Patent Application
20120183650
1. Field of the Invention
The present invention relates to a method of packaging a moldable food product and a package of a moldable food product.
2. Background Art
The food packaging industry is concerned with a variety of factors when creating packaging for a food product, including efficiency of the packaging process, in terms of both time and cost, unit size of the food product, environmental impact of the packaging and/or shelf life of the food product.
Baking products, such as butter or margarine, are traditionally manufactured as quarter pound sticks wrapped in parchment paper. Four quarter pound sticks are then packaged in a cardboard package and sold as one pound units. However, wrapping sticks of butter or margarine in parchment paper can be a time consuming and costly process and the outer cardboard package creates extra waste that generally ends up in a landfill. There is a need in the food packaging industry to improve the packaging of food products similar to butter or margarine given the concerns noted above.
The present invention is directed to a process of packaging a moldable food product, including: providing a base tray having a plurality of compartments arranged in an array, wherein each of the compartments has an interior space defining a volume for storing the moldable food product, an open end, and inter-compartmental walls extending from the open end on at least two sides; filling the compartments with the moldable food product, wherein the moldable food product is in a first phase; sealing the filled compartments so as to cover the open ends of the compartments; and cooling the moldable food product in each of the compartments to increase a solidity of the moldable food product with respect to the first phase to allow the moldable food product to conform to the shape of the interior space of the compartment.
In some embodiments, sealing includes covering the open ends of the compartments with a removable film.
In some embodiments, the removable film is perforated so that the compartments can be uncovered individually.
In some embodiments, filling includes dispensing the moldable food product heated in a range from 10 degrees Celsius to 26 degrees Celsius.
In some embodiments, the base tray is vibrated after filling the compartments with the moldable food product in order to level the moldable food product.
In some embodiments, the first phase is a liquid phase or semi-liquid phase and cooling includes refrigerating the base tray with the filled compartments for a sufficient time to increase the solidity of moldable food product in the compartments.
In some embodiments, the base tray is a food safe plastic material.
In some embodiments, the base tray further includes points of weakness on the inter-compartmental walls so that each compartment may be separated from a remainder of the compartments.
In some embodiments, the points of weakness are perforations and the at least two inter-compartmental walls of each compartment can be separated along the points of weakness to remove each compartment from adjacent compartments of the base tray.
In some embodiments, the interior space of each compartment is sufficient for storing 7 g to 8 kg of the moldable food product. In some embodiments, the interior space of each compartment is sufficient for storing 1 tsp to 1 gallon (5 mL to 4.5 L) of the moldable food product.
In some embodiments, the plurality of compartments includes a range from 2 to 72 compartments.
In some embodiments, the base tray includes four compartments.
In some embodiments, the base tray includes twelve compartments.
In some embodiments, the compartments further includes an indicium of a unit of gradation.
In some embodiments, the indicium is located in the interior space of the compartments so as to imprint the indicium on the moldable food product after increasing the solidity of the moldable food product.
In some embodiments, the indicium is located on the inter-compartmental walls.
In some embodiments, the moldable food product is chosen from the group consisting of butter, margarine, shortening, lard, and chocolate.
The present invention is also directed to a package of moldable food product including: a base tray having a plurality of compartments arranged in an array, wherein each of the compartments has an interior space defining a volume for storing a moldable food product, an open end, and inter-compartmental walls extending from the open end on at least two sides; a moldable food product contained in the interior space of each compartment and molded to a shape of the interior space of each compartment; and a cover which seals the open ends of the compartments.
In some embodiments, the package of moldable food product further includes an indicium of a unit of gradation.
In some embodiments, the package of moldable food product includes an indicium of a unit of gradation which includes 1 teaspoon, 1 tablespoon, 1/4 cup, 1/3 cup, 1/2 cup, and 1 cup.
In some embodiments, the package of moldable food product includes a cover wherein the cover is a removable film.
In some embodiments, the package of moldable food product includes a removable film wherein the removable film is perforated so that the compartments can be uncovered individually.
In some embodiments, the package of moldable food product includes a plurality of compartments wherein the plurality of compartments includes a range from 2 to 72 compartments and wherein the volume for storing the moldable food product is sufficient for containing the moldable food product in an amount in a range from 7 g to 8 kg.
In some embodiments, the package of moldable food product includes a base tray wherein the base tray includes four compartments and wherein the volume for storing a moldable food product is sufficient for containing a ¼ lb of the moldable food product.
In some embodiments, the package of moldable food product includes a base tray wherein the base tray includes twelve compartments and wherein the volume for storing a moldable food product is sufficient for containing a ¼ lb of the moldable food product.
In some embodiments, the package of moldable food product includes a base tray wherein the base tray further includes points of weakness on the inter-compartmental walls so that each compartment may be separated from a remainder of the compartments.
In some embodiments, the package of moldable food product includes points of weakness wherein the points of weakness are perforations and wherein the at least two inter-compartmental walls of each compartment can be detached along the points of weakness to remove each compartment from adjacent compartments of the base tray.
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention by way of example, and not by way of limitation. The drawings together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
The present invention will be described with reference to the accompanying drawings, in which like reference numerals refer to similar elements. While specific configurations and arrangements are discussed, it should be understood that this is done for illustrative purposes only. A person skilled in the pertinent art will recognize that other configurations and arrangements can be used without departing from the spirit and scope of the present invention. It will be apparent to a person skilled in the pertinent art that this invention can also be employed in a variety of other applications.
An exemplary packaged food product that results from the exemplary method illustrated in
In some embodiments, process 10 can including providing base tray 20. Base tray 20 can have an array of compartments 22. In some embodiments, for example, there can be two compartments, four compartments, eight compartments, twelve compartments, twenty-four compartments, thirty-six compartments, forty-eight compartments, sixty compartments, or seventy-two compartments.
In some embodiments, interior space 24 of each compartment 22 can have a sufficient volume for storing a desired food product. For example, interior space 24 can have a volume sufficient to store food products ranging in weight from about seven grams to about eight kilograms. In some embodiments, the interior space of each compartment is sufficient for storing 1 tsp to 1 gallon (5 mL to 4.5 L) of the moldable food product.
Base tray 20 can be any food safe plastic material known in the art, including bioplastics. In some embodiments, material for base tray 20 has sufficient flexibility and can withstand temperatures in a range from −10 degrees Celsius to 40 degrees Celsius.
In some embodiments, base tray 20 can also include points of weakness 36 to allow an individual compartment 22 to be separated from adjacent compartments of the base tray 20, as shown in
In some embodiments, base tray 20 can include indicia of a unit of measure 38, as shown in
In some embodiments, indicia of a unit of measure 38 can indicate the volume or weight of the moldable food product in each compartment 22. For example, indicia of a unit of measure 38 can be in units of 1 teaspoon, 1 tablespoon, ¼ cup, ⅓ cup, ½ cup, 1 cup, 1 ounce, ¼ lb, ½ lb, 1 lb, 1 gram, ¼ kg, ½ kg, 1 kg, 5 mL, 10 mL or 250 mL increments. Indicia of a unit of measure 38 can also include recipe specific units. For example, the indicia of a unit of measure can indicate 14 oz. of the moldable food product for use in a recipe calling for such an amount.
In some embodiments, the food product filled into compartments 22 in process 12 can include a moldable food product. As used herein, “a moldable food product” refers to a food product that can be molded to conform to a shape of a container as the solidity of the food product increases. In some embodiments, the moldable food product can include butter, margarine, shortening, chocolate, or animal fat (e.g., lard). In some embodiments, the filling process of process 12 can include injecting or squirting heated food product from a nozzle into compartments 22. In some embodiments, the food product can be heated in a range of 10 to 26 degrees Celsius, depending upon the properties of the specific food product, such as, whether the food product is hydrogenated or not, when the food product is filled into compartments 22. In some embodiments, compartments 22 can be filled with a food product that is in a liquid phase. Liquid phase, as utilized herein, includes a semi-liquid (i.e., an item that does not hold its shape, but is more viscous than a liquid).
In some embodiments, process 14 of sealing can include covering open end 28 of compartments 22 of base tray 20 with film 34. In some embodiments, film 34 can be molded, glued, or heat sealed to compartment 22. In some embodiments, film 34 can be attached such that the food product can be pushed out of compartment 22 causing film 34 to at least partially release from the inter-compartmental walls 38. In some embodiments, film 34 can be perforated so that individual compartments 22 can be uncovered individually. In some embodiments, film 34 can be applied in process 16 of sealing such that it can be resealable. Film 34 can be any material which can create a barrier for controlled atmosphere. In some embodiments, for example, film 34 can be a transparent or opaque plastic or foil. In some embodiments, film 34 can be constructed from one or more layers of a given material and can include nylons, ethylene vinyl alcohol (EVOH), metallocene linear low density polyethylene (mLLDPE), or other advanced polymers. Certain combinations of different materials can also be employed to provide product specific solutions for a given food product. In some embodiments, film 34 has thickness in a range of 14 mm to 26 mm.
In some embodiments, process 16 of cooling can include placing tray 20 in a reduced temperature environment (e.g., refrigerating) or allowing the food product to air cool over time. In some embodiments, for example, a base tray 20 can be placed in an environment below 7 degrees C. to allow the moldable food product to cool. In some embodiments, process 14 of cooling can allow a food product heated to a liquid phase in process 12 to at least partially solidify to conform to the interior of compartment 22. In some embodiments, the food product can change phases, for example from a liquid phase to a semi-liquid phase, from a liquid phase to a solid phase, or from a semi-liquid phase to a solid phase. In some embodiments, the duration of process 14 of cooling can be varied as to accommodate different food products. For example, in some embodiments, the duration of process 14 of cooling is dependent upon the oil components in the food product such that, for example, a food product high in saturated fat can cool more rapidly than a food product low in saturated fat and, thus, the required duration of process 14 of cooling can be less for a food product high in saturated fat.
The packaged food product can have a base tray 20 with a variety of configurations based on the particular food product, as well as the quantity of the food product for each compartment 22. In some embodiments, as shown for example in
In some embodiments, a distance L1 measures an overall width of the 2 by 6 tray from the edge of inter-compartmental walls 32 on Side 1 of the tray to the edge of inter-compartmental walls 32 on Side 3 of the tray. Distance L1 can be in a range of 155 mm to 160 mm, such as about 156.67 mm. In some embodiments, a distance L2 measures an overall length of the 2 by 6 tray measured from the edge of inter-compartmental walls 32 on Side 2 of the tray to the edge of inter-compartmental walls 32 on Side 4 of the tray. Distance L2 can be in a range of 265 mm to 270 mm, such as about 268.5 mm.
Each compartment 22 can have a chamfered edge 40 below open end 28 to define interior space 24. In some embodiments, a distance L3 measures a length of each compartment 22 along Side 2 and Side 4 from the interior of chamfered edge 40 along Side 1 to the interior of chamfered edge 40 along Side 3. Distance L3 can be in a range of 60 mm to 62 mm, such as about 60.33 mm. In some embodiments, a distance L4 measures a width of each compartment 22 along narrow Side 1 and Side 3 from the interior of chamfered edge 40 along Side 2 to the interior of chamfered edge 40 along Side 4. Distance L4 can be in a range of 28 mm to 30 mm, such as about 29.75 mm.
In some embodiments, a distance L5 measures a spacing between adjacent interconnected compartments along Side 2 and Side 4, in particular between the interior of chamfered edge 40 on Side 1 of a first compartment 22 to the interior of chamfered edge 40 on Side 3 of a second and adjacent compartment 22. Distance L5 can be in a range of 17 mm to 19 mm, such as about 18 mm. In some embodiments, distance L6 measures a spacing between adjacent compartments along Side 1 and Side 3, measured from the interior of chamfered edge 40 on Side 2 of a first compartment 22 to the interior of chamfered edge 40 on Side 4 of a second and adjacent compartment 22. Distance L6 can be in a range of 14 mm to 16 mm, such as about 15 mm.
In some embodiments, a distance L7 measures a distance from the inner edge of inter-compartmental wall 32 of a compartment 22 to the edge of film 34 along Side 1. Distance L7 can be in a range of 5 mm to 7 mm, such about 5.5 mm. In some embodiments, a distance L8 measures a distance from the edge of film 34 to the outer edge of inter-compartmental wall 32 of compartment 22 along Side 1. Distance L8 can be in a range of 0.3 mm to 0.7 mm, such as about 0.5 mm. In some embodiments, along Side 2 and Side 4, a distance L9 measures a width of chamfered edge 40 of a compartment 22. Distance L9 can be in a range of 1 mm to 2 mm, such as about 1.5 mm. In some embodiments, a distance L10 measures a distance from the interior of chamfered edge 40 to the edge along Side 2 or Side 4 of inter-compartmental wall 32. Distance L10 can be in a range of 6 mm to 8 mm, such as about 7.5 mm. In some embodiments, along Side 1 and Side 3 of each compartment 22, a distance L11 measures the width of chamfered edge 40 of a compartment 22. Distance L11 can be in a range of 2 mm to 4 mm, such as about 3 mm. In some embodiments, a distance L12 measures a distance from the interior of chamfered edge 40 along Side 1 or Side 3 to the outer edge of inter-compartmental wall 32 on Side 1 or Side 3. Distance L11 can be in a range of 8 mm to 10 mm, such as about 9 mm.
In some embodiments, the outside of chamfered edge 40 of a compartment 22 can have a radius R1 as shown in
In some embodiments, a distance L15 measures an overall depth of each compartment 22 in the 2 by 6 tray as shown in
As shown in
In some embodiments, compartments 22 can be configured to hold ¼ lb of margarine having a density of 0.0329 pounds per cubic inch. Each compartment can have a width of 1.5 in, a length of 2.5 in, and a depth of 2.375 in. When filled with a ¼ lb of margarine, each compartment can be filled to a depth of 2.15 in, such that the margarine can occupy a volume of 7.60 cubic inches.
In some embodiments, compartments 22 can be configured to hold 1 lb of margarine having a density of 0.0329 pounds per cubic inch. Each compartment can have a width of 2.5 in, a length of 6.375 in, and a depth of 2.375 in. When filled with 1 lb of margarine, each compartment can be filled to a depth of 2.15 in, such that the margarine can occupy a volume of 30.4 cubic inches.
In some embodiments, compartments 22 can be configured to hold 3 lb of margarine having a density of 0.0329 pounds per cubic inch. Each compartment can have a width of 5.75 in, a length of 5.75 in, and a depth of 3 in. When filled with 3 lb of margarine, each compartment can be filled to a depth of 2.78 in, such that the margarine can occupy a volume of 91.19 cubic inches.
In some embodiments, compartments 22 can be configured to hold 4 lb of margarine having a density of 0.0329 pounds per cubic inch. Each compartment can have a width of 5.75 in, a length of 5.75 in, and a depth of 4 in. When filled with 4 lb of margarine, each compartment can be filled to a depth of 3.7 in, such that the margarine can occupy a volume of 121.58 cubic inches.
As illustrated by the flow chart in
In some embodiments, process 11 of adding a flavor ingredient can include spraying, injecting, dumping or any other suitable means of adding the flavor ingredient into compartment 22. In some embodiments, the flavor ingredient added in process 11 can include, for example, garlic, herb, cinnamon, or any other suitable flavor ingredient. In some embodiments, such as illustrated in
In some embodiments, process 13 of leveling can include shaking, vibrating, or rocking base tray 20 back and forth to achieve a substantially even distribution of the food product inside each compartment 22. In some embodiments, the frequency and duration of process 13 can be varied based upon the specific food product in compartment 22. In some embodiments, for example, the frequency and duration of process 13 can be dependent upon the amount of saturated fat in the moldable food product. Process 13 of leveling can also be used to remove air from the moldable food product in compartment 22. In some embodiments, process 13 of leveling can also aid in mixing the flavor ingredient of process 11 with the food product.
In some embodiments, process 15 of injecting gas can include injecting nitrogen, carbon dioxide, or a combination of the two into compartments 22. In some embodiments the gas injected in process 15 can occur simultaneously with process 12 of injecting a moldable food into compartment 22. In some embodiments, the gas injected in process 15 can extend the shelf life of the moldable food product. For example, by injecting nitrogen, carbon dioxide, or a mixture of the two, the shelf life of the moldable food product can be increased by at least 10 percent, at least 20 percent, at least 30 percent, at least 40 percent or at least 50 percent.
In some embodiments, the packaged product can be sold as is to reduce unnecessary packaging and be more environmentally friendly. In some embodiments, for example, product identification and labeling can be printed on film 34 to allow the product to be identified and sold without additional packaging. In some embodiments, the packaged product can be placed in an outer covering, such as cardboard, for example.
In some embodiments, the compartments 22 can have serial number or bar codes imprinted thereon to facilitate traceability of products. For example the serial number or bar codes can be used in identifying products to be recalled, tracking products with a particular expiration date, and the ability to intermingle products from different manufacturing lots while retaining the ability to identify and track specific products. In some embodiments, serial numbers or bar codes can be printed on film 34 to facilitate identification of recalled products.
Thus, the present invention provides a packaged moldable food product with increased shelf life wherein the package moldable food product is made by a process including providing a base tray having a plurality of compartments arranged in an array, wherein each of the compartments has an interior space defining a volume for storing the moldable food product, an open end, and inter-compartmental walls extending from the open end on at least two sides; filling the compartments with the moldable food product, wherein the moldable food product is in a first phase; cooling the moldable food product in each of the compartments to increase a solidity of the moldable food product with respect to the first phase to allow the moldable food product to conform to the shape of the interior space of the compartment; and sealing the filled compartments so as to cover the open ends of the compartments.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.
The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents,
