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(11) | EP 3 251 969 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | HEATABLE FOOD PRODUCT PACKAGING |
| (57) The present disclosure relates to packaging for heatable food products. More specifically,
an aspect relates to packaging for microwaveable food products, configured such that
the food products can be microwaved in the packaging. Examples of such heatable food
products include, but are not limited to, battered and/or breaded fish, meat and poultry
products such as fish fingers and chicken nuggets. There is described herein heatable
food product packaging comprising: a carton for containing a food product; and a cover
comprising a first part and a second part, the first part being affixed to the carton
and the second part being at least partially separable from the first part, wherein
the first part is configured to provide a handle for grasping the packaging once the
second part has been at least partially separated from it. A blank and a method for
forming such packaging are also described.
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[0001] The present disclosure relates to packaging for heatable food products. More specifically, an aspect relates to packaging for microwaveable food products, configured such that the food products can be microwaved in the packaging. Examples of such heatable food products include, but are not limited to, battered and/or breaded fish, meat and poultry products such as fish fingers and chicken nuggets. The packaging can for example also be used to store the food products prior to heating, for example in a freezer.
[0002] Further, the disclosure relates to a blank for forming such packaging and a method of forming such packaging from such a blank.
[0003] A well understood problem in the field of home-cook convenience foods is that, while heating of a food product can be relatively straightforward, handling the food product once heated can be dangerous as it may have been heated to temperatures high enough to result in burns. This problem is a particular concern when the user is in a hurry, or is a child or a person with impaired motor functions.
[0004] Further, many such food products have to be removed from their packaging and placed on a cooking receptacle for heating, such as a baking tray for oven heating or a ceramic plate for microwave heating. The cooking receptacles then tend to become heated along with the food product, and can pose as much or even more of a burn risk to the user than the food product itself. They also typically require cleaning after use. Microwave cooking also poses an added danger if a metallic coking receptacle is used by mistake.
[0005] What is needed is heatable food product packaging (i.e. packaging for a food product which can be heated with the food product still inside), which reduces the risk of burns to the user following heating of the food product.
[0006] According to a first aspect, there is provided heatable food product packaging comprising: a carton for containing a food product; and a cover comprising a first part and a second part, the first part being affixed to the carton and the second part being at least partially separable from the first part, wherein the first part is configured to provide a handle for grasping the packaging once the second part has been at least partially separated from it.
[0007] The first part could comprise: a spine portion affixed to the carton; and a wing portion on either side of the spine portion, the two wing portions configured to provide the handle.
[0009] The first and second parts could be at least partially separable from one another along one or more tear strips and/or perforated tear lines.
[0010] Portions of those tear strips and/or perforated tear lines could be connected to one another by one or more cut lines.
[0012] The first and second parts could be completely separable from one another; and each wing portion could be delimited from the spine portion by at least three fold lines connected in an alternating series by at least two cut lines, the at least three fold lines being longitudinally aligned with one another and parallel with a longitudinal axis of the spine portion, each cut line describing a protrusion of the outline of the spine portion away from the axis, and the wing portions being reflections of one another in the axis such that the spine portion comprises at least three narrower parts delimited transversely with respect to the axis by fold lines, alternating with at least two wider parts delimited transversely with respect to the axis by cut lines; the adhesive being located at least in the at least two wider parts.
[0013] The second part could be at least partially separable from the carton along one or more tear strips and/or perforated tear lines.
[0014] The packaging could further comprise one or more additional perforated tear lines and/or cut lines arranged to, together with the one or more tear strips and/or perforated tear lines along with the second part is at least partially separable from the carton, describe a push-out region of the second part which is at least partially separable from the rest of the second part. Alternatively or additionally, the packaging could further comprise one or more additional perforated tear lines and/or cut lines arranged to, together with the one or more tear strips and/or perforated tear lines along with the second part is at least partially separable from the carton, describe a push-out region of the carton which is at least partially separable from the rest of the carton. The push-out region could be arranged such that pushing on it with a finger results in its at least partial separation, providing a finger hold from which the at least partial separation of the first and second parts can be begun.
[0015] The second part could comprise a pointed or tabbed flap from which it can be grasped to at least partially separate it from the carton along the one or more tear strips and/or perforated tear lines.
[0019] The carton and cover could be configured such that the food product is completely enclosed before the first and second parts are at least partially separated.
[0020] The carton could comprise one or more openings covered by the second part, such that the one or more openings are revealed by the at least partial separation of the second part.
[0021] The carton could comprise one or more separable regions configured to be removed by the at least partial separation of the second part of the cover, so as to provide one or more openings in the carton.
[0022] The separable regions could each be delineated from the rest of the carton by perforated tear lines, and affixed to the second part of the cover.
[0025] The width of the wing portions with respect to a longitudinal axis of the spine portion could be greater towards the pack's front end than its back end.
[0026] The wing portions could comprise tabs extending away from the axis and being located exclusively forwards of a median line of the carton.
[0029] The packaging could comprise one or both of: a top susceptor film patch located on the interior of the carton's top wall such that, in use, the top susceptor film patch faces the top of the food product; and a bottom susceptor film patch located on the interior of the carton's bottom wall such that, in use, the bottom susceptor film patch faces the bottom of the food product.
[0030] The packaging could be configured such that, in use, there is a headspace of between 3 and 10 mm between the food product and the carton's top wall.
[0034] According to a second aspect there is provided a blank for forming heatable food product packaging, the blank comprising a carton portion and a cover portion; the carton portion comprising: at least one carton top panel for forming a carton top wall; at least one carton bottom panel for forming a carton bottom wall; and at least one carton back panel, for forming a carton back wall, between the carton top and bottom panels and articulated thereon along fold lines; the cover portion comprising: a cover main panel for forming a cover top wall; and a cover front panel, for forming a cover front wall, articulated on the cover main panel along a fold line; wherein: adhesive is provided on one or both of a first part of the cover main panel and the carton top panel, for affixing them to one another when the blank is folded; and one or more perforated tear lines are provided between the first part of the cover main panel and a second part of the cover so that they can be at least partially separated from one another in such a way that the first part can provide a handle for grasping the packaging.
[0035] Portions of those tear strips and/or perforated tear lines could be connected to one another by one or more cut lines.
[0036] The first part could extend closer to the edge of the cover main panel adjoining the cover front panel than the opposing edge of the cover main panel.
[0037] The first part could comprise: a spine portion configured to be affixed to the carton top panel; and a wing portion on either side of the spine portion, the two wing portions configured to provide the handle.
[0039] The width of the wing portions with respect to a longitudinal axis of the spine portion could be greater towards the edge of the cover main panel adjoining the cover front panel than the opposing edge of the cover main panel.
[0040] The wing portions could comprise tabs extending away from the axis and being located exclusively forwards of a median line of the cover main panel.
[0041] The first and second parts could be completely separable from one another; and each wing portion could be delimited from the spine portion by at least three fold lines connected in an alternating series by at least two cut lines, the at least three fold lines being longitudinally aligned with one another and parallel with a longitudinal axis of the spine portion, each cut line describing a protrusion of the outline of the spine portion away from the axis, and the wing portions being reflections of one another in the axis such that the spine portion comprises at least three narrower parts delimited transversely with respect to the axis by fold lines, alternating with at least two wider parts delimited transversely with respect to the axis by cut lines; the adhesive being located at least in the at least two wider parts when the blank is folded.
[0042] One or more tear strips and/or perforated tear lines could be provided between the second part and the carton bottom panel.
[0043] The blank could further comprise one or more additional perforated tear lines and/or cut lines arranged to, together with the one or more tear strips and/or perforated tear lines along with the second part is at least partially separable from the carton, describe: a push-out region of the second part which is at least partially separable from the rest of the second part; and/or a push-out region of the carton which is at least partially separable from the rest of the carton; such that pushing on the push-out region with a finger results in its at least partial separation, providing a finger hold from which the at least partial separation of the first and second parts can be begun.
[0044] The blank could further comprise a pointed or tabbed cover back flap articulated on the cover main panel along a fold line.
[0045] The blank could further comprise: at least one flap articulated along a fold line at an edge of one or more of the main panels for forming a left side wall; and at least one flap articulated along a fold line at an edge of one or more of the main panels for forming a right side wall.
[0046] The blank could further comprise at least one cover back flap articulated along a fold line at the edge of the cover main panel opposing the cover front panel, for forming a cover back wall; wherein: the at least one carton back panel comprises one or more vent hole cut-outs; and/or the at least one carton back panel comprises one or more vent fillers delineated by perforated tear lines and configured to be affixed to the at least one cover flap when the blank is folded.
[0047] The at least one carton top panel could comprise one or more vent fillers delineated by perforated tear lines and configured to be affixed to the at least one cover flap when the blank is folded.
[0048] The sides of one or both of the carton top and bottom panels that face the interior of the carton when the blank is folded could be provided with susceptor film patches.
[0049] The blank could be configured such that, when folded and in use, there is a headspace of between 3 and 10 mm between the food product and the carton's top wall.
[0052] According to a third aspect there is provided a method of making packaging according to the first aspect, comprising folding a blank according to the second aspect.
[0053] According to a fourth aspect there is provided packaging substantially as herein described, with reference to the accompanying figures.
[0054] According to a fifth aspect there is provided a blank substantially as herein described, with reference to the accompanying figures.
[0055] According to a sixth aspect there is provided a method of making packaging substantially as herein described, with reference to the accompanying figures.
[0056] Aspects of the present invention will now be described by way of example with reference to the accompanying figures. In the figures:
Figures 1 a to 1 f illustrate use of example packaging;
Figures 2a to 2d illustrate the example packaging of Figures 1 a to 1f prior to removal of a cover;
Figures 2e to 2j illustrate the packaging of Figures 2a to 2d following removal of the cover;
Figures 3a and 3b illustrate an example blank for forming the packaging of Figures 1 a to 2j;
Figure 4 is a flowchart of an example method for forming the packaging of Figures 1 a to 2j from the blank of Figures 3a to 3b;
Figures 5a to 5d illustrate alternative example packaging; and
Figure 6 illustrates an alternative example blank for forming the alternative packaging of Figures 5a to 5d.
[0057] Throughout the figures, dotted lines indicate perforated tear lines, dash-dot lines indicate fold lines and solid lines indicate edges or slits (i.e. cut lines).
[0058] Perforated tear lines, as referred to herein, are any lines of packaging material weakened in such a way as to allow a user to easily tear the material along them. This may be achieved for example by making several dot and/or dash like holes, slits, scores or indentations in the packaging material, along the desired tear line, separated by regions which have not been weakened (or which have been weakened to a lesser extent). Alternatively, the line may be cut straight through and then partially re-joined in places to hold the packaging material either side of the line together.
[0059] As referred to herein, the phrase "cut line" includes any line made by cutting, comprising both slits (formed from a single cut with no deliberate removal of material) and cut-outs (formed from one or more cuts which outline a portion of material so that it is no longer attached to the material surrounding it).
[0060] The terms "top", "bottom", "side", "right", "left" and other terms describing the orientation of features are not intended to be limiting and are purely included in order to facilitate the description of the relative location of these features in the context of the accompanying drawings. In use, the features may be disposed in other orientations.
[0061] The following description is presented to enable any person skilled in the art to make and use the system, and is provided in the context of a particular application. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art.
[0062] What is proposed is a heatable food product packaging comprising a carton for containing a food product and a cover comprising a first part and a second part. The first part is affixed to the carton and the second part is at least partially separable from the first part. When the second part is at least partially separated from the first part, the first part creates a handle for grasping the packaging.
[0063] An example of such packaging 100, and how it can be used, is illustrated in Figures 1 a to 1 f. In Figure 1a, the carton 110 is obscured by the cover 120. The user has grasped one end of the second part 122 of the cover to start separating it from the first part 121 of the cover. The separation of the second part from the first part continues through Figures 1b, 1c and 1d. The first part of the cover remains affixed to the carton as the second part is peeled back and away. In the example shown, the second part of the cover is completely removed, but in other examples it could for example only be folded back, remaining partially attached to the first part.
[0064] As the cover is removed, optionally one or more parts of the carton may be removed with it, e.g. vent fillers 312f shown in Figure 1d. These will be discussed further in relation to Figure 3b below.
[0065] Once the second part of the cover has been separated from the first part, as shown in Figure 1e the edges of the first part which were previously attached to the second part are free to move. The user can therefore pick them up and pinch them together as shown in Figure 1f to create a handle for transporting the carton and its contents 130 (e.g. fish fingers), e.g. into a microwave for heating. (The handle can be made of material flexible enough to permit this pinching action.)
[0066] Following heating, the carton and contents can be safely picked up using the handle, which is configured to be one or both of resistant to heating and rapidly cooling. For example, the handle may be configured to have a much larger surface area in contact with the surrounding air than with the carton containing the heated food product, leading to rapid cooling of the handle. Alternatively or additionally, the handle may be made of a material with a relatively high heat capacity, so that the handle does not heat up as much as the food product. Alternatively or additionally, if the packaging is intended for microwave cooking, the handle may be made of a material with a relatively low water content, e.g. of less than 10 %, e.g. from 8 to 9 %, so that the handle does not heat up as much as the food product.
[0067] The packaging may be configured such that, while grasping the handle, the user can tilt the carton to gently slide the contents out, e.g. onto a plate, without damaging the food product or substantially changing its orientation - e.g. there is no need to flip the food product over. For example, following the at least partial separation of the first and second cover parts, an open front end of the carton could be revealed out of which the contents can be slid as illustrated in Figure 1f. It may be preferable to allow for emptying of the carton while substantially maintaining the orientation of the food product, since the upper surface of the food product may be more appealing than the lower surface, for example due to it being crispier and/or more browned. (This could for example be due to airflow over the top surface carrying away moisture evaporated therefrom and/or due to infrared browning by a susceptor patch on the interior of the carton's top wall as explained in more detail below in relation to Figure 3b.)
[0068] Figures 2a to 2d illustrate an example pack 200, as provided to a user with the second part 222 of the cover 220 fully attached to the first part 221. In this state the pack has a compact and easily stackable shape (in this example cuboid) to facilitate easy transportation and storage, e.g. in a freezer or cupboard. Figure 2a is a perspective view, Figure 2b is a top view, Figure 2c is a bottom view and Figure 2d is a back view.
[0069] As shown in Figures 2a and 2b, the first part 221 of the cover is delineated from the second part 222 of the cover by a perforated tear line 225c. In this example, the first part is in a "butterfly" shape, with a central spine portion and distal wing portions. The spine portion is affixed to the top of the carton, e.g. with adhesive, while the wing portions are free to be grasped to form the handle once separated from the second part 222 of the cover. The spine portion is delineated from the wing portions by fold lines 225d. The fold lines can be provided by weakening the packaging material, for example by scoring cardboard.
[0070] In the example shown in Figures 2a and 2b, the fold lines are broken in two places by cut lines 225e. These cut lines are provided symmetrically with respect to the spine portion's central axis and extend the spine portion's outline to a greater width than in the regions transversely bounded by fold lines. The spine portion may be glued to the carton in at least the wider regions, which provide a large surface area for adhesive to stick, facilitating a strong bond. Alternatively, the fold lines could extend from one end of the spine to the other with no breaks (i.e. no cut lines 225e). The fold lines delineating the spine could be straight, or curved, or some other shape.
[0071] Instead of the first and second parts of the cover being delineated exclusively by a perforated tear line, at least a part of line 225c could be a cut line. For example, the parts of line 225c outlining the wing portions could be formed of slits or cut-outs, with only the parts of line 225c outlining the distal ends of the spine portion being formed of perforated tear lines. In this example, the short perforated tear lines at the distal ends of the spine portion are all that connects the first and second parts of the cover, 221 and 222. This type of delineation of the wings helps to indicate to the user that the pack cannot be opened by lifting the wings; they must look for another opening point (and thus find the flap described below).
[0072] As shown in Figure 2c, the second part 222 may extend over the front face of the carton and wrap around underneath to a perforated tear line 223c on the bottom face. Alternatively the tear line could for example be along one of the upper or lower front edges, or on one of the top or front faces. The tear line may be arcuate as shown to facilitate easy tearing by hand. Easy tearing is further facilitated if at least one end of the tear line is at a corner of the pack as shown.
[0073] As shown in Figure 2d, the second part 222 may also extend (e.g. as a flap) over the back face of the carton. It may be shaped so as to point downwards as shown to indicate to a user that they should grasp the point/tab to begin tearing the second part away. The flap may for example be loosely affixed to the back face of the carton with adhesive. Alternatively, it could be tucked into a slit in the back face of the carton or loosely held there in some other way.
[0074] As another option (not shown), instead of such a tab-style opening, a tear strip could be provided. This could for example be provided by a pair of tram-line perforations extending transversely across the cover, close to its distal end. A distal strip of cover beyond the tram lines could be affixed (e.g. with adhesive) to the carton, such that, when it is connected to the rest of the cover, the cover remains affixed to the carton, but when the strip of cover between the perforated tram lines is pulled away along the perforations, while the distal strip remains adhered to the carton, the part of the cover on the other side of the tram lines flaps freely and can be grasped to pull the cover away from the wings.
[0075] Figure 2e is a perspective view of pack 200 following removal of the second part of the cover, leaving the first part 221 attached to the carton 210. In Figure 2f the wings have been partially raised and in Figure 2g the wings have been fully raised to form the handle. Figures 2h and 2i respectively show front and back views with the wings partially raised. Figure 2j shows a side view with the wings fully raised.
[0076] As illustrated in Figures 2e to 2h, the carton may have an open front face. This can provide the advantages noted above in terms of ease and accuracy of serving of the food product. It can also allow for escape of steam during and immediately after heating, which is preferable for food products which are intended to have crispy outer surfaces, such as breaded or battered food products. Where the food product comprises individual portions which extend significantly further in length than width (e.g. fish fingers), the best ventilation is achieved from the sides perpendicular to the length of the food portions. Therefore the food portions are preferably introduced into the carton in such a way that they lie with their longest sides perpendicular to the open front end. Further ventilation can be provided by vent holes in any of the back, top or side faces. For example vent holes 211 can be provided in the back face of the carton as shown in Figures 2h and 2i.
[0077] It may be preferable for any ventilation openings in the carton to be covered during transport and storage of the pack, to keep the food product fresh and clean, to prevent freezer burn if the pack is transported and/or stored in a freezer, and to prevent spillages of the food product out of the pack. In the example shown in Figure 2, all of the openings in the carton are blocked by the second part of the cover when it is in place. Alternatively or additionally, the pack may be transported and stored inside an outer protective layer, for example a plastic overwrap might be provided. Such an overwrap might also be used to hold several packs together for sale as a multipack.
[0078] The profile of the wing portions can be asymmetrical as shown (see, in particular, Figure 2j) so that the handle is higher towards the front of the pack, encouraging a user to pick it up closer to the open front end of the carton than the partially closed back end, making it less likely that the contents of the pack will be spilled unintentionally when the user picks up the pack by the handle. As an additional cue to the user to grasp the wings towards their front edges, the wing profiles could comprise tab portions which, when the wings are held vertically, extend upwards from the front part of the wings. For the same reason, the first part may extend closer to the front edge than the back edge of the top surface, so that when the pack is picked up by the handle it is more likely to balance tilted backwards than forwards.
[0079] As shown in Figures 2e to 2g, a susceptor board or patch 213f can be included, as discussed in further detail below in relation to Figure 3b.
[0080] Figures 3a and 3b show an example blank or net 300 for forming example heatable food product packaging. Figure 3a shows principally the faces that will be on the exterior after folding and Figure 3b shows principally the faces that will be on the interior after folding. The blank comprises a carton portion 310 and a cover portion 320. The panels of the blank will now be described, proceeding from right to left along the length of the blank.
[0081] The carton portion 310 comprises a carton top panel 311 for forming the carton top wall. This is connected along a fold line to a back panel 312 for forming the carton back wall. Back panel 312 is in turn connected along a fold line to a carton bottom panel 313 for forming the carton bottom wall.
[0082] The cover portion 320 may comprise a cover bottom wall part 323 connected to the carton bottom panel 313 by a perforated tear line 323c. (Alternatively, a tear line between the carton and cover portions may be provided in another location as explained in relation to Figure 2c above.) Cover bottom wall part 323 is connected by a fold line to a cover front panel 324 for forming the cover front wall. Cover front panel 324 is in turn connected by a fold line to a cover main panel 325 for forming the cover top wall. Finally, a cover back panel 326 for providing a cover back wall may be connected by a fold line to cover main panel 325.
[0083] If the sides of the pack are to be closed, then one or more side flaps can be provided along each long edge of the blank. For example, as shown in Figures 3a and 3b, side flaps 311 a are articulated along fold lines at the right and left edges of carton top panel 311 for forming carton right and left side walls respectively. Further side flaps 312a, 313a and 324a may be provided at the right and left edges of carton back panel 312, carton bottom panel 313 and cover front panel 324 respectively to provide support to the pack structure.
[0084] Adhesive or other fixing means may be provided at various locations on the blank to hold the pack together when the blank is folded. For example, as shown in Figure 3a, adhesive 313b may be provided on side flaps 313a (if present) for sticking them to the reverse sides of any of side flaps 311 a, 312a and 324a that are present. As shown in Figure 3b, adhesive 325b may be provided on the first part of the cover portion 320 for sticking to the reverse side of carton top panel 311. Adhesive 326b may also be provided on cover back panel 326 (if present) for sticking to the reverse side of carton back panel 312. Adhesive may alternatively or additionally be provided in the locations the adhesive patches illustrated are intended to stick to on folding of the blank.
[0085] Optionally, vent fillers 312f may be provided. As shown in Figure 3b, these are portions of carton back wall panel 312 outlined by perforated tear lines. When the blank is folded, adhesive patches 326b on cover back flap 326 adhere to the vent fillers 312f. When the cover is at least partially removed by pulling on the tab at the bottom of cover back flap 326, the vent fillers 312f remain adhered to the cover, leaving vents in the carton back wall. (See the outermost vents 211 in Figure 2h and vent fillers 112f in Figure 1 d.)
[0086] As shown in Figures 3a and 3b, the cover main panel 325 may comprise perforated tear line 325c, fold lines 325d and slits 325e for forming the "butterfly" type handle structure described above in relation to Figures 2a and 2b.
[0087] As shown in Figure 3b, if the pack is to be heated in a microwave then one or both of the carton top and bottom panels 311 and 313 (and optionally any of the other panels that will face the food product once the blank is folded and the carton filled) might bear a susceptor film patch 311f/313f respectively so that susceptor material faces the food product during heating. Susceptor materials absorb electromagnetic energy and convert it to heat. This heat can be transmitted to any food product in contact with the susceptor via conduction (as will be the case for susceptor film patch 313f on the bottom wall of the carton), or re-emitted as infrared radiation (as will be the case for susceptor film patch 311 f on the top wall of the carton if a headspace is provided between the food protect and the carton top wall). Susceptor materials can thus be used to apply heat to the exterior of food products during microwaving to keep them crisp and/or provide browning. Susceptors can also contribute to more even cooking of the exterior of the food product, since heating by conduction and infrared radiation does not suffer from the "hot spot" problem which arises in microwave ovens at microwave constructive interference nodes.
[0088] If there is an air gap (or otherwise poor thermal contact) between the susceptor and the food surface, the susceptor heats to higher temperatures and will therefore radiate more infrared radiation. Since infrared radiation cannot penetrate the food product as far as microwave radiation, the infrared radiation selectively heats the surface of the food product, without over-heating the interior (which could cause it to dry out). It may therefore be preferable for the pack to be sized relative to the food product so as to allow a headspace to form between the food product and susceptor-bearing top wall of the carton. This headspace might be fully present on packing the food product. Alternatively, the food product might fit snugly into the carton on packing, or fit in with a small headspace, and the carton might be configured to expand to create/increase the size of the headspace during cooking.
[0089] A susceptor board could be used instead of a susceptor film patch. Either way, the susceptor could be affixed to the carton material (e.g. with adhesive), or could be included within it. For example, if the carton is made of plastic (e.g. polyethylene terephthalate, 'PET') lined cardboard as described below, the susceptor could be laminated between the cardboard and plastic. This construction has the advantage that no adhesive is required and the susceptor cannot peel away at the edges during cooking, e.g. due to steam weakening an adhesive bond or causing one component of the packaging to warp more/in a different direction to another.
[0090] According to one example method 400, the blank of Figures 3a and 3b can be used to create heatable food product packaging as shown in Figure 4. At step 410, adhesive is applied to the cover main panel and cover back flap at 325b and 326b respectively. At step 420, the blank is folded over on itself in the following manner. Carton back panel 312 is folded at a right angle to carton top panel 311. Carton bottom panel 313 is folded at a further right angle (continuing to turn in the same sense) to carton back panel 312. Cover front panel 324 is folded at a further right angle (continuing to turn in the same sense) to carton bottom panel 313 to complete a full turn. Cover top panel 325 is folded at a further right angle (continuing to turn in the same sense) to overlay carton top panel 311 (and will stick thereto due to adhesive 325b). Finally, cover back panel 326 is folded at a further right angle (continuing to turn in the same sense) to 325 to overlay carton back panel 312 (and will stick thereto due to adhesive 326b). This creates an open sided "sleeve" type pack. At 430, the pack is filled with the food product, e.g. by sliding four fish fingers side-on into the sleeve through one of the open sides. At 440 adhesive is applied at 313b. Finally, at 450 the side flaps are folded in to close up the sides of the pack. This may be done in the following manner. Flaps 313a are folded in at a right angle to 313 (towards the sleeve interior). Flaps 312a and 324a are then folded in at right angles to 312 and 324 respectively (towards the sleeve interior) to overlay flaps 313a (and will stick thereto due to adhesive 313b). Flaps 311 a are then folded in at right angles to 311 (towards the sleeve interior) to overlay flaps 313a, 312a and 324a (and will stick to flaps 313a due to adhesive 313b). As explained above, the filled and closed pack can optionally then be overwrapped, either singly or with one or more additional packs to form a multipack.
[0091] As illustrated by Figures 1 a to 1 f, packaging of the type described above can be configured for opening such that vent holes in the back wall of the carton are revealed first, followed by freeing of the wings from the rest of the cover, then finally the cover is removed from the open front end of the carton.
[0092] As an alternative to this, another example of this type of packaging could be provided which is configured for opening in the reverse direction. That is, the cover could be removed starting from the front end of the carton, followed by release of the wings and finally revealing of the vent holes in the back wall. In this way, the user becomes aware of the open front end of the carton earlier in the process, reducing the risk that they will spill the carton contents.
[0093] This could be achieved, for example, using a similar blank to that shown in Figures 3a and 3b, but with one or more features to indicate to the user that they should start opening from perforated tear line 323c.
[0094] For example, rather than a perforated tear line, line 323c could be a tear strip. It could end in a tab providing an indication to the user that they should start tearing it off by grasping the tab. Visual cues such as contrasting colouring of the tab, an arrow and/or "open here" lettering or similar could be provided to draw the user's attention to where to grasp the tab to tear the strip.
[0095] Alternatively, one or more further perforations and/or cut lines could be provided adjacent the centre of line 323c so as to, along with a portion of line 323c, describe a push-out region sized such that a user could press a finger (e.g. their index finger) into the push-out region, partially separating it from the surrounding material to allow them to hook the end of their finger underneath the end of the cover and tear along line 323c to start removal of the cover.
[0096] The push-out region could for example be crescent shaped, or could be another shape e.g. rectangular, square or triangular. It could be formed completely on one side or the other of line 323c (i.e. formed completely from the cover or the carton), or could straddle line 323c.
[0097] For such "reverse opening" style packaging examples, to avoid any implication that removal of the cover should start at flap 326, it could be rectangular instead of having a pointed or tabbed end.
[0098] To make the opening process quicker and easier for users, the cover could wrap around fewer faces of the pack. For example, Figures 5a to 5d and 6 illustrate an alternative example pack formed from a blank 600 having a cover which covers the front and top faces of a carton 510, plus a small portion of the bottom face of the carton. This alternative example pack is of the "reverse opening" style described above.
[0099] Figure 5a is a front/top perspective view of carton 510 of the alternative example pack following removal of the second part 522 of the cover. The remaining first part 521 of the cover forms wings as in the previous example, shown half-raised.
[0100] The alternative example pack of Figures 5a to 5d is similar in many respects to the example pack 100, 200 of Figures 1a to 2j. However, since the cover does not wrap around the back of the carton, instead of providing vent holes in the carton back face, vent holes 511 are instead provided in the carton top face, as shown in Figure 5b, which is a back/top perspective view of carton 510 of the alternative example pack following removal of the second part 522 of the cover.
[0101] Figure 5c is a front/bottom perspective view of carton 510 of the alternative example pack following removal of the second part 522 of the cover. Figure 5d is a view of the underside of the second part 522 of the cover following removal from the carton 510. These figures illustrate the push-out region 523g which the user starts the tearing process from and susceptor film patch 513f, the underside of which is partially revealed by removing the cover.
[0102] Figure 5d also illustrates vent fillers 512f which remain adhered to the second part 522 of the cover following its removal from the carton 510.
[0103] Figure 6 shows an example blank or net 600 for forming the alternative example heatable food product packaging of Figures 5a to 5d. Figure 6 shows principally the faces that will be on the exterior after folding. The blank comprises a carton portion 610 and a cover portion 620. The panels of the blank will now be described, proceeding from right to left along the length of the blank.
[0104] The carton portion 610 comprises a carton top panel 611 for forming the carton top wall. This is connected along a fold line to a back panel 612 for forming the carton back wall. Back panel 612 is in turn connected along a fold line to a carton bottom panel 613 for forming the carton bottom wall.
[0105] The cover portion 620 may comprise a cover bottom wall part 623 connected to the carton bottom panel 613 by a perforated tear line 623c. Cover bottom wall part 623 comprises push-out portion 623g, intended to help a user start to tear long perforated tear line 623c. Cover bottom wall part 623 is connected by a fold line to a cover front panel 624 for forming the cover front wall. Cover front panel 624 is in turn connected by a fold line to a cover main panel 625 for forming the cover top wall.
[0106] Side flaps 611 a are articulated along fold lines at the right and left edges of carton top panel 611 for forming carton right and left side walls respectively. Further side flaps 612a, 613a and 624a are provided at the right and left edges of carton back panel 612, carton bottom panel 613 and cover front panel 624 respectively to provide support to the pack structure.
[0107] Adhesive 611 b is provided on side flaps 611 a for sticking them to the reverse sides of side flaps 612a, 613a and 624a. Adhesive 612b and 624b is also provided on side flaps 612a and 624a respectively for sticking them to the reverse sides of side flaps 613a.
[0108] Vent fillers 611f are provided as portions of carton top panel 611 outlined by perforated tear lines.
[0109] The cover main panel 625 comprises perforated tear line 625c, fold lines 625d and slits 625e for forming the "butterfly" type handle structure described above.
[0110] The alternative packaging of Figures 5a to 5d and 6 can be formed by the same general method 400 as detailed in the flowchart of Figure 4. At step 410, adhesive is applied to the reverse of the cover main panel 625. The adhesive is located in corresponding locations to adhesive 625b of Figure 3b, as well as towards the two distal corners such that the vent fillers 611f can be stuck to the cover main panel 625. At step 420, the blank is folded over on itself in the following manner. Carton back panel 612 is folded at a right angle to carton top panel 611. Carton bottom panel 613 is folded at a further right angle (continuing to turn in the same sense) to carton back panel 612. Cover front panel 624 is folded at a further right angle (continuing to turn in the same sense) to carton bottom panel 613 to complete a full turn. Finally, cover top panel 625 is folded at a further right angle (continuing to turn in the same sense) to overlay carton top panel 311 (and will stick thereto due to the adhesive mentioned above). This creates an open sided "sleeve" type pack. At 430, the pack is filled with the food product, e.g. by sliding four fish fingers side-on into the sleeve through one of the open sides. At 440 adhesive is applied at 611 b, 612b and 624b. Finally, at 450 the side flaps are folded in to close up the sides of the pack. This may be done in the following manner. Flaps 611 a are folded in at a right angle to carton top panel 611 (towards the sleeve interior). Flaps 612a and 624a are then folded in at right angles to 612 and 624 respectively (towards the sleeve interior) to overlay flaps 611 a (and will stick thereto due to adhesive 611 b). Flaps 613a are then folded in at right angles to 613 (towards the sleeve interior) to overlay flaps 611 a, 612a and 624a (and will stick thereto due to adhesive 611 b, 612b and 624b respectively).
[0111] The blanks may for example be formed primarily from lined cardboard, e.g. GZ (coated cellulose) cardboard. The lining can be of a suitable material to protect the cardboard from grease in the carton contents, for example PET. The cardboard could be ∼230 g/m2. The PET could be ∼35g/m2.
[0112] The packaging material should preferably be chosen such that its properties (thickness, density, heat capacity, water content etc.), shape and size are configured so that the handles do not get too hot to handle during cooking, or cool rapidly to a suitable temperature for handling after cooking. For example, for the PET lined GZ described above, formed to the shape illustrated in the figures, with a mass of 0.4 g, microwave cooking for 3 minutes at 600 W has been found to raise the temperature of a wing from 18.6°C to 42.6°C at the upper edge and 55.2°C in the central region, but that within 20 seconds the wing cools to 27.3°C at the upper edge (which is comfortable to touch) and 36.7°C in the central region (which is low enough to be handled without causing burns).
[0113] Where perforations are included, some or all of these may be supported on one or both sides by some additional material, for example a strip of an additional PET layer. This construction is particularly applicable to the tram line perforations of the tear strip opening variant described above.
[0114] Where adhesive is used, this could for example be of a hotmelt type. It could for example have a viscosity at 160°C of 400 to 3000 mPas, e.g. 1400 to 1800 mPas. It could for example have an optimal processing temperature of 90 to 200°C, e.g. 160 to 190°C. The adhesive's melting point should preferably be higher than the temperatures likely to be encountered during microwave cooking. It could be an adhesive whose bond strength is not significantly reduced by low temperatures, such as may be used for deep freezing of food products. For example, it could be Henkel's Technomelt Supra 300 HT hotmelt adhesive. Alternatively, Henkel's Ultra-Melt 85 adhesive could be used.
[0115] While the packaging described herein has been primarily discussed in relation to freezer storage and microwave cooking of breaded/battered fish or poultry pieces, the packaging can also have other applications. For example the packaging could alternatively be used for ambient or chilled storage. The food products need not be breaded or battered, and can be of a larger size, for example the packaging could be used for chicken breasts or burgers.
[0116] Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only.
[0117] In addition, where this application has listed the steps of a method or procedure in a specific order, it could be possible, or even expedient in certain circumstances, to change the order in which some steps are performed, and it is intended that the particular steps of the method or procedure claims set forth herein not be construed as being order-specific unless such order specificity is expressly stated in the claim. That is, the operations/steps may be performed in any order, unless otherwise specified, and embodiments may include additional or fewer operations/steps than those disclosed herein. It is further contemplated that executing or performing a particular operation/step before, contemporaneously with, or after another operation is in accordance with the described embodiments.
1. Heatable food product packaging comprising:
a carton for containing a food product, the carton having an open front face; and
a cover comprising a first part and a second part, the first part being affixed to the carton and the second part being at least partially separable from the first part, wherein the first part is configured to provide a handle for grasping the packaging once the second part has been at least partially separated from it; wherein the first part comprises:
a spine portion affixed to the carton; and
a wing portion on either side of the spine portion, the two wing portions configured to provide the handle and the width of the wing portions with respect to a longitudinal axis of the spine portion being greater towards the pack's front end than its back end.
2. The packaging of claim 1, wherein the spine portion is connected to each wing portion
by at least one fold line.
3. The packaging of either of claims 1 or 2, wherein the first and second parts are at
least partially separable from one another along one or more tear strips and/or perforated
tear lines, and optionally:
portions of those tear strips and/or perforated tear lines are connected to one another by one or more cut lines.
4. The packaging of any of claims 1 to 3, wherein the first part is affixed to the carton
with adhesive, and optionally:
the first and second parts are completely separable from one another; and
each wing portion is delimited from the spine portion by at least three fold lines connected in an alternating series by at least two cut lines,
the at least three fold lines being longitudinally aligned with one another and parallel with a longitudinal axis of the spine portion,
each cut line describing a protrusion of the outline of the spine portion away from the axis, and
the wing portions being reflections of one another in the axis such that the spine portion comprises at least three narrower parts delimited transversely with respect to the axis by fold lines, alternating with at least two wider parts delimited transversely with respect to the axis by cut lines;
the adhesive being located at least in the at least two wider parts.
5. The packaging of any preceding claim, wherein the second part is at least partially
separable from the carton along one or more tear strips and/or perforated tear lines,
and optionally:
the packaging further comprises one or more additional perforated tear lines and/or cut lines arranged to, together with the one or more tear strips and/or perforated tear lines along with the second part is at least partially separable from the carton, describe:
a push-out region of the second part which is at least partially separable from the rest of the second part; and/or
a push-out region of the carton which is at least partially separable from the rest of the carton;
such that pushing on the push-out region with a finger results in its at least partial separation, providing a finger hold from which the at least partial separation of the first and second parts can be begun.
6. The packaging of any preceding claim, comprising one or more vent holes in the carton.
7. The packaging of any preceding claim, wherein the carton comprises one or more openings
covered by the second part, such that the one or more openings are revealed by the
at least partial separation of the second part.
8. The packaging of any preceding claim, wherein the carton comprises one or more separable
regions configured to be removed by the at least partial separation of the second
part of the cover, so as to provide one or more openings in the carton, and optionally:
wherein the separable regions are each delineated from the rest of the carton by perforated tear lines, and affixed to the second part of the cover.
9. The packaging of either of claims 7 or 8 as dependent directly or indirectly on claim
5, including its optional portion, wherein at least one of the openings is a vent
hole.
10. The packaging of any preceding claim, wherein the carton's interior comprises susceptor
material, and optionally:
wherein the packaging comprises one or both of:
a top susceptor film patch located on the interior of the carton's top wall such that, in use, the top susceptor film patch faces the top of the food product; and
a bottom susceptor film patch located on the interior of the carton's bottom wall such that, in use, the bottom susceptor film patch faces the bottom of the food product.
11. The packaging of any preceding claim, configured such that, in use, there is a headspace
of between 3 and 10 mm between the food product and the carton's top wall.
12. The packaging of any preceding claim, wherein the first part is formed of a material
with a water content of less than 10 %.
13. A blank for forming the heatable food product packaging of any preceding claim, the
blank comprising a carton portion and a cover portion;
the carton portion comprising:
the carton portion comprising:
at least one carton top panel for forming a carton top wall;
at least one carton bottom panel for forming a carton bottom wall;
andat least one carton back panel, for forming a carton back wall, between the carton top and bottom panels and articulated thereon along fold lines;
the cover portion comprising:a cover main panel for forming a cover top wall; and
a cover front panel, for forming a cover front wall, articulated on the cover main panel along a fold line;
wherein:adhesive is provided on one or both of a first part of the cover main panel and the carton top panel, for affixing them to one another when the blank is folded; and
one or more perforated tear lines and/or tear strips are provided between the first part of the cover main panel and a second part of the cover so that they can be at least partially separated from one another in such a way that the first part can provide a handle for grasping the packaging.
14. The blank of claims 13, further comprising:
at least one flap articulated along a fold line at an edge of one or more of the main panels for forming a left side wall; and
at least one flap articulated along a fold line at an edge of one or more of the main panels for forming a right side wall.
15. A method of making packaging according to any of claims 1 to 12, comprising folding
a blank according to either of claims 13 or 14.