[0001] This invention relates to machines for packaging food products, packages and related
methods such that the packaged product may be maintained in one condition under certain
circumstances and then converted to another condition. For example, during transportation
the food package might maintain an inert gaseous atmosphere and then, when the package
reaches a supermarket or other retail outlet, the food package will permit exposure
of the food product to the ambient atmosphere. While a wide variety of food products
can be packaged in accordance with the teachings of this invention, it is particularly
advantageous in connection with the packaging of meat in a modified atmosphere package
such that the meat may be transported in a relatively inert atmosphere and then caused
to bloom when it reaches a retail outlet by exposure to oxygen.
[0002] Historically, meat products have been butchered and packaged in each supermarket
or other retail outlet. It has long been recognized that this arrangement is extremely
inefficient and expensive. Instead, it would be preferable to permit the meat to be
butchered and packaged at an efficient facility which benefits from economies of scale
and thereafter shipped to individual supermarkets or other retail outlets.
[0003] In the past, this desirable goal has not been achievable because most consumers prefer
to buy meat which is red in color as a result of exposure to oxygen. However, the
meat maintains its red color for only one to two days. Thereafter, it turns to a purple
color which is undesirable to most consumers. Therefore, if the meat was butchered
and packaged in one location and then shipped to another location for eventual sale,
by the time the package reached the retail outlet the meat would have undergone the
transformation to the purple color and would be effectively unsalable.
[0004] To overcome these problems, there have been a number of efforts to maintain the food
product in a first atmosphere during shipping and a second atmosphere when the meat
product is ready for retail sale. It is not believed that any of these techniques
have yet achieved significant commercial acceptance. Therefore, it is highly desirable
to provide a package that would permit remote meat preparation, and subsequent sale
several days later.
[0005] One problem is that while the need for such a package is great, consumers may not
be willing to invest much money in elaborate packages. Thus, it would be highly desirable
to have a package that is convertible between two very different packaging conditions,
and yet is very economical. Moreover, it is also advantageous for the package to look
similar to packages to which consumers are currently accustomed.
[0006] One attempted solution to these problems is to use a dual layer cover over a plastic
package containing the meat product. The upper cover is gas impermeable and may be
removed to expose a lower cover that is air permeable. Thus, the package may be shipped
with the upper cover intact so that a inert gaseous atmosphere may be maintained within
the package during shipping. Then the upper cover may be removed at the supermarket
leaving the lower cover. Since the lower cover is oxygen permeable, it allows the
meat to bloom in the presence of oxygen.
[0007] Conventionally, such dual layer packages have been implemented by adhesively securing
the upper layer to the lower layer and thereafter heat sealing or otherwise securing
both layers to the package itself. For example, when the upper layer is removed the
adhesive may be retained on the lower layer, interfering with the ability of the lower
layer to pass oxygen. Also when removing the top layer it may be difficult to avoid
tearing or otherwise removing the lower layer. Moreover, it is difficult to produce
such a package with controlled delamination of the two layers.
[0008] US-A-4939332 discloses a tray packaging with a dual layer cover. The two covering
layers are spaced apart, therefore the two layers may be removed separately. However,
since the inside cover is located on a step on the rim of the tray, it may not be
severed from a roll of covering material in place on the tray, but must be cut-out
separately and later assembled.
[0009] While various elaborate techniques have been conceived for avoiding the interference
between the layers, these approaches generally add cost and complexity to the packaging.
Moreover, the removal of the upper layer (which is sealed to the lower layer) without
removing the lower layer is problematic. Although attempts have been made to overcome
these problems, no commercially viable solution has been achieved.
[0010] Domed meat packages have been used in the past to contain large cuts of meats such
as chickens or roasts. However, these packages have suffered from a number of drawbacks.
[0011] It is desirable to control the atmosphere within the meat package to delay the aging
of the food product and to extend its shelf life in the supermarket. For example,
by providing low oxygen environments, the shelf life of the food product can be extended
from a few days to as long as two weeks or more perhaps.
[0012] In order to make the customer feel comfortable with the food packaging, the customer
should be able to view a substantial portion of the food product. In order to maintain
a desired atmosphere around the package, a package which is somewhat larger than the
food product is required. However, with a large, relatively heavy meat product it
is difficult to allow for spacing around the food product and yet maintain the product
in an attractive fashion within the container.
[0013] Moreover, since the consumer would normally desire that he or she be able to see
the food product, the spacing becomes visible to the consumer. The consumer may believe
that the package is too large and wasteful. Moreover, if the product is substantially
larger than the food product, the food product may move around during transportation
and handling, and the package itself may be indented or otherwise damaged.
[0014] In the past, deep draw packages may have been used for this type of packaging. However,
deep draw packages become difficult to form at large sizes and may experience significant
deformation of the packaging material. These packages are particularly susceptible
to the formation of thin spots and to the indenting and collapsing of the corner regions.
[0015] Thus, the present applicant has appreciated that it would be desirable to form a
domed package rather than to use the deep draw plastic forming technique. With the
domed package, the product may protrude above the sealing flanges that connect the
upper and lower package portions. It is also possible to form the package portions
from different materials adapted to particular packaging needs. For example, it may
be desirable to form the bottom portion out of foam material and the top out of transparent
plastic.
[0016] The requirements of a relatively large package made of relatively rigid packaging
material seem to be incompatible with the necessity of extra space within the package
for conventional gas exchange techniques to extend the shelf life. Thus, most conventional,
large food products are simply overwrapped with plastic wrap, and the supermarket
endures the additional costs that result from meat loss.
[0017] Therefore, it would be highly desirable to provide a relatively rigid domed food
package, packaging method, and packaging apparatus which allows relatively large cuts
of meat to be efficiently packaged in a desirable gas environment.
[0018] According to the present invention, there is provided a package comprising a tray;
a pliant first membrane sealed to said tray; and a pliant second membrane sealed to
said tray over said first membrane, said membranes being secured to respective separate
locations on said tray, wherein said locations are substantially coplanar, said coplanar
locations being separated by a trough, such that said membranes are substantially
coplanar with one another, said second membrane being removable from the tray independently
of said first membrane.
[0019] Preferably, the second membrane is less permeable than the first membrane to gases.
[0020] Conveniently, the first and second membranes each comprise a resilient material.
[0021] Advantageously, said first and second membranes each comprise a substantially impermeable
material.
[0022] Conveniently, the tray comprises a foam, said coplanar locations comprise ledges,
said ledges being pressed to substantially uniform thickness.
[0023] Advantageously, the first and second membranes are only connected by way of said
tray.
[0024] Conveniently, said second membrane is peelable from said tray.
[0025] According to another aspect of the present invention, there is provided a method
for packaging a food product (A) comprising the steps of: filling a tray with a food
product; covering said tray with a pliant first membrane by severing the membrane
from a web of material, locating said first membrane in place on said tray and sealing
said membrane to said tray at a first location, wherein the method comprises the subsequent
steps of: a) severing the first membrane over a trough formed in said tray; b) covering
said tray and said pliant first membrane with a substantially coplanar pliant second
membrane; and c) sealing said second membrane to said tray at a second location outwardly
of said first location, said first and second locations being substantially coplanar
and being separated by said trough.
[0026] Preferably, said first membrane is sealed to said tray and then severed from said
web.
[0027] In order that the invention may be more readily understood, and so that further features
thereof may be appreciated, the invention will now be described, by way of example,
with reference to the accompanying drawings, in which:
Figure 1 is a plan view of one embodiments of a package 10 in accordance with the
present invention;
Figure 2 is an enlarged side cross-sectional view of the package 10, taken along the
line 2-2 of Figure 1;
Figure 3 is a schematic view showing a method for assembling the package 10 of Figure
1.
[0028] Referring to the drawings, wherein like reference characters are used for like parts
throughout the several views, a package
10 for containing one or more food products "A" is shown (Figures 1-2). The package
10 is especially advantageous for containing red meat. The package
10 includes a relatively rigid tray
12, a more permeable membrane
14, and a less permeable membrane
16. The membranes
14 and
16 are peripherally connected to the tray
12.
[0029] The tray
12 may be made of a relatively rigid plastic, formed by thermomolding or the like. The
tray is preferably made of a material which is gas impermeable, and may be composed
of a single polymeric sheet such as polyvinyl chloride, nylon, fluorohalocarbon, polyurethane
or a composite of polymeric materials including: PVC; PVC and polyolefin; PVC and
saran; PVC and saran and polyolefin; PVC, saran, ethylenevinylacetate copolymer; polystyrene,
saran and polyolefin; polystyrene, saran and copolymer; nylon, saran, polyolefin;
polyolefin, saran and polyethylene; polyester, saran, polyolefin; polycarbonate, saran
and polyolefin; or many other materials which are well known in the art. Advantageously,
the tray
12 is preferably formed of a material that forms a good oxygen barrier, has adequate
thermoformability, is sufficiently strong, and facilitates the attachment of other
materials to the tray.
[0030] Although the tray
12 is shown in the illustrated embodiment as being generally rectangular, other shapes
of the tray
12, such as a round form (not shown), are contemplated in accordance with the invention.
The tray
12 includes a curved base
18 which defines a cavity for receiving the food product A, and a double flanged edge
20 which extends around the periphery of the base
18.
[0031] The double flanged edge
20 defines a pair of ledges
22 and
24 separated by a trough
26. The outermost edge
28 of the flange
20 may be turned downwardly. In an illustrative embodiment, the base
18 and the flange
20 may be molded as a single piece. In an exemplary embodiment, upper surfaces of the
ledges
22 and
24 may be positioned in a single plane, such that the ledges
22 and
24 and the membranes
14 and
16 provide a substantially flat surface on top of the package
10. In this regard, the tray
12 may be formed from a porous, foam-like material that is heat pressed to ensure uniformity
in the height of the ledges
22, 24 and the thickness of the tray
12. Such a flat surface facilitates a more reliable connection to the membranes
14, 16, and also permits multiple packages to be easily stacked on top of each other.
[0032] The more permeable layer
14 preferably comprises a flexible, resilient material such as a pliant plastic substance,
to permit gaseous exchange therethrough as required by the particular application.
In connection with the blooming of red meat, it is generally desirable that the more
permeable membrane
14 be highly transmissive of ambient atmosphere. A wide variety of materials are capable
of acting as the membrane
14, including polyvinyl chloride, polycarbonate, cellophane, polypropylene, polyethylene,
polyethylene copolymers, ionomer film or any other gas permeable materials which are
well known in the art. The membrane
14 may also be constructed of microporous films which have holes formed either chemically
or mechanically. The membrane
14 need only be sufficiently strong to prevent perforation in use.
[0033] The membrane
14 is secured to the tray
12 at the inner ledge
24. In this regard, it is desirable that the membrane
14 be of a material that is heat sealable to the tray
12. However, it is also possible to adhesively secure the peripheral edge of the membrane
14 to the inner ledge
24. As used herein, the film is "sealed" to the tray, signifying that it is heat fused
or adhesively secured to the tray as opposed to being frictionally connected thereto.
Between the ledges
22 and
24, a trough
26 is defined. The trough
26 aids in securing the membrane
14 to the inner ledge
24. In particular, after the membrane
14 is stretched over the tray
12 and the ledges
22, 24, the membrane
14 is secured to the inner ledge
24, then trimmed by moving a cutting press downwardly through the membrane
14 and into the trough
26 as explained later. Although the trough
26 has a "U"-shape in Figure 2, it is also understood that the trough
26 may assume a "V"-shape, a semi-circular shape, a rectangular shape, or another suitable
shape that may be desired for aesthetic, functional, or other reasons.
[0034] The less permeable membrane
16 also preferably comprises a flexible, resilient material such as a pliant plastic
substance. However, the membrane
16 is preferably selected from a group of materials that are relatively less gas permeable,
such as polyester, nylon, cellophane, polypropylene, polyvinyl acetate, saran, or
combinations of these materials. Advantageously, the less permeable membrane
16 is impermeable to gases.
[0035] The less permeable membrane
16 is removably secured to the outer ledge
22, again by heat sealing, adhesive techniques, or other techniques known in the art.
After the less permeable membrane
16 is secured to the outer ledge
22, the membrane
16 may be trimmed by moving a cutting press downward through the membrane
16, at a position outward from the outermost edge
28 as explained later. Alternatively, if desired, the membrane
16 may be trimmed before sealing it to the outer ledge
22. In either case, the membrane
16 is preferably trimmed to leave an overhang
19, to facilitate later removal of the membrane
16 by lifting the overhang
19 and peeling the membrane
16 back from its connection to the outer ledge
22. The less permeable membrane
16, when secured to the ledge
22, is totally free of any connection to the more permeable membrane
14, except frictional connection or indirect connection through the tray
12. This facilitates the convenient removal of the less permeable membrane
16 from the package while leaving the more permeable membrane
14 in place and undisturbed. Although the membranes
14, 16 are not connected to each other, the membranes
14, 16 are substantially coplanar to each other, in face to face abutment, each advantageously
being under slight resilient tension.
[0036] After both the membranes
14 and
16 are secured to the tray
12, a desirable atmosphere may be maintained within the package
10 for the benefit of the food product A contained therein. This may be done by sealing
the package closed in the desired atmosphere. In the case of red meat products, the
initial atmosphere in some embodiments may contain a relatively low concentration
of oxygen. For example, gases including substantial concentrations of carbon dioxide
or nitrogen may be maintained with the package to reduce the exposure of the food
product A to oxygen. In the case of meat products, this forestalls the blooming of
the meat product until a later time.
[0037] When the product reaches a supermarket or other retail outlet, it may be desirable
to remove the less permeable membrane
16. This is conveniently done by grasping the edge of the upper membrane
16 and pulling it upwardly. Since the membrane
16 is not connected to the membrane
14, it may be easily removed from the remainder of the package
10.
[0038] Thereafter, the package
10 exists without the less permeable membrane
16, and includes only the more permeable membrane
14 and the tray
12. In embodiments containing meat products, it may be desirable to allow oxygen transmission
through the more permeable membrane
14 to cause blooming of the meat product. Thus, in the store, once the less permeable
membrane
16 has been removed, the red meat product
A can be caused to turn red or bloom in the presence of a higher concentration of oxygen.
[0039] In an alternate embodiment, both membranes
14, 16 may be formed from substantially impermeable materials, for use in certain applications.
This arrangement may be useful, for example, to provide alternative labeling schemes.
With such an embodiment, the lower membrane may contain a label of a supermarket or
other retail store, such as an advertising label; the upper membrane, on the other
hand, may display a label from an initial meat packer, providing instructions to the
retail butcher rather than the ultimate buyer of the meat. Then the outer membrane
16 may be easily removed relative to the inner membrane
14.
[0040] Referring to Figure 3, an exemplary process for forming the package 10 will be explained.
Starting at the right side of Figure 5, a tray 12, held from below in a rigid confirming
carrier 60, is filled in a conventional fashion with a food product A. Next, the package
10 is evacuated of oxygen and gas back-filled with a transportion gas which is lower
in oxygen content. A web 70 of the more permeable membrane 14 is unwound from a pair
of rolls 62 and 64 and positioned over the tray 12. The more permeable web 70 is secured
to the inner ledge 24, for example by a heat sealing machine 66. Thereafter, a conventional
cutting press 68 is used to cut the web 70. In the embodiment of Figure 1-2, the web
70 is cut at a position adjacent to the trough 26. It should be clear that the trough
26 facilitates the removal or cutting of the membrane 14 from the web 70 in place
on the package 10. The web 70 may also be severed by using heat or ultrasonic energy
or the like.
[0041] At the next station, a web 76 of the less permeable material 16 is unrolled from
a pair of rolls 72, 74 so that the less permeable web 76 may be positioned on the
package 10. In the embodiment of Figures 1-2, the less permeable web 76 is secured
to the ledge 22. This securing is performed using conventional techniques, such as
using a heat sealing machine 42. At this point, the transportation gas is sealed inside
the package 10. Finally, the web 76 is cut by conventional cutting equipment 78. In
the embodiment of Figures 1-2, the cutting occurs slightly outward from the edge 28.
[0042] When the package 10 has been assembled, the package may be shipped to locations for
retain sale. At the retail establishment, the package is held until the package is
ready to be displayed. At that point, the less permeable membrane 16 is peeled away
and discarded. After a short holding period, the package may be displayed for retain
sale. The holding period is necessary to allow the package to absorb oxygen through
the more permeable membrane 14. After the meat product has bloomed, it can be displayed
for retail sale.
[0043] It can be understood that through the provision of the trough 26, both membranes
14, 16 may be attached to the same tray 12 in a fashion that permits high speed manufacture.
While the simplified process depicted in Figure 3 suggests that the material may be
packaged in a serial fashion, this approach would likewise apply to conventional packaging
equipment.
[0044] Advantageously, the more permeable membrane is sufficient to maintain the desired
gaseous environment in the package until the less permeable membrane is in place.
This is especially true with high speed systems. However, in some circumstances, it
may be useful to provide a particular gaseous atmosphere between the stations where
the more permeable and less permeable membranes are applied.
[0045] The same process can be used to make a package wherein both membranes are substantially
impermeable.
[0046] Thus, it is apparent that there has been provided, in accordance with the invention,
a package and a method that satisfies the aims, objects, and advantages set forth
above. While the invention has been described in conjunction with specific embodiments
thereof, it is evident that many alternatives, modifications, and variations will
be apparent to those skilled in the art in light of the foregoing description. Accordingly,
it is intended to embrace all such embodiments, alternatives, modifications, and variations
that fall within the scope of the appended claims.
1. Verpackung (10), umfassend:
eine Schale (12);
eine biegsame erste Membrane (14), die dicht mit der Schale verbunden ist;
und eine biegsame zweite Membrane (16), die oberhalb der ersten Membrane dicht mit
der Schale verbunden ist, wobei besagte Membrane an jeweils getrennten Stellen (24,
22) an der Schale befestigt sind, dadurch gekennzeichnet, dass
besagte Stellen (24, 22) im wesentlich koplanar sind, wobei besagte koplanare Stellen
über eine Vertiefung (26) voneinander getrennt sind, so dass besagte Membrane im wesentlichen
zueinander koplanar sind, wobei die zweite Membrane von der Schale unabhängig von
der ersten Membrane entfernbar ist.
2. Verpackung (10) nach Anspruch 1, dadurch gekennzeichnet, dass
die zweite Membrane (16) weniger permeable als die erste Membrane (14) gegenüber Gas
ist.
3. Verpackung (10) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass
die erste Membrane (14) und die zweite Membrane (16) jeweils ein elastisches Material
umfassen.
4. Verpackung (10) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass
die erste Membrane (14) und die zweite Membrane (16) jeweils ein im wesentlichen impermeables
Material umfassen.
5. Verpackung (10) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass
die Schale (12) einen Schaum umfasst, und die koplanaren Stellen (24, 22) Lagen umfassen,
wobei die Lagen zu einer im wesentlichen uniformen Dicke verpresst sind.
6. Verpackung (10) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass
die erste Membrane (14) und die zweite Membrane (16) lediglich über die Schale (12)
miteinander verbunden sind.
7. Verpackung (10) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass
die zweite Membrane (16) von der Schale (12) abziehbar ist.
8. Verfahren zur Verpackung eines Lebensmittelprodukts (A), umfassend die folgenden Schritte:
Befüllen einer Schale (12) mit einem Lebensmittelprodukt;
Überdecken der Schale mit einer biegsamen ersten Membrane (14) durch Abteilen der
Membrane von einem Gewebematerial (70), Anordnen der ersten Membrane auf der Schale
und Herstellen einer dichten Verbindung zwischen der Membrane und der Schale an einer
ersten Stelle (24),
wobei das Verfahren durch folgende zusätzliche Schritte gekennzeichnet ist:
a) Abtrennen der ersten Membrane oberhalb einer Vertiefung (26), die in der Schale
ausgeformt ist,
b) Überdecken der Schale und besagter biegsamen ersten Membrane mit einer im wesentlichen
koplanaren biegsamen zweiten Membrane (16), und
c) Herstellen einer dichten Verbindung der zweiten Membrane auf der Schale an einer
zweiten Stelle (22) außerhalb der ersten Stelle, wobei die erste Stelle und die zweite
Stelle im wesentlichen koplanar und über besagte Vertiefung voneinander getrennt sind.
9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass
die erste Membrane (14) dicht mit der Schale (12) verbunden und dann von besagtem
Gewebe (70) abgetrennt wird.
1. Un emballage (10) comprenant :
un plateau (12);
une première membrane (14) flexible, reliée de façon étanche audit plateau;
et une deuxième membrane (16) flexible, reliée de façon étanche au dit plateau sur
ladite première membrane, lesdites membranes étant fixées à des emplacements (24,
22) séparés respectifs, sur ledit plateau, caractérisé en ce que lesdits emplacements (24, 22) sont sensiblement coplanaires, lesdits emplacements
coplanaire étant séparés par un creusement (26), de manière que lesdites membranes
soient sensiblement coplanaires l'une envers l'autre, ladite deuxième membrane étant
amovible du plateau, indépendamment de ladite première membrane.
2. L'emballage (10) selon la revendication 1, dans lequel la deuxième membrane (16) est
moins perméable aux gaz que la première membrane (14).
3. L'emballage (10) selon l'une quelconque des revendications précédentes, dans lequel
les première (14) et deuxième (16) membranes sont chacune formées d'un matériau élastique.
4. L'emballage (10) selon l'une quelconque des revendications précédentes, dans lequel
lesdites première (14) et deuxième (16) membranes contiennent chacune un matériau
sensiblement imperméable.
5. L'emballage (10) selon l'une quelconque des revendications précédentes, dans lequel
le plateau contient un produit alvéolaire, lesdits emplacements (24, 22) coplanaires
comprennent des rebords, lesdits rebords étant pressés à une épaisseur sensiblement
uniforme.
6. L'emballage (10) selon l'une quelconque des revendications précédentes, dans lequel
les première (14) et deuxième (16) membranes sont reliées uniquement par ledit plateau
(12).
7. L'emballage (10) selon l'une quelconque des revendications précédentes, dans lequel
ladite deuxième membrane (16) est susceptible d'être enlevée dudit plateau (12) par
pelage.
8. Un procédé d'emballage d'un produit alimentaire (A), comprenant les étapes suivantes
:
remplir un plateau (12) avec un produit alimentaire;
couvrir ledit plateau avec une première membrane (14) flexible en séparant la membrane
depuis une nappe de matériau (70), positionner ladite première membrane en place sur
ledit plateau et refermer de façon étanche ladite membrane sur ledit plateau en un
premier emplacement (24);
ledit procédé étant
caractérisé en ce que le procédé comprend les étapes subséquentes suivantes :
a) séparer la première membrane sur un creusement (26) formé dans ledit plateau;
b) couvrir ledit plateau et ladite première membrane flexible par une deuxième membrane
(16) flexible, sensiblement coplanaire, et;
c) refermer de façon étanche ladite deuxième membrane sur ledit plateau en un deuxième
emplacement (22), extérieur audit premier emplacement, lesdits premiers et deuxième
emplacements étant sensiblement coplanaires et séparés par ledit creusement.
9. L'emballage (10) selon la revendication 8, dans lequel ladite première membrane (14)
est fermée de façon étanche sur ledit plateau (12), puis séparée de ladite nappe (70).