Produce Containers and Methods for Manufacturing and Packing Produce Containers

TECHNICAL FIELD

The present disclosure is directed to containers for packaging produce and other food items and methods of manufacturing and packing such produce containers. More specifically, the present disclosure is directed to produce containers and methods of manufacturing and packing such containers that manage and control the physical characteristics of produce such that the produce remains contained within the storage space of the container during packing and thereafter, and the produce container can be consistently closed or sealed without interference from the packed produce.

BACKGROUND

Agricultural products, such as lettuce, cilantro, basil, thyme, and many other herbs and vegetables (collectively, “produce”), are commonly packaged in containers. Such containers come in a variety of shapes, sizes, and arrangements designed to accommodate the type of produce, the amount of produce to be packaged, and the characteristics of the produce. One particular characteristic of produce that is not accounted for when designing containers and packaging produce is its “springiness.” This is to say that due to, for example, the physical structure, moisture content, and general shape of certain produce (particularly produce that is packaged with the stem intact), the produce often exhibits a significant resilient nature. When produce is packaged, each individual piece of that produce is twisted, bent, folded, and generally departs from its natural shape, and due to the resilient nature of the produce, such individual pieces tend to spring back to their natural shape and orientation. This springiness and inability to control packaged produce can cause issues in packaging such produce.

One option for produce containers is a relatively rigid rectangular or square container with an opening along the top of the container through which produce is inserted for packaging and subsequently removed for consumption. Such a rigid container protects the produce against damage during shipping and storage. During packaging, after the produce is inserted, the opening along the top of the container is typically closed with a lid or plastic sheet stretched across the opening to fully cover the opening. In one example, the container is a plastic tray with a hinged cover that includes protrusions that snap into recesses to close the tray. Such an arrangement secures the produce in the container and provides for repeated opening and closing of the container but does not necessarily control the flow of air into and out of the container. Uncontrolled airflow can cause the packaged produce to dry out during storage and shipment prior to retail sale to a consumer. This can result in spoliation of the produce. Another container useful in packaging produce is a plastic tray with a top opening that is sealed with a flexible plastic sheet stretched across that top opening. Such an arrangement better manages the airflow into and out of the container and typically results in the consumer receiving and enjoying fresher produce.

When either of the containers described above is used to package springy produce, the effectiveness and efficiency of the packaging and/or sealing process can be affected by the springy nature of the produce. As produce is packaged into a container, it is manually or via automated processes placed into the container through the top opening using a downward force. Once this force is removed, and before the closing or sealing of the container, the produce tends to spring toward its natural shape, which typically means it springs upward toward the opening. Portions of the produce, such as the stems, can often extend out of the opening and over the edge of the container to interfere with the closing of a hinged lid or the sealing of the opening with a plastic sheet. In a common example of prior art packing processes, a human packer places produce into a container with a hinged lid. The packer manually applies force to the produce to counteract the springiness of the produce. The packer has to remove his or her hand from the container and attempt to quickly close the lid before the produce springs upward to interfere with that closing of the lid. If any produce is caught in the interface between the lid and the container, the packer must repeat this process. If the packer does not note and correct the packaging issue, then the defectively packaged produce continues down the production line and may ultimately reach a consumer. This prior art process relies heavily on the quickness, dexterity, and constant attention of the packer, which is difficult to sustain for long periods of time.

As will be appreciated, such interference results in containers that are not properly closed or sealed, which, if not caught on the production line, cause significant issues for distributors, retailers, and consumers. Even if such issues are caught on the production line, such errors result in inefficiencies in production. In one estimate, the error rate on a production line for packaging springy produce is as high as five percent. Such an error rate adds significant inefficiencies and cost to the produce packaging industry and leads to lower margins and lost profits.

One remedial adjustment made by produce packers is to make the container taller, creating more room for the produce to spring upward without interfering with the closing or sealing process. However, as will be appreciated, this remedial measure adds its own inefficiencies to the produce packaging process including added material costs, added shipping costs due to increased volume of containers, and added shelf space required in retail establishments to display the produce for sale.

There is a need for novel produce containers and methods of manufacturing and packing such produce to better manage springy produce that can interfere with the packaging and sealing process. Disclosed and described herein are such novel containers and methods of manufacture such containers and packing produce in such containers.

SUMMARY

Disclosed herein are produce containers and methods of manufacturing and packing such produce containers to managing springy produce during the packaging process. Generally, embodiments of the produce containers disclosed herein are designed and manufactured such that the interaction between springy produce packaged in a produce container and the structure of the produce container maintains the produce within the storage space of the produce container during the process of packing produce and closing or sealing the container. The produce container is designed and manufactured such that the structure of the produce container applies forces on the springy produce that encourage the produce downward and/or inward into the storage space of the produce container and resists the tendency of the produce to spring upward toward the opening of the produce container.

In one exemplary embodiment, a produce container includes a wall structure defining a storage space to hold the produce. The wall structure includes four side panels, a bottom panel, and an opening opposite the bottom panel to provide access to the storage space. The opening includes a lip extending along the perimeter of the opening. The side panels of the produce container are slightly angled inward from the opening to the bottom panel to allow the produce container to be nested with other produce containers to minimize the volume of multiple containers during shipping and storage prior to the produce container being packed with produce. Prior to the produce being packed within the container, two flanges are secured to the lip of the produce container to cover a portion of the opening of the produce container. Generally, the two flanges are secured to opposite sides of the produce container and result in the formation of a wide slot through which produce can be packed into the storage space of the container during the packaging process. Such a produce container can be fabricated from a polymeric materials, preferably from post-consumer recycled materials.

In another exemplary embodiment, a produce container includes a wall structure defining a storage space to hold the produce. The wall structure includes four side panels, a top panel with an opening providing access to the storage space, and a bottom panel opposite the top panel. The horizontal cross-sectional area of the storage space progressively increases from the top panel to the bottom panel. The progressively increased cross-sectional area is facilitated by the arrangement of the four side panels, one or more of which is inclined at an angle such that the top portion of the side panel is located inward with regard to the storage space in comparison to the bottom portion of the side panel. In an arrangement where all four side panels are so included, the result is a produce container with a storage space that is in a truncated pyramidal configuration. Such a produce container can be constructed from paper materials including recyclable paper materials.

In yet another exemplary embodiment, a produce container combines features disclosed herein. Such a produce container includes a wall structure defining a storage space to hold produce. The wall structure includes four side panels, a top panel with an opening providing access to the storage space, and a bottom panel opposite the top panel. The horizontal cross-sectional area of the storage space progressively increases from the top panel to the bottom panel, where such a progressively increased cross-sectional area is facilitated by the arrangement of the four side panels, one or more of which is inclined at an angle such that the top portion of the side panel is located inward with regard to the storage space in comparison to the bottom portion of the side panel. The top panel includes a flange that extends inward from the top portions of each of the four side panels to define the perimeter of the opening. Such a container can be constructed from paper materials including recyclable paper materials.

In one exemplary embodiment for a method of forming such a produce container, the produce container (the four wall panels, bottom panel, and lip around the opening) can be vacuum formed from a polymeric material, preferably from post-consumer recycled polymeric material. A pair of opposing flanges can be subsequently formed by placing a polymeric sheet across the opening and securing the sheet to the lip of the produce container. Once secured, the sheet can be cut to remove the middle section of the sheet to form a wide slot to provide access to the storage space of the produce container so that produce can be packed in the produce container and subsequently removed for consumption by the consumer.

In another exemplary embodiment of forming such a produce container, the produce container is formed from a single unitary sheet of foldable material in which the top, bottom, and side panels are interconnected along fold lines that, upon construction of the container, define corners of the produce container. The single unitary sheet further includes tabs extending from certain edges. Once the single unitary sheet is manipulated to form the structure of the produce container, the tabs are adhered to other edges of the single unitary sheet to construct a useable produce container.

In another exemplary embodiment of forming a produce container, the produce container is formed in a molding or vacuum forming process. In such an embodiment, features of the container disclosed herein are incorporated into the produce container.

In yet another exemplary embodiment of forming a produce container, the produce container is formed by a two-step process. In the first step, four side walls and a bottom wall are formed by any suitable manufacturing process. In the second step, the top panel is formed such that the top panel is a flange that extends inward from the top portions of each of the four side panels to define the perimeter of the opening. The underside of the flange in part defines the storage space.

In an exemplary embodiment of a method for packaging produce in a produce container, the method includes the use of a nestable produce container as described herein. The packaging method includes a staging area, a de-nesting station, a flange forming station, an accumulator, a packing station, a sealing station, and a labeling station. The staging station includes an area to store nested produce containers prior to use in the packaging method. The nested produce containers are de-nested by the de-nesting station and set on a conveyor that move the produce containers to the flange forming station. The flange forming station forms two parallel and opposing flanges over the opening of the produce container to form a wide slot that provides access to the storage space of the produce container. After the flange is formed, the produce container is moved to the accumulator, which selectively stacks and stores the produce containers depending on the collective flow rate of the produce containers through the packaging process. The produce containers are then moved to the packing station where produce is packaged into the produce containers either manually or through an automated process. Once the produce is packed into the produce container, a top seal sheet is applied and secured to the produce container by the sealing station to close and seal the opening between the flanges, and a label is applied to the top seal sheet by the labeling station to complete the packaging method. At the conclusion of this packaging method, the produce container is ready for shipment to distributors or retailers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view illustrating an embodiment of a produce container fabricated from an opaque material.

FIG. 2 is a schematic perspective view illustrating the produce container of FIG. 1 with two flanges secured to the produce container.

FIG. 3 is a schematic top view illustrating the produce container of FIG. 2.

FIG. 4 is a schematic perspective view illustrating the produce container of FIG. 1 fabricated from a transparent material with two flanges secured to the produce container.

FIG. 5 is a schematic top view illustrating the produce container of FIG. 4.

FIG. 6 is a schematic cross-sectional side view illustrating another embodiment of a produce container.

FIG. 7 is a schematic top view illustrating the produce container of FIG. 6.

FIG. 8 is a schematic cross-sectional side view illustrating another embodiment of a produce container.

FIG. 9 is a schematic top view illustrating the produce container of FIG. 8.

FIG. 10 is a perspective view illustrating another produce container.

FIG. 11 is a perspective view illustrating yet another produce container.

FIG. 12 is a top view illustrating the produce container of FIG. 11.

FIG. 13 is a side view illustrating the produce container taken on line 13-13 of FIG. 12.

FIG. 14 is a bottom view illustrating the produce container of FIG. 12.

FIG. 15 is a side view illustrating the produce container taken on line 15-15 of FIG. 12.

FIG. 16 is a plan view of a sheet of foldable material for forming the produce container of FIG. 12.

FIG. 17 is a sectional view of the produce container taken on line 17-17 of FIG. 12.

FIG. 18 is a sectional view of the produce container taken on line 18-18 of FIG. 12.

FIG. 19 is an enlarged partial view of parts of the produce container illustrated in FIG. 18.

FIG. 20 illustrates a side view of the produce container similar to FIG. 12.

FIG. 21 is a schematic view of produce packed into a produce container.

FIG. 22 is another schematic view of produce packed into a produce container.

FIG. 23 is yet another schematic view of produce packed into a produce container.

FIG. 24 is a flow diagram illustrating a method for packaging produce into a produce container.

FIG. 25 is a schematic top view illustrating equipment for use with the method of FIG. 24.

DETAILED DESCRIPTION

The apparatus, systems, arrangements, and methods disclosed in this document are described in detail by way of examples and with reference to the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatus, methods, materials, etc. can be made and may be desired for a specific application. In this disclosure, any identification of specific techniques, arrangements, method, etc. are either related to a specific example presented or are merely a general description of such a technique, arrangement, method, etc. Identifications of specific details or examples are not intended to be and should not be construed as mandatory or limiting unless specifically designated as such. Selected examples of novel produce containers and methods of manufacturing and packing such produce containers are hereinafter disclosed and described in detail with reference made to FIGS. 1-25.

Novel produce containers disclosed herein include multiple walls or panels that define an internal storage space into which produce is packed during packaging of the produce. In one example, a produce container can be defined by four side walls, a bottom wall, and a top opening opposite the bottom wall. The four side walls can be slightly tapered from the top opening to the bottom wall. Such tapering can provide for nesting of the produce containers to conserve space prior to packing the produce containers with produce and sealed the containers for shipment to distributors and retailers. Such a produce container 1 is illustrated in FIGS. 1-5, where the produce container 1 illustrated in FIGS. 1-3 is fabricated from opaque materials, and the produce container 1 of FIGS. 4 and 5 is fabricated from transparent materials. As illustrated in FIGS. 1 and 4, the produce container 1 includes four side walls 2 and a bottom panel 3 that define the inner storage space of the produce container 1. A lip 4 extends outward from the parameter of the top edges of the four side walls 2. As illustrated in perspective view in FIG. 2 and top views in FIGS. 3 and 5, two flanges 7, 8 can be applied to and secured to portions of the lip 4 to partially cover the opening of the produce container 1 to form a wide slot between the flanges 7, 8. This wide slot provides ample access to the storage space to insert and remove produce while encouraging produce to remain within the storage space during the packing of the produce and final sealing of the produce container.

In an exemplary method for fabricating a produce container 1 as illustrated in FIGS. 1-5, the side walls 2, bottom panel 3, and lip 4 are formed from a polymeric sheet by a thermal forming process, vacuum forming process, or a combination of the two process. It will be understood that other methods of fabrication can be used and that references to thermal forming and vacuum forming are exemplary of the possible methods of fabrication. Once the produce container 1 is so formed, a second polymeric sheet is positions over the opening of the produce container 1 and heat and pressure are applied to secure the polymeric sheet along sections of the lip 4 of the produce container 1. Any excess material extending outward from and beyond the lip 4 is trimmed. A pair of cutters are used to cut two slits through the polymeric sheet, and the material between the two slits is removed, which forms the wide slot providing access to the storge space of the container 1. The process of using the pair of cutters to cut and remove material to form the wide slot is referred to herein as an “inside cut.” As will be appreciated, such a process can result in the formation of two flanges 7, 8 that are secured to the lip 4 such that the flanges 7, 8 are generally taut and, as will be further described herein, engage with and encourage produce packed within the storage space of the container 1 to remain within the storage area during the packaging process.

In another embodiment of a produce container, the storage space of the produce container can, for example, take the shape of a truncated pyramid with a sealable opening in the top of the container (for insertion and removal of produce) and a relatively flat bottom panel. While examples herein are generally directed to different arrangements of truncated pyramid shaped produce containers, it will be understood that the principles disclosed herein regarding the interaction between the produce container and the produce positioned within the container can be applied to other shapes for produce containers.

The produce container generally includes a top panel with an opening for access to the storage space, and four side walls that extend downward from the top panel to the bottom panel. Two exemplary embodiments of such produce containers are schematically illustrated in FIGS. 6-9 (FIG. 6 is a cross-sectional side view and FIG. 7 is a top view of a first embodiment, and FIG. 8 is a cross-sectional side view and FIG. 9 is a top view of a second embodiment). Generally, one or more side walls angle outward as the side wall(s) extends from the top panel to the bottom panel. This is to say that for an angled wall(s), a vector normal to the angled wall (V_n) is directed inward and downward into the storage space relative to the wall(s). Such an arrangement results in the horizontal cross-sectional area of the storage space progressively increasing from the top panel to the bottom panel of the produce container. As illustrated in FIGS. 6 and 8, a first width of the storage space near the top panel (represented by W₁and W₃, respectively) is smaller than a second width of the storage space near the bottom panel (represented by W₂and W₄, respectively). Thus the horizontal cross-sectional area progressively increases from the top panel to the bottom panel of the produce container.

For such novel produce containers, one embodiment of the present invention provides for containers that apply at least one force upon the springy produce located in the container to maintain the produce within the container, specifically the storage space of the container, during packaging of the produce. The force applied upon the produce is a result of the angle of one or more walls or panels relative to the storage space. Such angled walls produce a reactive force against the springy nature of the produce. It is contemplated that a container of the present invention has one or more walls that are orientated relative to the springy produce such that the one or more walls can exert a force in one or more directions against the springy produce to contain the produce within the storage space of the container during packaging.

The forces produced by the orientation of one or more walls or panels relative to the springy produce positioned within the storage space can vary in direction and can include, for example, forces directed toward the bottom of a container, toward the center of the storage space, toward the opposite side of the wall that is exerting the force, and any other directions that can be desirable to maintain the springy produce within the storage space within the container.

It is further contemplated that two or more walls of a container can work in conjunction to produce a reactive force (or forces) upon a springy produce that is placed within the storage space of the container. The reactive forces are generated in response to the forces applied to the walls by the springy produce, and it is understood that the amount of downward and inward force will depend on forces applied to the walls by the springy produce and the angle of the wall relative to the base of the container. For example, as the angle of the wall decreases as measured between the base of the container and the said wall (i.e., A₁-A₄in FIGS. 6 and 8) the more the reactive force exerted by the wall on the springy produce is directed downward and inward into the storage space.

The arrangement of the side walls may vary from one embodiment to another. For example, in the first embodiment illustrated in FIGS. 6 and 7, all four side walls of the produce container can be angled outward as the side walls extend from the top panel to the bottom panel. Such an arrangement provides inward reactive forces on all four sides of the produce located in the storage space. Such a combination of reactive forces applied to the springy produce results in the retention of the springy produce within the storage space.

In another example, the second embodiment illustrated in FIGS. 8 and 9, two opposing side walls of the produce container can be angled outward as the side walls extend from the top panel to the bottom panel. The other pair of opposing walls are generally perpendicular to the top and bottom panels. Such an arrangement provides a greater storage space relative to the general footprint of the produce container while still providing substantial inward and downward reactive forces on two sides of the produce located in the storage space. Such an arrangement can provide the reactive forces required to keep the springy produce within the storage space while providing a greater storage space for the produce.

It will be understood that the length, width, and height of the produce container can be varied to accommodate the amount of springy produce to be packaged in a produce container. Additionally, the angles of one or more side walls can be varied to accommodate the nature of the produce to be packaged in the container and the density of the produce to be packaged (i.e., whether the produce is tightly packaged or loosely packaged).

With the novel produce containers disclosed herein, produce packaging processes can be more automated and more error-free. In one exemplary method for packing and packaging produce begins with forming the produce container, which, for example, includes the steps of receiving a single unitary sheet of foldable material; passing the sheet of foldable material though a box erecter, which manipulates the sheet of material into a produce container; and printing useful information onto the produce container such as produce type, brand names, logos, UPC codes, nutritional facts, marketing information, etc. The produce container is then moved to the packaging area, where produce is placed into the container, either manually or via an automated system. With the significant reduction of issues related to the springiness of the produce, this step is relatively simple as compared to prior art packaging processes. The produce container is then moved to a sealing area, where a top seal is placed on the top surface of the container to complete the packaging process. The arrangement of the container greatly reduces the probability of any produce springing upward to interfere with the sealing of the container, thus, providing for a more consistent and error-free packaging method.

The materials used for the produce containers disclosed herein can substantially reduce or even eliminate the use of plastics for produce containers by constructing such containers from paper materials, including recycle paper materials. In certain embodiments, the paper material can include a thin polymer layer to assist the paper in managing the water content of the produce. In such embodiments, the polymer layer can be arranged such that the container remains fully recyclable. Furthermore, the use of paper materials for produce containers enhances the opportunity for merchandising and marketing by providing printable surface areas to identify the product and print additional useful information. These sustainability and marketing advantages are in addition to the functionality of the novel container, which better contains springy produce within the container during packaging.

Examples of produce containers are described herein for use with packaging produce. Two exemplary containers for packaging produce are illustrated in FIGS. 10 and 11, which are described in detail below. In both examples of containers, all four side walls are inclined to form a truncated pyramid shaped storage space. The container illustrated in FIG. 10 includes a lip 11 that extends outward from the top of the side walls and creates a sealing surface for the top sheet used to seal the container. Generally, in the embodiment of FIG. 10, the intersection of the side walls and the lip defines the perimeter of the opening. FIG. 11 includes a flange 70 extending inward and defines the perimeter of the opening. The flange creates a sealing surface for the top sheet used to seal the container but is also useful in keeping springy produce within the container. Generally, the illustrative examples provided herein are directed to shallower containers that are useful for packaging herbs. However, it will be appreciated that the principles discussed and illustrated herein are applicable to deeper and larger containers for any and all types of produce such as lettuce and other springy vegetables.

As shown in the figures, a container 10 is provided for packaging items of produce such as cilantro, basil, thyme, and other herbs. The container 10 includes a wall structure 12 defining a storage space 15 with an opening 17 into the storage space 15. A transparent peel off cover 18 closes the opening 17 and is sealed to a portion of the wall structure 12. This cover 18 can be arranged so that the end user peels off the cover 18 once and discards the cover 18, or it can be arranged so that the end user can peel the cover 18, remove a portion of the produce, and reseal the cover 18 for future use.

As further shown in FIGS. 12-15, the wall structure 12 in the given example includes a top panel 20, a bottom panel 22, and four side panels 30, 32, 34, and 36. The top panel 20 has an elongated rectangular shape with cantilevered opposite end portions 40 and 42. The top panel 20 further has an inner perimeter 44 defining the opening 17 into the storage space 15. An aperture 45 is provided on the second end portion 42 for hanging the container 10 on a display rack.

The bottom panel 22 is located opposite the opening 17, and has an elongated rectangular configuration aligned with the top panel 20. The side panels 30-36 surround and define a rectangular periphery of the storage space 15 between the top 20 and bottom 22 panels. The side panels 30-36 also define the depth of the storage space 15. As shown, this example of the wall structure 12 is configured as a tray, with the storage space 15 having length and width that are both greater than the depth.

In the given example, each of the four side panels 30-36 extends toward the bottom panel 22 at a respective angle inclined away from the opening 17. The angles of inclination in the given example are substantially equal, and the side panels 30-36 have equal heights reaching fully from the top panel 20 to the bottom 22 panel in the inclined orientations. More specifically, such an arrangement gives the side panels 30-36 a truncated pyramidal configuration that progressively increases in cross-sectional area from the top of the container 10 to the bottom of the container 10. A first opposed pair 30 and 32 of the side panels form the length of the container 10. A second opposed pair 34 and 36 form the width of the container 10.

As illustrated in FIG. 16, the wall structure 12 can be defined by a single unitary sheet 60 of cardboard or other foldable material. Such a single unitary sheet 60 can be constructed into the container 10. The sheet 60 includes each of the panels 20, 22, and 30-36 interconnected along fold lines 61. When the sheet 60 is folded into the configuration shown in FIGS. 10, 11, 17, and 18, the fold lines 61 define corners of the wall structure 12. Tabs 62 at other edges of the panels 20, 22, and 30-36 provide surface areas for adhesive to bond the adjacent panels together. The adhesive can be arranged such that it generally seals the adjacent panels together so that airflow is controlled to preserve the moisture of the produce packaged inside.

As further shown in FIGS. 11, 17, and 18, the top panel 20 has a portion defining a flange 70 that surrounds the opening 17 at the perimeter 44. The side panels 30-36 project downward from the top panel 20 at locations that are spaced from the opening 17 by the flange 70. This arrangement of the flange 70 about the opening 17, as well as the pyramidal expansion of the storage space 15 downward from the opening 17, helps to retain produce with resiliently deflectable stems from springing outward through the opening 17.

Another feature of the wall structure 12 is shown in FIG. 20. One of the transversely oriented side panels 34 projects over the bottom panel 22 a distance D1 in a direction parallel to the bottom panel 22. That distance D1 extends in a direction lengthwise of the bottom panel 22. The adjacent end portion 40 of the top panel 20 projects over the side wall 34 an equal distance D2 in the same direction. In this arrangement, the adjacent bottom corner 61 of the wall structure 12 and the adjacent free end 80 of the top panel 20 are located at the same level to serve as supports for the container 10 to stand vertically upright on a horizontal surface 82 as shown in FIG. 20.

FIGS. 21-23 schematically illustrate the interaction between produce packaged in a produce container and the features of the produce container. FIG. 21 schematically illustrates a top panel with a flange 70 and the downwardly angled sided panels that form the storage space 15, all of which are helpful in packing the produce container with produce. Using prior art container products and packaging method, an individual who is packing springy produce into a prior art container must pick up the container, insert a bundle of the produce, and then hold the inserted produce in place with one hand while attempting to close the cover with the other hand. In contrast, an individual using the novel container disclosed herein can pack produce into the container, release the produce, and the features of the novel container maintain the produce within the storage space. Once packed with produce, the container can progress along the assembly line to be sealed and subsequently sent to distributors and retailers.

The progressively increasing cross-sectional area of the storage space 15 created by the angled side panels 30-36 impedes springing movement of the inserted produce upward toward the opening 17. As illustrated in both FIGS. 21 and 22, the angles of side panels 30-36 exert a downward and inward force (F_sp) on the springing produce to counteract the resilience of the produce. The flange 70, which extends over the storage space 15 between the side panels 30-36 and the opening 17, is positioned to block any further upward movement of the inserted produce, and to do so without blocking the opening 17 to insertion of additional produce. As illustrated in FIG. 21, the flange 70 exerts a downward force (F_tp) on the produce to maintain the produce inside the container. The container 10 thus enables produce to be tucked securely into the storage space 15, which greatly increases efficiency of the packing process.

FIG. 23 schematically illustrates produce packaged in a produce container 1 as illustrated and described in regard to FIGS. 1-5. The flanges 7, 8 extend over the storage space between the side panels 2 and form a wide slot over the storage space. The flanges 7, 8 are positioned to block any further upward movement of the inserted produce and to retain the produce within the storage space. The wide slot over the storage space accommodates the insertion and removal of produce from the storage space. As will be understood, the flanges 7, 8 can exert a downward force (F_tp) on the produce packed in the storage space to maintain the produce inside the produce container 1 during the packaging process. The produce container 1 thus enables produce to be tucked securely into the storage space of the container 1 without any of the produce extending beyond the opening and interfering with sealing the produce container 1, which greatly increases efficiency of the packing process.

The features described herein can be incorporated into many different containers to achieve similar results. For example, the flange feature can be formed into a paper, cardboard, or plastic container generally useful for the purpose of packing produce and other items. A plastic container can be formed with the angled side panels that form the truncated pyramid shaped or tapered storage space. Such containers can be formed using molding or vacuum forming processes. The process of forming such containers can be incorporated into a manufacturing line such that first the container is formed, then produce is inserted into the container, and lastly the container is sealed.

Furthermore, existing containers can undergo a secondary process to form an inwardly extending flange to define the perimeter of the container opening. In one example, an existing container with a lip is provided. The plastic film is applied to the lip of the existing container such that the plastic film forms an inwardly extending flange that covers a portion of the original opening of the existing container. The flange formed by the plastic film defines a new perimeter for the opening and provides a top panel over the original opening that manages upward movement of springy produce. After the flange is formed, produce can be inserted into the opening and the opening can be sealed with a cover (such as another thin plastic sheet) to close the opening. The materials used for the flange and the cover, along with adhesives optionally applied between the flange and the cover, can form a system where the cover can be opened (such as pealed back) to provide access to the produce and resealed to preserve produce remaining in the container.

An exemplary method of packaging produce into a produce container is illustrated in FIGS. 24 and 25. FIG. 24 is a flow diagram illustrating the method 100 for packaging produce into a produce container. The method 100 includes the use of the nestable produce containers 1 as described with reference to FIGS. 1-5. The packaging method 100 includes a staging area 110, a de-nesting station 120, a flange forming station 130, an accumulator 140, a packing station 150, a sealing station 160, and a labeling station 170. FIG. 25 schematically illustrates the various stations and equipment used in the method 100.

In the embodiment illustrated in FIG. 25, the staging area 110 is an area arranged to store nested (i.e., stacked) produce containers 180 that were fabricated in bulk in an off-line process. The nested produce containers 180 are located on a flat surface, such as a table, at the beginning of the production line. It will be appreciated that the design of the produce container 1 provides for stacking the produce containers 1 in a manner that greatly minimizes the volume occupied by the nested produce containers 180. Such an arrangement allows for having a large number of produce containers 1 close at hand to feed into a high-speed, high-volume manufacturing process. In an alternative embodiment, the produce containers are fabricated in-line and on demand by a thermal forming or vacuum forming machine that is located at the beginning of the production line.

When the nested produce containers 180 are needed for the packaging method 100, one or more stacks of nested produce containers 180 are manually or through an automated process fed into the de-nesting station 120. The de-nesting station 120 separates the nested produce containers 180 into individual produce containers 1 and positions each on a conveyor belt 190 that move the produce containers 1 along to the next step of the packaging method 100. In the exemplary method 100, the conveyor 190 includes four tracks. It will be understood that the conveyor can be arranged with any number of tracks based on the needs of the particular production line. In the described embodiment, the conveyor 190 moves the produce containers to the flange forming station 130.

The flange forming station 130 applies a polymeric sheet to the top of each produce container 1 and secures the polymeric sheet to the lip 4 of the produce container 1 through a combination of heat and pressure. Once secured, the flange forming station 130 uses a cutting edge to trim any excess polymeric material that extends outward from the lip 4 to create a clean appearance along the outer edge of the lip 4. The flange forming station 130 then performs an inside cut to remove a center section of the polymeric sheet to form a pair of flange 7, 8 and a wide slot in the top of the produce container 1 between that pair of flanges 7, 8. This wide slot provides access to the storage space of the produce container 1 for packing of produce into the storage space of the container 1 and for the consumer to subsequently remove the produce from the container 1. It will be understood that the flanges 7, 8 can be formed so that the flanges 7, 8 are taut and arranged to apply a downward forces on produce packed within the produce container 1 to keep the produce within the storage space. Once the flanges 7, 8 are formed, the flange forming station 130 places the produce containers 1 on another conveyor 200, which moves the produce containers 1 further along in the production line. In the example illustrated in FIG. 25, the conveyor includes 8 tracks.

The produce containers 1 continue on to an accumulator 140. The accumulator 140 is arranged to selectively gather and temporarily store produce containers 1. The accumulator 140 functions as a governor on throughput of the overall packaging method 100 adjusting for variability in the speed of upstream and downstream steps. For example, if method steps that are upstream of the accumulator 140 produce more produce containers 1 that are needed by the downstream method steps, the accumulator 140 with gather and temporally store a select number of produce containers 1 to account for the difference in upstream production of containers 1 and the downstream need for containers 1. Conversely, if downstream method steps need more containers 1 than are currently being produced by the upstream method steps, the accumulator 140 will pass through all containers 1 made by upstream method steps and additionally release enough stored containers 1 from the stockpile build up by the accumulator 140 to meet the needs and requirements of the downstream method steps. In one embodiment, the accumulator 140 is arranged as a series of siloed towers. When the accumulator 140 is selectively storing produce containers 1, the containers 1 are stacked vertically in each tower. The relative speeds of the upstream and downstream method steps can vary and be out of synch due to a number of issues such as mechanical breakdowns, human error, fluctuations in number of workers on the production line, need to switch labels as differed produce is packed in the containers, and other similar issues. In one embodiment of the packaging method 100, the accumulator 140 can be pre-loaded with a number of produce containers 1 so that upon the startup of the production line, the accumulator 140 has a reserve of produce containers 1 to address any issues that arise soon after the packing method 100 is initiated,

The accumulator 140 releases produce containers 1 (or allows containers 1 to freely flow through) to the packing station 150. The packing station 150 is a conveyor that moves the containers 1 forward, but at a speed that allows each container 1 to be packed with produce. Such packing of produce can be accomplished manually by line workers or mechanically with automated machinery that places produce into the containers 1. Once the produce is packed into the produce container, the containers 1 are moved to a sealing station 160 where a polymeric sheet is applied to and secured to the produce container 1. This polymeric sheet is applied to the flanges 7, 8 and the exposes lip 4 of the container 1. This step effectively covers the wide slot and seals the container 1 to preserve the produce within the container 1 during shipping and subsequent storage of the produce. As will be appreciated, the arrangement of the flanges 7, 8 minimize the occurrences of produce extending out of the storage area and interferent with the sealing of the produce container 1.

The container 1 is subsequently placed on another conveyor 210 and moved to a labeling stations 170, which applies a label to the top polymeric sheet that includes information identifying the produce in the container 1 and proving additional useful information. This final step completes the packaging method 100, and the resulting product is ready for inspection and/or shipment to distributors or retailers or directly to the consumer.

The foregoing description of examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. The examples were chosen and described in order to best illustrate principles of various examples as are suited to particular uses contemplated. The scope is, of course, not limited to the examples set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art.

	Number	Date	Country
	63171795	Apr 2021	US
	63160440	Mar 2021	US

Produce Containers and Methods for Manufacturing and Packing Produce Containers

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