Bulk bin assembly with a horizontal ventilation insert and method for forming the same

A plurality of blanks for forming a bulk bin assembly comprising:

• a first blank comprising:
• a first plurality of side panels for forming side walls of a container portion of the bulk bin assembly, wherein at least one of the first plurality of side panels comprises a ventilation opening defined therein;
• and
• a second blank configured to couple to at least one side panel of the first plurality of side panels when the container portion is formed from the first blank, the second blank comprising:
• a second plurality of side panels for forming side walls of a ventilation insert, wherein the second plurality of side panels at least partially define an air flow channel when the ventilation insert is formed from the second blank, wherein, when formed, the ventilation insert is positionable within the container portion such that the ventilation opening is in air flow communication with the air flow channel;
• a third blank configured to couple to at least one side wall of a formed container portion, the third blank comprising a third plurality of side panels for forming a sanitary insert, each of the third plurality of side panels configured to substantially align with at least one side panel of the first plurality of side panels when the formed sanitary insert is coupled within the formed container portion of the bulk bin assembly;
• wherein the first blank further comprises at least one bottom flap for forming a bottom wall of the container portion, the at least one bottom flap extending from a bottom edge of a respective side panel of the first plurality of side panels, wherein the third blank further comprises a plurality of locking flaps extending from a bottom edge of a respective side panel of the third plurality of side panels, and wherein the plurality of locking flaps are configured to couple to the at least one bottom panel of the first blank when the formed sanitary insert is coupled within the formed container portion of the bulk bin assembly.

A bulk bin assembly comprising:

• a container portion comprising a plurality of side walls defining a cavity of the container portion, wherein at least one side wall of the plurality of side walls has at least one ventilation opening defined therein;
• and
• a ventilation insert comprising a plurality of side panels and at least one insert opening defined in at least one of the plurality of side panels, wherein the ventilation insert is positioned within the cavity of the container portion such that an air flow channel defined by the plurality of side panels is in air flow communication with the ventilation opening of the container portion to permit ambient air to flow through the ventilation opening and through the insert opening;
• wherein the container portion further comprises a bottom wall, said bulk bin assembly further comprising a sanitary insert assembly comprising:
• a plurality of sanitary insert side panels coupled within the container portion;
• and
• a plurality of locking flaps coupled to the bottom wall of the container portion.

A method for forming a bulk bin assembly from a plurality of blanks, said method comprising:

• forming a container portion from a first blank that includes a first plurality of side panels for forming side walls of the container portion, wherein at least one of the first plurality of side panels includes a ventilation opening defined therein;
• forming a ventilation insert from a second blank that includes a second plurality of side panels for forming side walls of the ventilation insert, wherein at least one side panel of the second plurality of side panels includes at least one insert opening defined therein, the plurality of side panels of the ventilation insert and the at least one insert opening at least partially defining an air flow channel;
• positioning the ventilation insert within the container portion such that the air flow channel is in air flow communication with the ventilation opening to permit ambient air to flow through the ventilation opening and through the insert opening;
• forming at least one sanitary insert from a third blank that includes a third plurality of side panels for forming the sanitary insert, each of the plurality of side panels configured to align with at least one side wall of the formed container portion;
• and
• coupling the at least one sanitary insert to an interior surface of at least one side wall of the formed container portion;
• wherein the first blank further includes a plurality of bottom flaps for forming a bottom wall of the container portion, and wherein the at least one sanitary insert further includes a plurality of locking flaps extending from a bottom edge of the third plurality of side panels of the sanitary insert, said method further comprising coupling the plurality of locking flaps of the at least one sanitary insert to an interior surface of the bottom wall of the container portion.