SYSTEMS AND METHODS FOR CREATING A SEALED PALLET ENCLOSURE

TECHNICAL FIELD

This patent application relates generally to improved systems and methods for creating a six-sided, sealed pallet enclosure around stacked cartons of perishable products using prescribed materials and designs for a top and bottom cap which are then sealed to compatible materials for the sides.

BACKGROUND

Currently and for many years, standard practice in the commercial perishable industry includes placing perishable products within a modified atmosphere that could contain a lower oxygen and higher carbon dioxide level than normal atmosphere. In order to create a modified atmosphere, a six-sided sealed enclosure must first be created around the perishable product which is packed in cartons and stacked on a pallet. A modified atmosphere can result from the perishable product's respiration or be directly created by the addition of modified atmosphere gasses within the sealed enclosure. The modified atmosphere is beneficial and often critical in the control of mold development on the surface of the perishable products and to reduce respiration and the rate of senescence of the product. This functionality comes at a substantial cost in terms of operational complexity, expensive custom-built assets, general labor and trained technicians, and finally use of extensive materials for the sealed enclosure. Importantly, these materials do not meet emerging standards and requirements for sustainability and environmental compliance.

A sealed enclosure for a pallet considers all 6 exterior sides of the shape. One exemplary current system and method for creating a sealed enclosure includes, for example, placement of a flat cardboard sheet glued to a larger plastic sheet overhanging the edges of a pallet at the time of harvest in the field. The perishable products packed in cartons are then stacked on the bottom sheet. The perishable product is transferred to a cooling and shipping facility for preparation for distribution. Corner posts, straps, and/or roping may be added to the pallet for support and stability of the perishable product during transit. After cooling, the edges of the bottom sheet are manually folded up and hand stapled, glued, or otherwise taped to the sides of the first layer of the perishable product cartons stacked on the pallet. A bag is then fitted over the cartons and taped to the bottom sheet to create the sealed enclosure. The modified atmosphere, typically a controlled amount of carbon dioxide, may then be injected into the sealed enclosure.

The aforementioned process is a highly manual slow process (that poses worker safety risks,) which requires significant labor and materials, customized equipment at a fixed location within the cooling and shipping facility, and is subject to multiple errors, rips, and tears leading to modified atmosphere process variation and/or failure. Further, the receiving customer must remove and dispose of all of these materials, including separating the enclosure materials from the bottom layer of cartons of perishable product. A typical truck delivery of these pallets yields about 65-108 total lbs. of this mixture of waste. The nature of the various materials makes them unlikely to achieve sustainability objectives.

Another exemplary system and method for creating a sealed enclosure occurs in a cold storage facility after cooling. In this example, a custom-built apparatus holds the cartons and lowers the pallet while a bottom sheet is applied between the cartons and the pallet. In some examples, the pallet is then wrapped, in which case, a top sheet may also be dispensed and applied. The bottom sheet (or for wrapped pallets both the bottom sheet and the top sheet) are then taped or secured to the sides of the cartons before a “pallet bag” or side sheet film (for wrapped pallets) is secured around the pallet to create the sealed enclosure. While these are more automated processes which require less labor and for wrapped pallets less materials and less tape, than the first exemplary system and method, the asset costs, need for highly trained maintenance and/or operating personnel, and space requirements create physical and thus commercial barriers to use in small to medium sized or remotely located operations. The wrapped pallet method yields a significant reduction but still about 26-30 lbs. of waste for a truckload of pallets.

Thus, there exists a need for improved systems and methods that: a) do not rely on expensive, custom-built equipment, b) can use the more efficient enclosure wrapping and sealing process, c) can use new, more environmentally friendly materials, and d) provide feasibility for use in small to medium to large and especially remote operations. Accordingly, there exists a need for more efficient and practical commercial systems and methods that can create a sealed enclosure by using more environmentally friendly, sustainable materials for the bottom, top and side elements of the enclosure.

The systems and methods of the present disclosure address all of the above noted needs including solutions for the issues and weaknesses present. They describe a unique and simple method of applying the key elements required to create the improved (e.g., six sided) enclosure. In addition to a preferred embodiment for the disclosure, other options are described that are solutions for the issues noted. The methods are only made possible in combination with the proper materials which can achieve the physical and adhesive properties to yield an (such as, e.g., a six sided) enclosure that is reliable and maintains the intended atmosphere conditions.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be apparent from the following, more particular, description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

FIG. 1A illustrates a schematic of a pallet of goods including a top cap and a bottom cap, according to the present disclosure.

FIG. 1B illustrates a schematic of a pallet of goods including a top cap, a bottom wrap, and a side wrap to form a sealed enclosure around the goods on the pallet, according to the present disclosure.

FIG. 1C illustrates a schematic of a pallet of goods including a top cap, a bottom wrap, and a side wrap in conjunction with a modified atmosphere system, according to the present disclosure.

FIG. 2 illustrates a schematic perspective view of a prefabricated cap, that may be employed with a pallet of goods, according to the present disclosure.

FIG. 3A illustrates a top, plan view of a cap in a substantially flat condition, that may be employed with a pallet of goods, according to the present disclosure.

FIG. 3B illustrates a perspective view of the cap of FIG. 3A in a substantially three-dimensional condition, according to the present disclosure.

FIG. 4A illustrates a top, plan view of a pop-up cap in a substantially flat condition, that may be employed with a pallet of goods, according to the present disclosure.

FIG. 4B illustrates a perspective view of a gusseted bag, that may be employed with a pallet of goods, according to the present disclosure.

FIG. 5A illustrates a front perspective view of a pallet of goods, according to the present disclosure.

FIG. 5B illustrates a front perspective view of the pallet of goods of FIG. 5A being lifted with a lifting assembly, according to the present disclosure.

FIG. 5C illustrates a rear perspective view of the pallet of goods of FIG. 5B, according to the present disclosure.

FIG. 5D illustrates a front perspective view of the pallet of goods of FIG. 5A having a bottom cap inserted between the pallet and goods, according to the present disclosure.

FIG. 5E illustrates a front perspective view of the pallet of goods of FIG. 5D with the bottom cap formed into the three-dimensional shape, according to the present disclosure.

FIG. 5F illustrates an exemplary lifting assembly for use with the steps of FIGS. 5A to 5E, according to the present disclosure.

FIG. 6A illustrates an exemplary lifting assembly for use with the steps of FIGS. 5A to 5E, according to the present disclosure.

FIG. 6B illustrates a schematic view of goods of a pallet of goods being lifted with the lifting assembly of FIG. 6A, according to the present disclosure.

FIG. 7 illustrates the pallet of goods of FIG. 5A with a top cap and bottom cap added, according to the present disclosure.

FIG. 8A illustrates a forklift employed with the systems and methods of the present disclosure, according to the present disclosure.

FIG. 8B illustrates a fixed structure employed with the systems and methods of the present disclosure, according to the present disclosure.

FIG. 9A illustrates a capping assembly for placing top caps and bottom caps on a pallet of goods, according to the present disclosure.

FIG. 9B illustrates a portion of the capping assembly of FIG. 9A, according to the present disclosure.

FIG. 9C illustrates a portion of the capping assembly of FIG. 9A, according to the present disclosure.

FIG. 9D illustrates a top view of the capping assembly of FIG. 9A, according to the present disclosure.

FIG. 9E illustrates a top view of the capping assembly of FIG. 9A, according to the present disclosure.

FIG. 10 illustrates a system for providing a sealed enclosure and optional modified atmosphere to a pallet of goods, according to the present disclosure.

FIG. 11 illustrates a system for providing a sealed enclosure and optional modified atmosphere to a pallet of goods, according to the present disclosure.

FIG. 12 illustrates a system for providing a modified atmosphere and side wrap to a pallet of goods, according to the present disclosure.

DETAILED DESCRIPTION

Various embodiments of the invention are discussed in detail below. While specific embodiments are discussed, this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the invention. This invention uses an improved and more efficient wrapping approach for addition of the top, bottom, and side elements of a six sided sealed enclosure.

The present disclosure relates to creating a sealed enclosure around stacked goods, such as, for example, cartons of packed fresh perishable produce, fruits, and/or vegetables using equipment and materials selected for the properties of the stacked goods. In some examples of the present disclosure, the equipment and materials include providing gas barrier, stretch, adhesion, and sustainability. The preferred enclosure begins with placement of a preformed bottom and top cap. Importantly, these preformed caps are not attached to the cartons using staples, glue, tape, etc. The film or sheet for the sides has gas barrier properties that control the amount of oxygen that can enter into the sealed enclosure and the amount of carbon dioxide that can exit the sealed enclosure. During wrapping, the film or side sheet material stretches and adheres to the top and bottom cap without use of a taping mechanism or additional adhesives. The material composition allows it to be recycled, composted, and/or decomposed to be considered “sustainable.” Within the enclosure, a modified atmosphere occurs or may be applied to enhance, preserve, and/or protect the stacked goods (e.g., the perishable product).

As used herein, the term “sealed enclosure” refers to a six-sided space that is sealed off with an artificial or natural barrier that prevents or limits the entrance or exit of gases and/or substances into and out of the space.

For ease of reference, the term “cartons” is used herein, however, the present application may be applied to any manner of stacked goods on a pallet. The goods may be perishable products, such as produce, fruits, and/or vegetables.

In order to achieve an effective modified atmosphere for perishable goods, there are two critical elements. The first is creating a sealed enclosure around the perishable goods (e.g., cartons on the pallet). The second is providing effective pressure regulation plus injection or addition of the modified atmosphere gasses to achieve the product specific treatment environment or conditions within the sealed enclosure. The preferred disclosure provides systems and methods that achieve both of these critical elements.

The preferred disclosure also provides for the use of materials for creating the sealed enclosure having improved environmental properties such as fully recyclable, biodegradable, compostable, and/or combinations thereof. The preferred disclosure also provides for a sealed enclosure that eliminates the need for filament tape and staples which prevent practical recycling.

Accordingly, the systems and methods of the present disclosure provide a bottom cap, a top cap, and a wrapping film (also referred to herein as a film side wrap, side enclosure film, a side sheet material, a semi-rigid sheet, a sleeve, and a stretch film), which will adhere or are affixed to the caps to create a stable and sealed pallet enclosure.

The systems and methods of the present disclosure allow for a major reduction in the cost of capital. The bottom and top elements of the enclosure can represent the highest capital cost components of the method. With this disclosure, a purpose designed preformed bottom cap made from appropriate physical and adherence materials can be placed on the pallet manually during harvest and packing. The preformed top cap can be applied at harvest or at the warehouse or cooling facility. Due to the adherence properties, these caps can then create an effective seal when the appropriate film is wrapped around at the warehouse. Importantly, the wrap process typically occurs within a refrigerated space or warehouse. And then the perishable is shipped to customers using refrigerated transportation. Accordingly, the materials intended for the caps and wrap need to maintain their adherence properties at cold temperatures such as 30° F. to 50° F.

The systems and methods of the present disclosure also allow for a reduction in the cost of capital associated with large commercial scale systems by using a manual or simple, easy to automate capping system. They provide a better seal by eliminating the top and bottom sheet which often may be pierced, creased, or misapplied during the process resulting in poor sealing for the sealed enclosure. They eliminate the use of commercial packing or filament tape which is not recyclable. They allow for a process that may be employed automatically, by a robot, or by a human. Accordingly, they may be applicable to small and large companies alike, are environmentally friendly by employing sustainable and recyclable materials, and can be located anywhere due to the small easy to move and assemble nature of the systems.

Stated another way, the systems and methods of the present disclosure provide a “cap and wrap” enclosure system, methods, equipment & design parameters that use more environmentally sustainable materials. Furthermore, the systems and methods of the present disclosure provide an improved sustainability for: 1) reducing the amount of material, 2) use of more recyclable and/or recycled material, and 3) use of reusable material.

Other options for creating a sealed enclosure are solutions for the issues noted. They all include the use of preformed caps. Some cap materials may present the opportunity for reusability. These can be collected, along with the elastic or reusable sealing bands if used, and returned to the source for use on future perishable product shipments. Some cap materials may not have compatible adhesive properties with the side wrapping or sheet material. In these cases, an elastic or sealing band or gasket may be used to hold the side wrapping/sheet in place against the cap sides or in a channel on the cap sides to create the airtight seal. In other examples, a third type of wrapping material may be used which has enhanced adhesive properties to adhere to both the cap and side wrapping/sheet. Importantly, the caps and wrapping materials used are not physically attached to the cartons.

Options for the cap design may include a design which has tabs that enable tucking the sides between layers of the cartons. This helps to hold the top and bottom part in place and prevents distortions for improved sealing during the enclosure process.

While the preformed caps can be placed manually under and on top of the cartons during harvest and packing, the disclosure also describes methods and systems more appropriate for large scale operations where process speed and further reduction in labor is important.

FIGS. 1A to 1C illustrate a pallet of goods 10. The pallet of goods 10 includes cartons 12 for perishable products located on a pallet 14. The pallet of goods 10 includes a bottom cap 16 located between the pallet 14 and the cartons 12. The pallet of goods 10 includes a top cap 18 located on a topmost row of the cartons 12. Although cartons 12 are illustrated as a plurality of cartons housing perishable products, other containers are contemplated. FIGS. 1B and 1C illustrate the pallet of goods 10 with a wrapping film 20 or semi-rigid sheet or sleeve 20 disposed around a circumference of the cartons 12, bottom cap 16, and top cap 18. A sealed enclosure is formed within the boundaries of the wrapping film 20. That is, the sealed enclosure is formed inside the wrapped film 20, the bottom cap 16, and the top cap 18 such that the cartons 12 are located within the sealed enclosure. FIG. 1C illustrates the pallet of goods 10 having the sealed enclosure with a system 50 for providing a modified atmosphere within the sealed enclosure. The pallet of goods may use an elastic or sealing band (and/or external or internal) gasket to affix the side material to the caps. The system 50 may include one or more nozzles for injecting into or removing one or more substances within the sealed enclosure. The system 50 may be any of the systems described herein or described in International Patent Application Nos. PCT/US2020/067731 and PCT/US2022/030263. The sequence of FIGS. 1A to 1C may be a method comprising stacking the cartons (see, e.g., FIG. 1), wrapping the cartons to create a sealed enclosure (see, e.g., FIG. 1B), and providing a modified atmosphere within the sealed enclosure (see, e.g., FIG. 1C).

FIG. 2 illustrates an exemplary preformed cap 100 that may be employed as the bottom cap 16, the top cap 18, or both the bottom cap 16 and the top cap 18. The cap 100 is a preformed cap, that is, constructed, assembled, or manufactured in the final state employed in the commercial environment (e.g., with the pallet of goods 10). The preformed cap may be provided to the location at which the cap 100 is placed on the pallet 14 (FIG. 1A) in the condition shown in FIG. 2. The cap 100 includes a cap base 102 and cap sides 104. The cap base 102 is coupled, connected, integral with, or unitary to a lower end 104a of each of the cap sides 104 such that there is a hollow interior 106 within the boundaries of the cap sides 104. The hollow interior 106 may receive the cartons 12 (FIG. 1A) and/or goods to be wrapped in a sealed enclosure, as will be described in more detail to follow. In the example of FIG. 2, the cap 100 is rectangular in plan view, though other shapes are contemplated.

FIGS. 3A and 3B illustrate an exemplary cap 200 that may be employed as the bottom cap 16, the top cap 18, or both the bottom cap 16 and the top cap 18. The cap 200 may be a prefabricated cap. The cap 200 may be formed in a flat manner (e.g., substantially two-dimensional) as shown in FIG. 3A and then folded into the three-dimensional cap shape of FIG. 3B. Like the cap 100, the cap 200 includes a cap base 202 and cap sides 204. As shown in FIG. 3A, the cap 200 is provided with a plurality of cuts 205, a plurality of score and fold lines 208, and a plurality of fold lines 210. In the example of FIG. 3A, two opposing cap sides 204 (e.g., cap sides 204a and 204b) are provided with a fold line 210 with the cap base 202 and are provided with score and fold lines 208 at each opposing end of the cap sides 204a, 204b. The other two opposing cap sides (e.g., cap sides 204c and 204d) are provided with a fold line 210 with the cap base 202 and are provided with cuts 205 at each opposing end of the cap sides 204c, 204d.

To construct the cap 200 of FIG. 3B from the preform/template of FIG. 3A, adhesive, tape, glue, or other adhering mechanism may be provided on an inner surface of each distal end 212 on the cap sides 204a, 204b. Once all cap sides 204 are folded upward (e.g., out of the page) with respect to the cap base 202 such that the cap sides 204 are substantially perpendicular to the cap base 202, the distal ends 212 may be folded on the score and fold lines 208 such that the distal ends 212 overlap an outer surface of the cap sides 204c, 204d. The adhesive located on the inner surface of the distal ends 212 can then be secured to the outer surface of the cap sides 204c, 204d to form the cap 200 of FIG. 3B. Pressure may be applied to the distal ends 212 (either manual or automated pressure, such as, for example, a human pressing in the sides) to secure the adhesive to the cap sides 204c, 204d. Once in the form of FIG. 3B, the cap 200 includes a hollow interior 206 for receiving the cartons 12 (FIG. 1A). The cap may have tabs which tuck between layers of the cartons to hold the caps in their proper place during handling and the enclosure process.

FIG. 4A illustrates an exemplary cap 300 that may be employed as the bottom cap 16, the top cap 18, or both the bottom cap 16 and the top cap 18. Like the cap 200, the cap 300 may be prefabricated such that it is provided to the commercial environment in a general flat manner to be unfolded into the cap (e.g., the shape shown in FIG. 3B). The cap 300, therefore, likewise includes a cap base 302 and a plurality of cap sides 304.

The cap 300 may be a “pop-open” or “pop-up” cap. The cap 300 may include coating improvements and may provide a cap for, for example, a 40 inch×48 inch pallet. This pop-up/pop-open version can be premade then shipped flat and popped open for use in the field or at a facility. The cap 300 may include one or more of the following: i) the folds, corner glue/seal tabs/corner seals, ii) the exterior and/or interior coating which must provide airtight or prescribed atmospheric and/or environmental barrier properties, as well as iii) the cap's adhesion/sealing properties which when mated or wrapped with the side sheet create the enclosure. The glue or adhesion of the sides of the cap 300 may be plant based or natural. The glue or adhesion of the sides of the cap 300 may be such that recyclability, sustainability, or compostability of the cap 300 can occur after usage of the cap 300.

FIG. 4B illustrates a cap 350 that may be a gusseted bag.

In the examples of FIGS. 2 to 4B, the caps may be stackable. This may allow for ease of transportation and reduced cost. Any of the caps of FIGS. 2 to 4B can be used for manual and/or automated applications. The caps may include unique designs (e.g., caps that can be folded, gusseted, or pressed from natural fibers, composite materials, or plastic sheets with 90 degree snug sides or slightly flared angled sides for stacking/nesting or stacking tabs for easy de-nesting) and/or may made from various materials (e.g., coated materials and/or barrier papers, linerboard and/or cardboard, various flexible, semi-ridged, and/or preformed plastics, and/or various virgin or recycled, treated and/or coated plastic materials (including, e.g., polypropylene, polyethylene (PE), PET, etc.)). The material may be selected based on the product, or costs, or both. The material may be environmentally sustainable (e.g., reusable caps, make use of recycled material vs. virgin materials) and/or the material may be recyclable materials (e.g., paperboard, cardboard, PET, and/or PE, or combinations thereof). The caps must have characteristics such as airtight sealing, barrier, or product specific oxygen transmission rate or carbon dioxide transmission rate properties that will work together with the barrier or prescribed properties of the side sheet material to create the required and product specific sealed pallet enclosure. To achieve adherence with the side sheet, the cap sides may be coated or laminated with natural materials or waxes, etc. In each case, the cap is sustainable and recyclable and never physically attached, glued, taped or stapled to the cartons. The cap is more sustainable and/or recyclable than current commercial materials used in all pallet bag MAP executions. The cap (including the material made therefrom) is also able to achieve an effective bond with the side sheet material to create a sealed pallet enclosure that ensures the modified atmosphere is maintained within the sealed pallet enclosure.

In use as the bottom cap 16, the caps 100, 200, 300 may be placed on the pallet 14 and the cartons 12 may be received therein. In one example, the bottom cap 16 may be place on the pallet 14 before the cartons 12 are loaded on the pallet 14. Alternatively, as illustrated in FIGS. 5A to 5E, the cartons 12 are loaded onto the pallet 14 to form the pallet of goods 10. The cartons 12 are illustrated schematically in FIGS. 5A to 5C for simplicity of description but may take the form of any of the products described herein. As shown in FIGS. 5B and 5C, a lifting assembly 500 is provided to lift the cartons 12 vertically (and horizontally if needed) off of the pallet 14. With the cartons 12 lifted off of the pallet 14, the bottom cap 16 may be placed on the pallet 14. FIG. 5D illustrates the bottom cap 16 placed on the pallet 14 in a substantially flat condition, however, as described previously and as shown in FIG. 5E, the bottom cap 16 may be formed in the final configuration (see, e.g., FIGS. 2 and 3B). Once the cartons 12 are located on the cap base, the cap sides may be folded upward to form the cap structure shown in FIG. 3B. Alternatively, the cap sides 204, 304 may be folded prior to placement on the pallet 14. With the cartons 12 now located in the bottom cap 16, the lifting assembly 500 may lower the cartons 12 onto the bottom cap 16 and pallet 14.

FIGS. 5A through 5E illustrate a schematic lifting assembly 500. FIG. 5F illustrates an exemplary lifting assembly 502 that may be the lifting assembly 500. FIGS. 6A and 6B illustrate another exemplary lifting assembly 600 that may extend downward from the top of the cartons in a vertical orientation to grasps all four sides of the stacked goods for lifting. The lifting assembly 600 may be a layer picker mechanism for lifting the cartons above the pallet. In contrast, FIGS. 5A to 5F illustrate a side oriented lifting assembly 500 that grasps three sides from a horizontal orientation. Either lifting assembly 500 or 600 may be employed in the systems and methods described herein with little or no modification. The lifting assemblies 500 and 600 comprise clamps for lifting the cartons above the pallet.

FIG. 7 illustrates the caps 100, 200, 300 in use as a top cap 18. The top cap 18 may be rotated 180 degrees from the view of FIG. 2 such that a top of the cartons 12 is received within the hollow interior 106 (see, e.g., FIG. 2). The top cap 18 may be lowered onto a topmost surface of the cartons 12. Although illustrated in the preformed configuration of FIG. 2, the top cap 18 may alternatively be placed onto the cartons 12 in the substantially flat configuration and folded after installation on the cartons 12.

As shown in FIGS. 8A and 8B, either of the lifting assemblies 500 or 600 may be operated with a forklift 800 or from a fixed structure 802.

FIGS. 9A to 9C illustrate a cap “pick and place” mechanism 900 for locating the bottom cap 16 and the top cap 18 on the cartons 12. As illustrated in FIG. 9A, the cap pick and place mechanism 900 includes a bottom cap placement mechanism 902 and a top cap placement mechanism 904. In both mechanisms 902, 904, the caps 16, 18 are located in a cold storage or distribution facility location 906, 908, respectively but may be considered modular and moveable/portable as may be useful to meet seasonal or volume requirements.

FIGS. 9B and 9C illustrate the top and bottom cap placement mechanism 902, 904, which may be identical. Each of the placement mechanisms 902, 904 includes a frame 910. One or more vertically moving arms 912 are coupled to the frame 910 and one or more horizontally moving arms 914 are coupled to the frame 910. The vertically moving arms 912 move vertically along the frame 910 to lower onto the bottom cap 16 and/or the top cap 18 at the appropriate location (e.g., this may be the topmost cap in a stack of caps). Once the vertically moving arms 912 are in the proper location, the arms 912 grab the cap. Then, the horizontally moving arms 914 may move the bottom cap 16 and/or the top cap 18 from the storage location 906, 908 onto the pallet 14 and/or the cartons 12 (depending on whether the cap is the bottom cap 16 or the top cap 18). This process may be automatic or semi-automatic. FIGS. 9D and 9E illustrate a top view of the pick and place mechanism 900. In FIG. 9D, the mechanism 900 is grasping the bottom cap 16 or the top cap 18 and in FIG. 9E, the horizontally moving arms 914 have moved the bottom cap 16 or top cap 18 onto the pallet 14 or the cartons 12, respectively.

FIG. 10 illustrates an exemplary system 1000 for creating a sealed enclosure around products and for providing a modified atmosphere within the sealed enclosure. The system 1000 includes a conveyor 1002 for an incoming pallet of goods 10 (e.g., a pallet 14 with cartons 12) to a first station 1004 for placing the bottom cap 16 and the top cap 18 on the pallet of goods 10 and to a second station 1006 for wrapping the pallet of goods 10 to create a sealed enclosure and for, optionally, providing a modified atmosphere within the sealed enclosure.

The first station 1004 may include a system 1008 for lifting the cartons 12. The system 1008 may be either of the lifting mechanism 500 or 600 or other lifting device capable of securely lifting the cartons 12 above the pallet 14. The first station 1004 also includes a cap pick and placement mechanism 1010, which may be the pick and place mechanism 900.

The second station 1006 includes a system for wrapping the pallet of goods 10 and for, optionally, providing a modified atmosphere within a sealed enclosure formed by the wrapping. The system may be any of the systems described herein capable of forming the sealed enclosure and/or modified atmosphere, or any of the systems described within the International Applications incorporated by reference herein.

During operation of the system 1000, the incoming pallet of goods 10 moves along the conveyor 1002 to the first station 1004. At the first station 1004, the cartons 12 are lifted, via the system 1008, from the pallet 14 (as illustrated), then the cap pick and placement mechanism 1010 delivers the bottom cap 16 to the pallet 14 in any of the manners described herein. Once the bottom cap 16 is in the appropriate location, the cartons 12 are lowered by the system 1008. Then, the cap pick and placement mechanism 1010 delivers the top cap 18 to the top of the cartons 12. The, now capped, pallet of goods 10 moves along the conveyor 1002 to the second station 1006. The second station 1006 provides a wrapping film 20 around the cartons 12, the bottom cap 16, and the top cap 18 to form a sealed enclosure. During wrapping or after wrapping, a system 50 may inject a modified atmosphere gas treatment within the sealed enclosure. As noted, the wrapping and modified atmosphere systems may be any of the systems described herein or within the International Applications incorporated by reference herein.

FIG. 11 illustrates another exemplary system 1100 for creating a sealed enclosure around products and for providing a modified atmosphere within the sealed enclosure. The system 1100 and the method of using the system 1100 may be the same as the system 1000 and the method of using the system 1000, with the following modifications. Instead of using a conveyor 1002, the system 1100 may use a robotic pallet (see, e.g., robotic pallet 1105) or forklift to move the pallet of goods 10 from station to station (e.g., from a first station 1102, to a second station 1104, to a third section 1106). At the first station 1102, for example, the incoming pallets 14 arrive. The robotic pallet 1105 or forklift may move the incoming pallets 14 to the second station 1104, where the top cap and bottom cap are applied. The robotic pallet 1105 or forklift then moves the pallets 14 to the third station 1106 where the sealed enclosure and modified atmosphere are provided. Alternatives to a robotic pallet may be employed, such as a forklift, or other robotic mechanism.

One exemplary system 1200 that may provide the modified atmosphere is illustrated in FIG. 12. The system 1200 may be employed as the system 50 of FIG. 10. In FIG. 12, the system 1200 illustrates a pallet of goods 10 having a pallet 14, a bottom cap 16, cartons (not visible behind wrapping film 20), a top cap 18, and a wrapping film 20. The wrapping film 20 may be dispensed from a film dispensing apparatus 22 that may be any of the dispensing apparatus described in the International Applications incorporated herein by reference. The system 1200 includes one or more nozzle assemblies 1202 and may, optionally, include the film dispensing apparatus 22. Each of the nozzle assemblies 1202 includes a manifold 1204, a nozzle 1206, and a pad 1208. A sealed enclosure is formed within the interior of the wrapped film 20. The nozzle 1206 may be inserted into the sealed enclosure between the wrapping film 20 and the of cartons (not visible). A modified atmosphere may be created by injecting and/or venting gases into the sealed enclosure. The system 1200 may provide a modified atmosphere within the wrapped pallet while preventing or reducing leakage from within the wrapped pallet. As illustrated in FIG. 12, a feed hose 1210, represented as an arrow, may have vacuum and venting and also may provide modified atmosphere gas and other treatments.

The nozzle 1206 may be an injection nozzle inserted into the inside of the film wrapped enclosure. The nozzle 1206 may have a center passage for providing the modified atmosphere gas and a perimeter passage for vacuuming and venting. The system may be robotic and mechanical, providing automated injection, venting/vacuuming, and servo driven containment pads 1208.

For example, in FIG. 12, the system 1200 may be a system and apparatus for delivery, containment, and uniform distribution of treatments and/or functional substances within the sealed enclosure. The nozzle 1206 may be inserted between the top cap 18 and the wrapping film 20 and/or the nozzle 1206 may be inserted between the bottom cap 16 and the wrapping film 20. The manifold 1204 has the pad 1208 and a stabilizing bracing bar 1212, which may be included with each nozzle 1206. The nozzle assemblies 1202 may include central modified air, gas and treatment injection and perimeter vacuum and venting, such as described in the International Applications incorporated herein by reference. Although two nozzle assemblies 1202 are shown, more or fewer may be provided. The process may occur simultaneously among the one or more nozzles and/or may occur sequentially. The features of FIG. 12 are illustrated schematically for ease of disclosure only, the structure and appearance of the features may be different than shown.

Method 1) of the preceding paragraph provides a simple seal (e.g., bottom and top caps applied then sealed to a side sheet (e.g., wrapping film)) to enclose pallets for environmental containment, stability, and passive MAP, or modified atmosphere with gasses.

The caps and/or wrapping film of the present disclosure are preformed or constructed of materials that include adhesion or texture properties compatible between the caps and the wrapping film to accomplish the sealed enclosure. For example, the wrapping film and/or caps may include a molecular weight, separation rate, fluid-solid behaviors during approach and detachment, surface roughness or texture, and/or polymer and additive chemistry that provides compatibility between the caps and wrapping film to ensure adherence of the caps to the wrapping film. The preformed cap design and shape is such that the cap will fit the pallet and contain the cartons while also providing sufficient side dimensions to connect with the side enclosure film or side sheet material. The caps and/or wrapping film of the present disclosure provides a sealed enclosure that does not include (e.g., is free from) staples, glue, and tape that prevent recycling of the caps and/or wrapping film. That is, no staples, glue, and/or tape will be employed to attach the caps to the cartons or to the wrapping film. In examples where staples, glues, and/or tapes are described with respect to constructing the caps of the present disclosure, said securing types may be plant based and/or recyclable such that the caps and wrapping films may be recycled within a commercial recycling facility. In cases where some adhesive may be used to secure the sides of the cap together to create the cap shape (e.g., FIG. 3A), the amount of adhesive, only to be used to create the cap shape, may be so small as to still allow for the cap to still be recyclable and/or may be a plant-based or natural based adhesive.

As used herein, the term “recyclable” means able to be recycled, such as, for example, in a commercial recycling facility. As used herein, “recycle” means the ability to convert waste materials (in the case of this application, the caps and/or films) into reusable materials to be used again for another purpose. In some examples, this may include returning the waste material to a previous stage in the lifecycle of the waste. As used herein, “sustainable” means products (e.g., the caps and/or films) that provide environmental, social, and economic benefits while protecting public health and the environment over the lifecycle of the product, from the extraction of the raw materials until the final disposal of the material. As used herein, recyclable and sustainable materials are those that do not need to be disposed of in the waste process (e.g., landfills) and may be disposed of in other means (e.g., compostable and/or recyclable). Some sustainable materials described herein may be plant based or natural fibers. As used herein the term “compostable” refers to products capable of being converted to compost. Some materials may be specified as recyclable and/or biodegradable, these materials may be recycled, or it may degrade in the environment or biodegrade in a landfill by microbes in a programmed and accelerated manner that does not result in micro plastic contamination. As used herein, “reusable” means components that can be collected after use and returned back to the source for repeat use on other shipments of perishable products.

The preformed caps of the present disclosure may be constructed or manufactured of one or more of the following: various types of plastic material (including coated and/or treated plastic materials), coated papers/cardboard, coated natural fibers, papers, cardboard, or other natural fibers. According to one embodiment, the aforementioned materials are recyclable, biodegradable, reusable, compostable, and/or sustainable.

One exemplary preformed cap of the present disclosure may be a cap made using a gusseted pallet bag design but cut or formed with a very short 1-to-10-inch side overhang or carton overlap. This unique gusseted pallet bag can be assembled from a roll of ready to use bags, with a tear off score for each pallet bag that can be assembled in the field or cooling facility. The gusseted pallet cap bags may be semi rigid when opened, laid out on an empty pallet. The sides (ideally the sides are +/−3 to 6 inches) are folded along the edges of the carton to form a cap, or they may be flipped down around the edge of the pallet, the first layer of cartons are then stacked on the pallet on top of the “bottom cap gusseted bag” resting on top of the pallet, then after the first layer of cartons has been stacked the sides are “flipped up or folded up or stability locking tabs tucked in between the tiers of carton layers” using their natural orientation with the tacking side facing out and supported in place by the cartons to form the bottom cap. The natural semi-rigid properties of the cap plastic material help facilitate a snug fitting cap around the stacked cartons and the tacky out facing surface provides a good bonding surface seal between the side sheet and the cap when wrapped.

Furthermore, the top and bottom caps and side wrap/wrapping film materials may be significantly more sustainable (as compared to the systems and methods of the prior art described herein), 100% recyclable films, coated plastic materials/cardboards/papers, natural fibers, and/or biodegradable, reusable, or combinations thereof.

According to the present disclosure, the bottom preformed cap may be placed on the pallet and under the cartons at the time of harvest and packing in the field or at the end of a packing line where cartons are stacked on the pallet. The preformed top cap can be placed above the cartons on the pallet at the same time (e.g., also at the time of harvest and packing in the field) or in the cooling warehouse. In the example where the bottom cap (and optionally, the top cap) is placed on the cartons at the time of harvest and packing, this minimizes the amount of labor and equipment needed (and space required) in the cooling warehouse as compared to the current processes for creating a sealed enclosure discussed in this application. This timing eliminates the need for lifting the pallet cartons in the cooling facility saving equipment cost, complexity, and process time. This timing also simplifies and speeds up the process in the cooling warehouse. Thus, this timing also enables practical applicability in small to medium size operations and especially seasonal harvest operations.

According to the present disclosure, the systems and methods may employ “off the shelf” equipment to accomplish the needed steps to create a sealed enclosure. “Off the shelf” equipment may be equipment that does not need to be custom built for one or more of a particular operator of the system and method or a particular product or a particular location. “Off the shelf” equipment may include equipment that may be integrated and configured into the overall processing system with only slight modification.

According to the present disclosure, a forklift side clamp attachment may be employed to squeeze and elevate the cartons above the pallet (e.g., such as illustrated in FIGS. 8A, 8B and 5F). In another example, a modified “4-way hold layer pick” mechanism (e.g., such as illustrated in FIGS. 6A and 6B) may be employed to squeeze and elevate the cartons above the pallet. The forklift side clamp attachment and/or the 4-way hold layer pick mechanism may be affixed to a forklift and/or the forklift side clamp attachment and/or the 4-way hold layer pick mechanism may be set up as stand-alone devices. Once the cartons are elevated, the bottom cap may be placed between the pallet and the cartons. In an example, this placement may be manual. In another example, a “pick and place” robotic mechanism (e.g., as illustrated in FIGS. 9A to 9E) can provide an automated method to place the bottom cap. A fitted top cap (instead of a top sheet) can be placed manually or by using the same type of pick and place robotic mechanism.

As described herein, the cap design of the present disclosure may be the same as the preformed top seal element and the preformed bottom seal element of the sealed enclosure. This may reduce operational complexity and cost. The cap provides environmental benefits as the cap can be made from materials that are recyclable plastic and/or use coated natural fibers that are biodegradable. In either case, the cap may still provide a gas and/or environmental barrier for the modified atmosphere or treatment containment.

The preformed caps, whether the bottom cap or the top cap, includes dimensions that match the surface area of the pallet and carton. The preformed caps may be i) preassembled, ready to use, ii) knocked down for shipping and quickly assembled (pop-up assembly), iii) snug fit around the cartons, and/or iv) telescoping to enable fitting around the cartons during placement and which may be snugged or pressed against the cartons during side sheet application and sealing. A pallet or stack of cartons may have a variety of physical dimensions. For example, and discussion purposes, this description will use the dimensions for a current standard US pallet. The dimensions are 40 inches×48 inches. The cap includes dimensions that if needed could match or be slightly larger, for example, by >/=0.1 inches on all sides, thus having a slightly larger footprint such as >/=40.2 inches×48.2 inches. Such a slightly larger dimension allows for the cartons to easily be received within the bottom cap and the top cap. In some examples, the cap may telescope at the open end to 40.5 inches×48.5 inches. In some examples, the cap is between 0.01 and 0.05 ( 1/10% up to 5%) percent larger than the pallet. That is, the base of the cap may be smaller than the top, open end of the cap, but the base of the cap would match or be slightly larger than the pallet size. The sides of the cap are pressed in between the cartons and the wrapping film after the wrapping film is applied to the cartons. The cap fits snug and secure with the cartons, while also being flexible to provide a good seal and prevent leakage at any corners, folds, scores, or creases.

According to the present disclosure, after the bottom cap and the top cap are in location with respect to the cartons, a standard commercial type of pallet stretch wrap device may add the wrapping film to the sides of the cartons. The film is stretched tightly to the cartons providing stability for handling and eliminating the need for the aforementioned prior art corner boards, straps, stretch rope, and/or tape. There is a preferred method based on the side sheet film and cap material characteristics, the perishable product needs, and a set of specific criteria for creating a prescribed pallet enclosure. This method includes one or more of the following: a) a percent film pre-stretch, b) a force to load setting for dispensing the film, c) a film overlap percentage, d) the number of side sheet film wraps and layers, e) film additive adhesion chemistry, f) film texturing during dispensing, g) electrostatic charging of cap and/or film, and g) the film wrap pattern used to enclose the perishable goods. During this step, in the preferred embodiment, one or more nozzles can be placed between an outer surface of the cap edge (e.g., the top cap edge, the bottom cap edge, and/or both the top cap edge and the bottom cap edge) and an inner surface of the wrapping film to inject the modified atmosphere treatment into the sealed enclosure. The nozzle may be any of the systems described herein or described in International Patent Application Nos. PCT/US2020/067731 and PCT/US2022/030263. Such nozzles provide a smart system with specially designed nozzle(s) that can regulate the internal pressure of the sealed enclosure and the rate and amount of a product specific modified atmosphere being injected. This provides a uniform distribution of the modified atmosphere and prevents puffing or bulging of the enclosure shape. The modified atmosphere provided in the sealed enclosure may be any of the modified atmospheres described herein and/or described in International Patent Application Nos. PCT/US2020/067731 and PCT/US2022/030263.

According to the present disclosure, the pallets themselves can be moved through the process steps by a pallet jack, a forklift, on a conveyor, using robotic pallet movers, or combinations thereof. With the importance for using less labor and space in large facility or operations, the novel combination of robotic pallet movers and flexible automated workstations composed of “off the shelf” equipment, along with biodegradable/recyclable top and bottom caps and side sheet material creating the sealed stable enclosure and resulting modified atmosphere/environment, this achieves overall benefits that prior art and current commercial operations have not considered nor can achieve.

The systems and methods of the present disclosure are modular for volume scalability and easily movable for flexibility of use at the next location. This allows for use for any harvest process. This is important since many harvest, packing, and cooling operations occur for only several weeks or months during the growing season and production volume may peak and fall by location. Off the shelf equipment, maintenance, spare parts, operational usage, and training are all added benefits. These provide a critical benefit to get maximum usage of the assets to reduce cost per pound of the process for a perishable product.

Furthermore, the systems and methods of the present disclosure provide simple, easy to use pallet systems to protect and preserve products (such as perishable products) during transport and distribution. The systems and methods of the present disclosure are scalable, modular, and movable systems to meet the volume and seasonal needs of customers small to large. The methods and systems of the present disclosure provide a reduction in total packaging material required: moving the industry towards a more sustainable circular economy using less plastic & packaging material which is more easily recycled.

Accordingly, an embodiment for providing a modular system and method may include modifying a transport trailer, container, and/or modular movable frameworks to contain the various equipment components needed for the operation, including gas cylinders, system for injecting modified atmosphere treatments, film wrapping equipment, and other assets as needed for the process to operate for some weeks and then quickly and easily relocate close to the next harvest, processing, and cooling location.

Aspects of the present disclosure are provided in the following clauses.

A method to create a sealed enclosure which places the bottom cap between the pallet and cartons during harvest and packing in the field, and where the top cap can be placed on top of the cartons in the field, at a packing facility, or cooling warehouse, and where the stretch wrap film is applied after cooling the perishables.

The method according to any previous clause, where the bottom and top cap are made from molded plastic or polymer lined cardboard or substrate to create the cap.

The method according to any previous clause, where the bottom cap begins as a sheet of the target materials with sections scored for folding to create the cap sides or cut to enable folding of the corner flaps which are then sealed together using sustainable adhesive materials to create the preformed cap shape.

The method according to any previous clause, wherein the cap is made from biodegradable and/or recyclable materials with prescribed gas and moisture barrier properties.

The method according to any previous clause, wherein the cap is constructed with tabs which are able to be tucked between layers of the cartons or lock the cap in place for improved stability and to prevent distortion of the cap during the process of forming the enclosure.

The method according to any previous clause, where the preformed cap for the bottom and top of the sealed enclosure have dimensions that are configured to the dimensions of a pallet to fit the stacked cartons snugly within the cap and without significantly overhanging the pallet so as to expose it to damage during handling and shipment; and wherein the sides would extend 1 inch or more and preferably 3 to 8 inches with adhesion and crease or leak proof properties that work together with the side sheet to create a sealed enclosure.

The method according to any previous clause, wherein the stretch film for wrapping and cap materials have compatible design, texture, and/or adhesion properties to eliminate the need for staples, filaments, tape, or glue as connection adhesives.

The method according to any previous clause, where the stretch film for wrapping and the cap materials have oxygen and carbon dioxide transmission properties which enable maintaining an intended modified atmosphere environment.

The method wherein the side component of the enclosure is a sleeve which fits over the sides of the cartons and is then sealed to the caps using an elastic band, a sealing gasket, and/or stretch film with an adhesive laminated side.

The method wherein the side components of the enclosure is a semi-rigid sheet that is placed along the sides of the cartons and is then sealed to the caps using an elastic band, a sealing gasket, and/or stretch film with an adhesive laminated side.

The method wherein the cap material is made of durable material enabling it to be returned to source for re-use.

The method according to any previous clause, where the modified atmosphere treatment is injected into the sealed enclosure before, during, or after the enclosure has been completed and sealed.

The method according to any previous clause, where a vacuum is pulled through the one or more nozzles to create a prescribed negative pressure before the modified atmosphere gas is injected.

The method according to any previous clause, where the vacuum is pulled through the pallet in one location as the modified atmosphere gas is injected into the enclosure at one or more other locations.

The system according to the previous clause, wherein the cartons are lifted or elevated above the pallet using a standard forklift with slightly modified-angled textured side clamp or layer picker attachment.

The system according to any previous clause, wherein a standard pick and place mechanism is used to place a bottom preformed cap between the pallet and cartons, and wherein a similar pick and place mechanism is used to place a preformed cap on the top of the cartons on the pallet.

The system according to any previous clause, wherein a standard film stretch mechanism is used to apply film to the sides of the pallet and complete the sealed enclosure.

The system according to any previous clause, wherein robotic pallet movers are used to move the pallets of cartons from one process station to the next.

A method for providing a sealed enclosure for a pallet of goods, the method comprising providing a prefabricated or pre-formed bottom cap to a stack of cartons on a pallet; providing a prefabricated or pre-formed top cap to the stack of cartons on the pallet; and wrapping a stretch film around sides of the stack of cartons, the bottom cap, and the top cap to create the sealed enclosure.

The method of any preceding clause, further comprising forming the bottom cap and the top cap of molded plastic, polymer lined cardboard, or a substrate, or a combination thereof.

The method of any preceding clause, wherein providing the preformed bottom cap comprises: a) providing a sheet of material with sections scored or cut for folding; b) folding the sections to create one or more cap sides; and c) sealing one or more corner flaps of the one or more cap sides together using sustainable adhesive materials.

The method of any preceding clause, further comprising forming the bottom cap or the top cap of a biodegradable material, recyclable material, or both biodegradable material and recyclable material and forming the bottom cap or the top cap with gas and moisture barrier properties.

The method of any preceding clause, where the preformed bottom cap or the pre-formed top cap have a cap base with perimeter dimensions that are configured to the dimensions of the pallet such that the cap base of the pre-formed bottom cap or the pre-formed top cap matches or is slightly larger in plan view than the pallet.

The method of any preceding clause, wherein the preformed bottom cap and the top cap comprise a cap base and a plurality of cap sides extending perpendicular to the cap base, and wherein the plurality of cap sides extends perpendicularly to the cap base by 1 inch or more, and preferably, 3 inches to 8 inches.

The method of any preceding clause, further comprising forming the stretch film, the preformed top cap, and the preformed bottom cap of materials that are compatible in design, texture, and/or adhesion properties.

The method of any preceding clause, wherein the sealed enclosure formed by the stretch film, the preformed top cap, and the preformed bottom cap is free from staples, filaments, tape, glue as connection adhesives.

The method of any preceding clause, further comprising forming the stretch film, the preformed top cap, and the preformed bottom cap of materials that have oxygen and carbon dioxide transmission properties selected based on the goods to provide a predetermined modified atmosphere environment.

The method of any preceding clause, further comprising providing the preformed bottom cap between the pallet and the cartons during harvest and packing of the cartons in the field with a product.

The method of any preceding clause, further comprising providing the preformed top cap on top of the cartons in the field, in a packing facility, or at a cooling warehouse. According to an embodiment, a bottom cap can be included during stacking of packed cartons in a packing facility).

The method of any preceding clause, further comprising providing the stretch film after cooling of the product within the cartons.

The method of any preceding clause, further comprising creating a modified atmosphere within the sealed enclosure, comprising injecting modified atmosphere gas or treatment into the sealed enclosure before, during, or after the enclosure has been completed and sealed.

The method of any preceding clause, further comprising pulling a vacuum through one or more nozzles to create a negative pressure before creating the modified atmosphere.

The method of any preceding clause, further comprising pulling a vacuum through one or more nozzles to create negative pressure from one location on the sealed enclosure, while injecting the modified atmosphere gas at a separate location on the sealed enclosure.

A flexible, modular, movable system for providing a sealed enclosure to a pallet of goods, the system comprising: a preformed top cap, a preformed bottom cap, and wrapping film, each formed of biodegradable and recyclable or reusable materials; a lifting system configured to elevate a stack of cartons from the pallet; and a pick and place mechanism configured to move the top cap and the bottom cap to the pallet of goods.

The system of the preceding clause, wherein the lifting system comprises a side lifting system or a top-down lifting system.

The system of any preceding clause, further comprising a forklift configured to elevate the stack of cartons.

The system of any preceding clause, wherein the pick and place mechanism is configured to provide the preformed bottom cap between the pallet and the stack of goods and configured to provide the preformed top cap on a topmost surface of the stack of goods.

The system of any preceding clause, further comprising a film stretch system configured to apply the wrapping film to the sides of the pallet of stacked goods to complete the sealed enclosure.

The system of any preceding clause, further comprising robotic pallet movers configured to move the pallets of goods from one process station to a subsequent process station.

The system of any preceding clause, wherein the pallet of stacked goods comprises a plurality of cartons (or goods) stacked on the pallet, each carton filled with perishable product. According to an embodiment, the pallet can be any dimensions or shape (carton could be even a bin) so long as it has a typical industry common forklift slots for handling in that manner.

A method which places the preformed bottom cap between the pallet and cartons during harvest and packing in the field, and where the preformed top cap can be placed on top of the cartons in the field or cooling warehouse, and where the stretch wrap film is applied after cooling the perishables. According to an embodiment, caps may be placed in the field, packing facility, or at the cooling facility.

A system that places a preformed bottom cap between a pallet and a stack of goods and a preformed top cap on top of the stack of goods, the system further providing a side sheet around the stack of goods, top cap, and bottom cap.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Features, in whole or in part, in one embodiment may be utilized in other embodiments. Thus, the breadth and scope of the present invention should not be limited by any of the above-described embodiments but should instead be defined only in accordance with the following claims and their equivalents.

SYSTEMS AND METHODS FOR CREATING A SEALED PALLET ENCLOSURE

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