Apparatus and method for forming a container having an enhanced corner support structure

A method of forming a container from a paperboard blank, the method comprising:

• providing a generally flat paperboard blank having a plurality of fold lines therein for defining a bottom panel, opposing end panels attached to the bottom panel via first fold lines, opposing side panels attached to the bottom panel via second fold lines, wherein each of the opposing end panels includes opposing outside edge portions for forming an inside corner support member, wherein each of the opposing outside edge portions are attached to opposing edges of the end panels via a third fold line;
• positioning the blank at a first forming position;
• supporting a platen proximate the first folding position in spaced relation to the blank, the platen dimensioned and aligned to fit proximate the first and second fold lines when contacting the bottom panel;
• providing first and second opposing edge rail pairs mechanically operable and positioned for folding the outside edge portions of the end panels;
• mechanically operating the first and second opposing edge rail pairs for folding the outside edge portions of the end panels along the third folding lines of the blank;
• providing opposing first and second mechanically operable end folding rails positioned for receiving the end panels of the blank;
• mechanically operating the opposing first and second end folding rails for folding the end panels upwardly from the bottom panel along the first folding lines, the outside edge portions of the end panel already being inwardly folded;
• providing opposing first and second side folding rails carried in a fixed position relative to and operable with the platen for receiving the opposing side panels through an action of moving the platen downstream from the first forming position;
• and
• biasing the platen against the bottom panel of the blank for advancing the blank downstream the first forming position for folding the opposing side panels upwardly from the bottom panel along the second folding lines, wherein an initial movement of the platen is sufficient for securing the outside edge portions of the end panels in a folded position through a biasing of the opposing side panels thereagainst, thus initially securing the outside edge portions of the end panels in the folded position prior to a further advancing of the platen further downstream.