Method of making an applicator package

A method of forming applicator packages, said method comprising the steps of:

• feeding a first continuous web of material having multilaminated layers comprising at least a foil layer and a heat activatable layer from a supply roll, said material comprising an aluminum foil having an inner coating of a thermoplastic material, such as polyethylene;
• forming successively a plurality of recesses along said first web of material;
• depositing a fabric applicator pad into each of said recesses;
• securing said fabric applicator to the inside portion of each said recess by means of heat sealing said pad to the thermoplastic polyethylene lining of said aluminum foil;
• dispensing a predetermined quantity of product to each said applicator pad;
• feeding a second continuous web of material having multilaminated layers comprising at least a foil layer and a heat activatable layer from a supply roll so as to be continuously aligned in a coextensive manner with said first web of material, said second web of material comprising an aluminum foil having an inner coating of a thermoplastic material, such as polyethylene;
• simultaneously heat sealing the entire peripheral marginal edges of each applicator package so as to form a thermoplastic hermetic closure about all sides of said recess leaving at least one corner portion of said webs of material unsecured together;
• cutting off each said applicator package from said webs of material;
• and the thickness of any laminate layer is is from about 0.00035 to about 0.010 inch with said foil ranging from about 0.00035 to about 0.003 inch in thickness and said thermoplastic material ranging in thickness from about 0.0005 to about 0.002 inch.