to the second position;
• folding a first front upper panel of the box blank with a first tucker assembly;
• folding a latching panel of the box blank using the first tucker assembly;
• folding a second front upper panel of the box blank using a fifth plow;
• rotating the flap holder assembly from the retracted position to the extended position, the flap holder assembly folding a flip top panel and first and second flip-top wing panels of the box blank;
• folding a first wing panel of the box blank using a second tucker assembly;
• folding a second wing panel of the box blank using the second tucker assembly;
• applying adhesive to either exposed surfaces on the first and second wing panels or an underside of a front flip-top panel;
• folding the front flip-top panel onto the exposed surfaces of the first and second wing panels using a sixth plow;
• rotating the flap holder assembly from the extended position to the retracted position;
• rotating the package-holding assembly about the first axis from the second position to the first position;
• folding a first rear upper panel of the box blank using a seventh plow;
• applying adhesive to either an exposed surface on the first rear upper panel or an underside of a second rear upper panel;
• folding the second rear upper panel onto the exposed surface of the first rear upper panel using an eighth plow.