Method of producing high burst zipper assemblies for large reclosable packages

A method of manufacturing a series of reclosable packages, comprising the steps of:

• providing a continuous length of zipper material, the zipper material including a first profile and a second profile, wherein the first profile includes a first interlocking element and a first flange, the second profile includes a second interlocking element and a second flange, the first flange including a first segment extending from the first interlocking element and a second segment extending from a substantially central location of the first segment, the zipper material further including a separable connection formed between the first segment and a central area of the second flange, wherein the separable connection is more resistant to a shear force than to a peeling force;
• providing a plurality of packages with a first wall and a second wall, wherein side edges of the first wall are secured to side edges of the second wall thereby forming an open top and an open bottom;
• for each of the plurality of packages, securing an interior portion of the first flange proximate to the top exterior of the first wall and the first interior portion of the second flange proximate to the top exterior of the second wall.