CA2319887A1 - Shrink packaging of food products - Google Patents
Shrink packaging of food products Download PDFInfo
- Publication number
- CA2319887A1 CA2319887A1 CA002319887A CA2319887A CA2319887A1 CA 2319887 A1 CA2319887 A1 CA 2319887A1 CA 002319887 A CA002319887 A CA 002319887A CA 2319887 A CA2319887 A CA 2319887A CA 2319887 A1 CA2319887 A1 CA 2319887A1
- Authority
- CA
- Canada
- Prior art keywords
- package
- food product
- accordance
- flexible material
- farinaceous
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
- A21D15/00—Preserving finished, partly finished or par-baked bakery products; Improving
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
- B65D75/52—Details
- B65D75/58—Opening or contents-removing devices added or incorporated during package manufacture
- B65D75/5805—Opening or contents-removing devices added or incorporated during package manufacture for tearing a side strip parallel and next to the edge, e.g. by means of a line of weakness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/18—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient
- B65D81/20—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient under vacuum or superatmospheric pressure, or in a special atmosphere, e.g. of inert gas
- B65D81/2007—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient under vacuum or superatmospheric pressure, or in a special atmosphere, e.g. of inert gas under vacuum
- B65D81/2038—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient under vacuum or superatmospheric pressure, or in a special atmosphere, e.g. of inert gas under vacuum with means for establishing or improving vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/32—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging two or more different materials which must be maintained separate prior to use in admixture
- B65D81/3294—Thermoformed trays or the like with a plurality of recesses for different materials located in different recesses
Abstract
A packaging system for storage of a ready-to-eat food product that is to be assembled in a meal kit is provided to limit migration of moisture from the food product. The food product is a farinaceous food product such as waffles, pancakes, bread, buns, tortillas or cereal. The ready-to-eat food product is separately packaged in a shrinkable thinly formed flexible material prior to being deposited within a tray of the meal kit. The package is provided with an easy open feature to facilitate tearing of the package.
Description
SHRINK PACKAGING OF FOOD PRODUCTS
FIELD OF THE INVENTION
The invention relates generally to a package for a food product which is part of a meal kit that includes multiple food items. More specifically, the invention relates to a package that limits migration of moisture from the food product during storage and display of the meal kit. The invention also relates to a method of packaging the food product and a packaging system for the food product contained in a meal kit.
BACKGROUND OF THE INVENTION
Pre-packaged meal kits which include multiple food items that require a minimal amount of consumer preparation and allow for quick assembly have become increasingly popular. Generally, a meal kit contains various ready-to-eat food items, and optionally a beverage, to provide an essentially complete meal.
Typical food items include meat products, cheese, and farinaceous food products, e.g., pancakes, waffles or buns. These food items may be contained in a main tray having one or more compartments.
Because of the perishable nature of certain food items, the meal kits should be stored and displayed at refrigerated temperatures. In stores, the meal kits typically may be displayed in open-front refrigerated cases. The temperature in these display cases may fluctuate with the cycling of the refrigeration system.
Additionally, a temperature gradient may exist through the depth of the case as a result of the front of the case being open to ambient conditions in the store.
The texture of the farinaceous food products may be affected by temperature fluctuations. More particularly, migration of moisture may result in portions of the product or the entire product becoming -drier, tougher or otherwise less fresh and appealing. Although the main tray of the meal kit may be hermetically sealed and the compartments gas flushed, moisture still may be lost from the farinaceous food product and at a rate more rapid than is desirable.
Document No. 205889 -1-It is known to separately package the farinaceous food product prior to its being deposited in the main tray to further limit moisture loss. The packaging material may be a thinly formed flexible material to which heat may be applied to shrink the material to fit more closely about the farinaceous food product, i.e.
"shrink wrap". Because the package is sealed prior to shrinking, the type of seal is chosen to ensure that the integrity of the seal is maintained during subsequent shrinking. For this reason, such a package typically is sealed using a hot wire heat seal at both ends and includes an electrostatic lap seal extending longitudinally of the product between the end seals. The lap seal comprises a simple overlap of the film without adhesive or heat sealing, but rather electrostatic forces, being relied upon to maintain the overlapped edges in contact with one another.
The package is typically subjected to a vacuum and gas flush at the time of final assembly into a meal kit. If the shrink wrap is airtight, the vacuum may cause the end seals to "blow out" or rupture. Accordingly, perforations may be provided in the shrink wrap film to facilitate evacuation of air from the package prior to gas flushing. To facilitate opening, a pull tab may be provided at the lap seal.
When the product is to be used by the consumer, the lap seal can be readily separated by pulling the tab. Tearing of one or both end seals can be initiated at one or both ends of the lap seal.
While the above described system has proven commercially successful, not all packaging lines are capable of forming electrostatic lap seals.
Some packaging lines are configured to form fin seals rather than electrostatic lap seals. Use of shrink wrap film with this type of equipment can be problematic.
One problem is that the perforations that have been employed in lap seal packages to facilitate evacuation of air from the package prior to gas flushing may not be effective in fin seal packages. Another problem is that opening of the package may be more difficult in the absence of a lap seal. The shrink wrap process reduces the surface area available on the seals for easy open features of the type that have been used with conventional films, i.e., films other than shrink wrap.
Document No. 205889 -2-There remains a need for a fin seal/shrink wrap package that can be used to individually wrap farinaceous food products to limit moisture loss within a gas-flushed, sealed compartment.
SUMMARY OF THE INVENTION
The invention generally relates to a packaging system for storage of a cooked food product to limit migration of moisture from the food product when the food product is assembled with other food items in a meal kit. The meal kit includes a substantially rigid tray having one or more compartments for receiving the multiple pre-cooked and ready-to-eat food items. The multiple food items are deposited within the tray which then is covered. A vacuum is applied to remove air from the headspace surrounding the food items in the compartments, and the compartments are flushed with a gas. The tray is then hermetically sealed.
One of the food items, a farinaceous food product, is further enclosed in a second package comprising a shrinkable thinly formed flexible material.
The package is formed by sealing the flexible material at transverse end seals and at a longitudinal fin seal extending between said end seals. After the flexible material is sealed, the package is subjected to heat to shrink the flexible material and form an essentially closely fitting package around the farinaceous food product. The package material is preferably supplied in web form, perforated with a pattern of openings that are sized and spaced so that, after heat shrinking of the package material, the resulting sizing and spacing of the perforations is sufficient to permit evacuation of air from the package without unduly comprising its ability to inhibit moisture migration. The package also has an easy open feature comprising a tear initiator at the fin seal to facilitate tearing of the flexible material to permit a consumer to remove the farinaceous food product from the package.
Although the invention is applicable to various farinaceous food products, it will be described by way of example principally in connection with waffles. As used herein, "farinaceous food product" is meant to include any wheat flour-based food item, such as waffles, pancakes, bread, buns; tortillas and cereals.
Document No. 205889 -3-BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in connection with the accompanying drawings wherein:
FIG. 1 is an exploded perspective view of a meal kit that includes a packaged farinaceous food product in accordance with the invention, illustrating waffles as the farinaceous food product;
FIG. 2 is a perspective view of the packaged farinaceous food product of FIG. 1 illustrating an easy-open feature on the fin seal in an inverted orientation;
FIG. 3 is a perspective view of a second embodiment of the invention in an inverted orientation;
FIG. 4 is a perspective view of a third embodiment of the invention, illustrating pancakes as the farinaceous food product;
FIG. 5 is a perspective view of a fourth embodiment of the invention, illustrating hamburger buns as the farinaceous food product; and FIG. 6 is a perspective view of a fifth embodiment of the invention, illustrating hot dog buns as the farinaceous food product.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention generally is embodied in a packaged food product included as part of a meal kit. As shown in FIG. 1, the meal kit 10 generally comprises a tray 12 containing multiple ready-to-eat food items 14, 16, 18, 20, one of which is a farinaceous food product 14., The tray 12 is made of a substantially rigid material and includes one or more compartments 22 to separate and display the food items. The food items generally include a pre-cooked meat product 16, a pre-cooked farinaceous food product 14, a dessert item 18 and condiments 20 or other accompanying food items.
The farinaceous food product 14 may be a breakfast item, such as waffles; pancakes or french toast, or a bread item, such as a hamburger bun, hot dog bun or tortilla. Typical meal kits include mini or bite-sized foods that are easily handled by children. The kits therefore generally contain two or more pieces of such smaller food items to provide a full serving, rather than one full-sized item.
For Document No. 205889 -4-example, four mini waffle sticks and two large coin sized sausage patties may be included in a particular meal kit or three cocktail-sized hot dogs with buns in another kit. For convenience, a breakfast meal kit that includes waffles is described herein.
The waffle formulation preferably is selected to provide a visually appealing, flavorful waffle. The waffle recipe also is selected to provide a waffle that has pleasing physical characteristics when eaten yet is durable enough to maintain these qualities as best as possible when the waffle is subjected to refrigeration and storage. The waffle is fully cooked and ready to eat before packaging.
The pre-cooked food items 14, 16, 18, 20, including the waffles, are assembled in the various compartments 22 of the tray 12, and a cover 24 is placed over the top of the tray to seal the meal kit 10. Preferably, the tray is hermetically sealed with the cover and a gas flushed environment provided in the compartments to preserve the freshness of the food items and extend shelf life. First, the headspace gas in the compartments of the tray is evacuated by vacuum to extract the oxygen-containing ambient air. Then the headspace is flushed with an inert gas.
Additionally to preserve the more perishable food items, the meal kit is refrigerated.
Although the compartment 22 is hermetically sealed, the waffles tend to lose moisture more quickly than is desirable. With the loss of moisture, the overall quality of the waffles diminishes and, more specifically, they may become drier, tougher or harder over time. As a result, the shelf life of the waffles is shortened relative to that of the meal kit generally.
Separate, individual packaging of the waffles significantly reduces the rate of moisture loss from the waffles, which, in turn, preserves freshness and increases the shelf life of the waffles. By packaging the waffles in a closely fitted package, moisture is more evenly retained within the waffles for a longer period of time. The waffles preferably are packaged as soon as possible after being produced to retain a maximum amount of moisture in the waffles. Pre-packaging of the multiple waffle pieces that are included in the meal kit provides the added benefit of Document No. 205889 -5-a unitizing package that improves ease of handling generally, as well as during the subsequent packaging of the meal kit.
The waffle package is made with a thinly formed film or sheet material that shrinks upon exposure to heat. The package material is effective for limiting migration of moisture from the waffle and through the package. The material also is durable enough to withstand handling but is readily torn by a consumer who uses an easy open feature provided on the package.
The package material preferably is a polyolefin shrink film, or "shrink wrap." Polyolefin shrink films are known in the art. The package material may be selected from the class of polyolefin shrink films. A particularly preferred package material is CRYOVACm MY available from Sealed Air Corporation of New Jersey. This material is a fully coextruded multilayer polyolefin shrink film.
Referring now also to FIG. 2, the preferred package material will be heat sealable and provide a high integrity seal that will generally withstand subsequent heat shrinking of the package. The package has a pair of transverse end seals 26. The package also has a longitudinal fin seal 28 extending between the end seals 26. With respect to the fin seal 28, the package material may be sealed inward of the edge 30 of the package material such that two flaps 32 of unsealed package material extend beyond the fin seal 28. Alternatively, the package material may be sealed out to the edge 30 with no unsealed flap. Each of the end seals 26 and the fin seal 28 should be of sufficient width to ensure that the seal is not broken during subsequent shrinking of the package material.
The preferred package material also will be of sufficient thickness and strength to withstand handling, both during packaging and subsequently by the consumer. The preferred package material will not be so thick and of such strength, however, so as to be completely resistant to tearing when a consumer seeks to manually remove the package from the waffle using an easy-open feature 34 provided on the package at the fin seal 28. To facilitate tearing of the package material by the consumer, the fin seal is adapted with a transverse slit or notch 36 extending inwardly from the outermost edge 30 of the package material at the fin Document No. 205889 -6-seal. The slit 36 is of sufficient length to allow the package material to be torn open with only minimal force by the consumer. The slit 36 may be reinforced with a tab 38 positioned on the flap 32 or fin seal 28 to one side of the slit 36. The package material may be marked or painted to indicate the location of the slit 36.
The easy open feature 34 preferably is positioned on the flap 32 of the fin seal 28 rather than on the end seal 26. If the easy open feature is positioned on the end seal, the slit may impact the integrity of the seal during subsequent packaging and handling. For example, during heat shrinking, the slit may weaken the seal so that a hole may open in the end seal at the slit as the seal shrinks.
The easy open feature 34 operates by having the consumer lift the Ilap 32 and grasp it in the vicinity of the tab 38 or at another location intermediate the slit 36 and the midpoint of the length of the fin seal. When the consumer pulls the flap in a direction upward and away from the package, the package material tears beyond the interior end of the slit 36 across the surface of the waffle package. The material also tears along the innermost edge 40 of the fin seal 28 in a direction away from the slit 36.
Alternatively, the fin seal may be provided with a second slit at the opposite end of the fin seal. The two slits are spaced apart and each positioned at or near the ends of the waffle. This two-slit easy open feature operates in a manner similar to the one-slit feature described above except that tearing of the package material is initiated from both slits so that the package may be opened from either end.
In another embodiment, as shown in FIG. 3, the easy open feature 42 may include a tab 44 extending from the fin seal 28 and affixed with an adhesive to the package material at the flap 32 or fin seal 28. The tab 44 is highly visible and provides a large, accessible appendage for the consumer to grasp, Opening of the waffle package is initiated by the consumer grasping the tab 44 and pulling in a direction upward and away from the package. The flap 32 then tears at both slits 36, tearing across the surface of the waffle package and along the fin seal 28.
Depending on the direction of the force exerted by the consumer in pulling the tab, tearing of the package material may occur more predominately at either one of the Document No. 205889 -7-two SlltS.
In other embodiments, other means to facilitate tear initiation may be employed, for example, V-notches, perforations, or surface treatments.
The waffles are packaged in the shrink film package material prior to being assembled in a meal kit. Before packaging of the waffles occurs, the package material is mechanically perforated using a perforation wheel as the film is unrolled.
The size, number and pattern of perforations is selected to avoid unduly high moisture loss from the finished package through the perforations. The perforations 46 in the finished package (FIGS. 1 and 2) should be large enough and of sufficient number, however, to allow the air contained within the sealed, finished package to pass through the perforations in a subsequent evacuation step. If the perforations are not properly sized, the package will expand excessively as the vacuum is pulled, causing one or more of the seals to open. As a result, the package may expand so far as to even explode. Although a microperforated shrink film may be used, these perforations generally are not sufficiently sized to allow the air to pass from the package to prevent the seals from opening.
The perforations preferably are formed by puncturing the web to form slits between about 1/16 and about I/8 inch in length. No material is removed, thus the slits do not have a defined width. Upon heat shrinking of the package material, some or all of the slits may open somewhat.
The fully cooked waffles are grouped in a bundle of four waffles and wrapped in the package material in a forming box. The two sides of the package material are wrapped around the waffles and the edges positioned adjacent each other, with the interior surfaces of the package material facing each other.
Then the fin seal is formed by heat sealing the two sides together along the length of the v~raffles. The end seals then are formed by heat sealing the package material at the two ends of the waffles. The easy open feature is formed by slitting the fin seal at the selected location and applying the tab or other markings.
After the package is formed and sealed, it is passed through a shrink tunnel where it is exposed to heat. Application of heat shrinks the package material, causing it to fit more closely about the waffles. The fin seal 28 is positioned on the Document No. 205889 -8-bottom of the package in the shrink tunnel, and heat is applied principally to the top and sides of the package within the tunnel. This results in relatively low shrinkage of the fin seal, so that the slits) 36 and associated tab or indicia on the fin seal remain functional after heat shrinking of the package, without the slits) propagating to form an opening in the package as a result of the heat shrinking process.
Preferably, the package material is fitted closely about the waffles after heat shrinking to maximize retention of moisture in the waffles.
The packaged waffles are subsequently assembled with other food items for packaging in the tray of the meal kit.
The following describes the dimensions of one example of a finished waffle package embodying the features of the present invention. The bundle of waffles are from about 3 '/, to about 3 '/2 inches long, from about 2 to about 2 '/4 wide and from about 1 to about 1 '/4 inches high. The fin seal is from about '/4 to about '/~
inches wide and the flap at the fin seal is from about '/4 to about '/z inches wide. The slit of the easy open feature is from about'/4 to about'/Z inches long and is positioned on the fin seal from about'/4 to about 1 inch inward of the end of the waffle.
'The perforations are spaced approximately'/4 inches apart in lines extending longitudinally of the package which are spaced approximately 1 '/4 inches apart. The perforations may be of any shape but preferably are from about 1/16 to about'/e inch at their greatest dimension.
In other embodiments of the present invention, different farinaceous food products are packaged in accordance with the invention. For example, the farinaceous food product may be pancakes (FIG. 4), hamburger buns (FIG. 5) or hot dog buns (FIG. 6).
Numerous modifications to the package may be possible to further improve the moisture retention and handling CharactarigtiC~ of the package, 'thug, modifications and variations in practice of the invention are expected to occur to those skilled in the art upon consideration of the foregoing detailed description of the invention. Although a preferred embodiment has been described above and illustrated in the accompanying drawings, there is no intent to limit the scope of the invention to this or any other particular embodiment. Consequently, any such Docnmcnt No. 205889 -9-modifications and variations are intended to be included within the scope of the following claims. The invention is described further and pointed out by the following claims.
Ducumcut Nu. 205889
FIELD OF THE INVENTION
The invention relates generally to a package for a food product which is part of a meal kit that includes multiple food items. More specifically, the invention relates to a package that limits migration of moisture from the food product during storage and display of the meal kit. The invention also relates to a method of packaging the food product and a packaging system for the food product contained in a meal kit.
BACKGROUND OF THE INVENTION
Pre-packaged meal kits which include multiple food items that require a minimal amount of consumer preparation and allow for quick assembly have become increasingly popular. Generally, a meal kit contains various ready-to-eat food items, and optionally a beverage, to provide an essentially complete meal.
Typical food items include meat products, cheese, and farinaceous food products, e.g., pancakes, waffles or buns. These food items may be contained in a main tray having one or more compartments.
Because of the perishable nature of certain food items, the meal kits should be stored and displayed at refrigerated temperatures. In stores, the meal kits typically may be displayed in open-front refrigerated cases. The temperature in these display cases may fluctuate with the cycling of the refrigeration system.
Additionally, a temperature gradient may exist through the depth of the case as a result of the front of the case being open to ambient conditions in the store.
The texture of the farinaceous food products may be affected by temperature fluctuations. More particularly, migration of moisture may result in portions of the product or the entire product becoming -drier, tougher or otherwise less fresh and appealing. Although the main tray of the meal kit may be hermetically sealed and the compartments gas flushed, moisture still may be lost from the farinaceous food product and at a rate more rapid than is desirable.
Document No. 205889 -1-It is known to separately package the farinaceous food product prior to its being deposited in the main tray to further limit moisture loss. The packaging material may be a thinly formed flexible material to which heat may be applied to shrink the material to fit more closely about the farinaceous food product, i.e.
"shrink wrap". Because the package is sealed prior to shrinking, the type of seal is chosen to ensure that the integrity of the seal is maintained during subsequent shrinking. For this reason, such a package typically is sealed using a hot wire heat seal at both ends and includes an electrostatic lap seal extending longitudinally of the product between the end seals. The lap seal comprises a simple overlap of the film without adhesive or heat sealing, but rather electrostatic forces, being relied upon to maintain the overlapped edges in contact with one another.
The package is typically subjected to a vacuum and gas flush at the time of final assembly into a meal kit. If the shrink wrap is airtight, the vacuum may cause the end seals to "blow out" or rupture. Accordingly, perforations may be provided in the shrink wrap film to facilitate evacuation of air from the package prior to gas flushing. To facilitate opening, a pull tab may be provided at the lap seal.
When the product is to be used by the consumer, the lap seal can be readily separated by pulling the tab. Tearing of one or both end seals can be initiated at one or both ends of the lap seal.
While the above described system has proven commercially successful, not all packaging lines are capable of forming electrostatic lap seals.
Some packaging lines are configured to form fin seals rather than electrostatic lap seals. Use of shrink wrap film with this type of equipment can be problematic.
One problem is that the perforations that have been employed in lap seal packages to facilitate evacuation of air from the package prior to gas flushing may not be effective in fin seal packages. Another problem is that opening of the package may be more difficult in the absence of a lap seal. The shrink wrap process reduces the surface area available on the seals for easy open features of the type that have been used with conventional films, i.e., films other than shrink wrap.
Document No. 205889 -2-There remains a need for a fin seal/shrink wrap package that can be used to individually wrap farinaceous food products to limit moisture loss within a gas-flushed, sealed compartment.
SUMMARY OF THE INVENTION
The invention generally relates to a packaging system for storage of a cooked food product to limit migration of moisture from the food product when the food product is assembled with other food items in a meal kit. The meal kit includes a substantially rigid tray having one or more compartments for receiving the multiple pre-cooked and ready-to-eat food items. The multiple food items are deposited within the tray which then is covered. A vacuum is applied to remove air from the headspace surrounding the food items in the compartments, and the compartments are flushed with a gas. The tray is then hermetically sealed.
One of the food items, a farinaceous food product, is further enclosed in a second package comprising a shrinkable thinly formed flexible material.
The package is formed by sealing the flexible material at transverse end seals and at a longitudinal fin seal extending between said end seals. After the flexible material is sealed, the package is subjected to heat to shrink the flexible material and form an essentially closely fitting package around the farinaceous food product. The package material is preferably supplied in web form, perforated with a pattern of openings that are sized and spaced so that, after heat shrinking of the package material, the resulting sizing and spacing of the perforations is sufficient to permit evacuation of air from the package without unduly comprising its ability to inhibit moisture migration. The package also has an easy open feature comprising a tear initiator at the fin seal to facilitate tearing of the flexible material to permit a consumer to remove the farinaceous food product from the package.
Although the invention is applicable to various farinaceous food products, it will be described by way of example principally in connection with waffles. As used herein, "farinaceous food product" is meant to include any wheat flour-based food item, such as waffles, pancakes, bread, buns; tortillas and cereals.
Document No. 205889 -3-BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in connection with the accompanying drawings wherein:
FIG. 1 is an exploded perspective view of a meal kit that includes a packaged farinaceous food product in accordance with the invention, illustrating waffles as the farinaceous food product;
FIG. 2 is a perspective view of the packaged farinaceous food product of FIG. 1 illustrating an easy-open feature on the fin seal in an inverted orientation;
FIG. 3 is a perspective view of a second embodiment of the invention in an inverted orientation;
FIG. 4 is a perspective view of a third embodiment of the invention, illustrating pancakes as the farinaceous food product;
FIG. 5 is a perspective view of a fourth embodiment of the invention, illustrating hamburger buns as the farinaceous food product; and FIG. 6 is a perspective view of a fifth embodiment of the invention, illustrating hot dog buns as the farinaceous food product.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention generally is embodied in a packaged food product included as part of a meal kit. As shown in FIG. 1, the meal kit 10 generally comprises a tray 12 containing multiple ready-to-eat food items 14, 16, 18, 20, one of which is a farinaceous food product 14., The tray 12 is made of a substantially rigid material and includes one or more compartments 22 to separate and display the food items. The food items generally include a pre-cooked meat product 16, a pre-cooked farinaceous food product 14, a dessert item 18 and condiments 20 or other accompanying food items.
The farinaceous food product 14 may be a breakfast item, such as waffles; pancakes or french toast, or a bread item, such as a hamburger bun, hot dog bun or tortilla. Typical meal kits include mini or bite-sized foods that are easily handled by children. The kits therefore generally contain two or more pieces of such smaller food items to provide a full serving, rather than one full-sized item.
For Document No. 205889 -4-example, four mini waffle sticks and two large coin sized sausage patties may be included in a particular meal kit or three cocktail-sized hot dogs with buns in another kit. For convenience, a breakfast meal kit that includes waffles is described herein.
The waffle formulation preferably is selected to provide a visually appealing, flavorful waffle. The waffle recipe also is selected to provide a waffle that has pleasing physical characteristics when eaten yet is durable enough to maintain these qualities as best as possible when the waffle is subjected to refrigeration and storage. The waffle is fully cooked and ready to eat before packaging.
The pre-cooked food items 14, 16, 18, 20, including the waffles, are assembled in the various compartments 22 of the tray 12, and a cover 24 is placed over the top of the tray to seal the meal kit 10. Preferably, the tray is hermetically sealed with the cover and a gas flushed environment provided in the compartments to preserve the freshness of the food items and extend shelf life. First, the headspace gas in the compartments of the tray is evacuated by vacuum to extract the oxygen-containing ambient air. Then the headspace is flushed with an inert gas.
Additionally to preserve the more perishable food items, the meal kit is refrigerated.
Although the compartment 22 is hermetically sealed, the waffles tend to lose moisture more quickly than is desirable. With the loss of moisture, the overall quality of the waffles diminishes and, more specifically, they may become drier, tougher or harder over time. As a result, the shelf life of the waffles is shortened relative to that of the meal kit generally.
Separate, individual packaging of the waffles significantly reduces the rate of moisture loss from the waffles, which, in turn, preserves freshness and increases the shelf life of the waffles. By packaging the waffles in a closely fitted package, moisture is more evenly retained within the waffles for a longer period of time. The waffles preferably are packaged as soon as possible after being produced to retain a maximum amount of moisture in the waffles. Pre-packaging of the multiple waffle pieces that are included in the meal kit provides the added benefit of Document No. 205889 -5-a unitizing package that improves ease of handling generally, as well as during the subsequent packaging of the meal kit.
The waffle package is made with a thinly formed film or sheet material that shrinks upon exposure to heat. The package material is effective for limiting migration of moisture from the waffle and through the package. The material also is durable enough to withstand handling but is readily torn by a consumer who uses an easy open feature provided on the package.
The package material preferably is a polyolefin shrink film, or "shrink wrap." Polyolefin shrink films are known in the art. The package material may be selected from the class of polyolefin shrink films. A particularly preferred package material is CRYOVACm MY available from Sealed Air Corporation of New Jersey. This material is a fully coextruded multilayer polyolefin shrink film.
Referring now also to FIG. 2, the preferred package material will be heat sealable and provide a high integrity seal that will generally withstand subsequent heat shrinking of the package. The package has a pair of transverse end seals 26. The package also has a longitudinal fin seal 28 extending between the end seals 26. With respect to the fin seal 28, the package material may be sealed inward of the edge 30 of the package material such that two flaps 32 of unsealed package material extend beyond the fin seal 28. Alternatively, the package material may be sealed out to the edge 30 with no unsealed flap. Each of the end seals 26 and the fin seal 28 should be of sufficient width to ensure that the seal is not broken during subsequent shrinking of the package material.
The preferred package material also will be of sufficient thickness and strength to withstand handling, both during packaging and subsequently by the consumer. The preferred package material will not be so thick and of such strength, however, so as to be completely resistant to tearing when a consumer seeks to manually remove the package from the waffle using an easy-open feature 34 provided on the package at the fin seal 28. To facilitate tearing of the package material by the consumer, the fin seal is adapted with a transverse slit or notch 36 extending inwardly from the outermost edge 30 of the package material at the fin Document No. 205889 -6-seal. The slit 36 is of sufficient length to allow the package material to be torn open with only minimal force by the consumer. The slit 36 may be reinforced with a tab 38 positioned on the flap 32 or fin seal 28 to one side of the slit 36. The package material may be marked or painted to indicate the location of the slit 36.
The easy open feature 34 preferably is positioned on the flap 32 of the fin seal 28 rather than on the end seal 26. If the easy open feature is positioned on the end seal, the slit may impact the integrity of the seal during subsequent packaging and handling. For example, during heat shrinking, the slit may weaken the seal so that a hole may open in the end seal at the slit as the seal shrinks.
The easy open feature 34 operates by having the consumer lift the Ilap 32 and grasp it in the vicinity of the tab 38 or at another location intermediate the slit 36 and the midpoint of the length of the fin seal. When the consumer pulls the flap in a direction upward and away from the package, the package material tears beyond the interior end of the slit 36 across the surface of the waffle package. The material also tears along the innermost edge 40 of the fin seal 28 in a direction away from the slit 36.
Alternatively, the fin seal may be provided with a second slit at the opposite end of the fin seal. The two slits are spaced apart and each positioned at or near the ends of the waffle. This two-slit easy open feature operates in a manner similar to the one-slit feature described above except that tearing of the package material is initiated from both slits so that the package may be opened from either end.
In another embodiment, as shown in FIG. 3, the easy open feature 42 may include a tab 44 extending from the fin seal 28 and affixed with an adhesive to the package material at the flap 32 or fin seal 28. The tab 44 is highly visible and provides a large, accessible appendage for the consumer to grasp, Opening of the waffle package is initiated by the consumer grasping the tab 44 and pulling in a direction upward and away from the package. The flap 32 then tears at both slits 36, tearing across the surface of the waffle package and along the fin seal 28.
Depending on the direction of the force exerted by the consumer in pulling the tab, tearing of the package material may occur more predominately at either one of the Document No. 205889 -7-two SlltS.
In other embodiments, other means to facilitate tear initiation may be employed, for example, V-notches, perforations, or surface treatments.
The waffles are packaged in the shrink film package material prior to being assembled in a meal kit. Before packaging of the waffles occurs, the package material is mechanically perforated using a perforation wheel as the film is unrolled.
The size, number and pattern of perforations is selected to avoid unduly high moisture loss from the finished package through the perforations. The perforations 46 in the finished package (FIGS. 1 and 2) should be large enough and of sufficient number, however, to allow the air contained within the sealed, finished package to pass through the perforations in a subsequent evacuation step. If the perforations are not properly sized, the package will expand excessively as the vacuum is pulled, causing one or more of the seals to open. As a result, the package may expand so far as to even explode. Although a microperforated shrink film may be used, these perforations generally are not sufficiently sized to allow the air to pass from the package to prevent the seals from opening.
The perforations preferably are formed by puncturing the web to form slits between about 1/16 and about I/8 inch in length. No material is removed, thus the slits do not have a defined width. Upon heat shrinking of the package material, some or all of the slits may open somewhat.
The fully cooked waffles are grouped in a bundle of four waffles and wrapped in the package material in a forming box. The two sides of the package material are wrapped around the waffles and the edges positioned adjacent each other, with the interior surfaces of the package material facing each other.
Then the fin seal is formed by heat sealing the two sides together along the length of the v~raffles. The end seals then are formed by heat sealing the package material at the two ends of the waffles. The easy open feature is formed by slitting the fin seal at the selected location and applying the tab or other markings.
After the package is formed and sealed, it is passed through a shrink tunnel where it is exposed to heat. Application of heat shrinks the package material, causing it to fit more closely about the waffles. The fin seal 28 is positioned on the Document No. 205889 -8-bottom of the package in the shrink tunnel, and heat is applied principally to the top and sides of the package within the tunnel. This results in relatively low shrinkage of the fin seal, so that the slits) 36 and associated tab or indicia on the fin seal remain functional after heat shrinking of the package, without the slits) propagating to form an opening in the package as a result of the heat shrinking process.
Preferably, the package material is fitted closely about the waffles after heat shrinking to maximize retention of moisture in the waffles.
The packaged waffles are subsequently assembled with other food items for packaging in the tray of the meal kit.
The following describes the dimensions of one example of a finished waffle package embodying the features of the present invention. The bundle of waffles are from about 3 '/, to about 3 '/2 inches long, from about 2 to about 2 '/4 wide and from about 1 to about 1 '/4 inches high. The fin seal is from about '/4 to about '/~
inches wide and the flap at the fin seal is from about '/4 to about '/z inches wide. The slit of the easy open feature is from about'/4 to about'/Z inches long and is positioned on the fin seal from about'/4 to about 1 inch inward of the end of the waffle.
'The perforations are spaced approximately'/4 inches apart in lines extending longitudinally of the package which are spaced approximately 1 '/4 inches apart. The perforations may be of any shape but preferably are from about 1/16 to about'/e inch at their greatest dimension.
In other embodiments of the present invention, different farinaceous food products are packaged in accordance with the invention. For example, the farinaceous food product may be pancakes (FIG. 4), hamburger buns (FIG. 5) or hot dog buns (FIG. 6).
Numerous modifications to the package may be possible to further improve the moisture retention and handling CharactarigtiC~ of the package, 'thug, modifications and variations in practice of the invention are expected to occur to those skilled in the art upon consideration of the foregoing detailed description of the invention. Although a preferred embodiment has been described above and illustrated in the accompanying drawings, there is no intent to limit the scope of the invention to this or any other particular embodiment. Consequently, any such Docnmcnt No. 205889 -9-modifications and variations are intended to be included within the scope of the following claims. The invention is described further and pointed out by the following claims.
Ducumcut Nu. 205889
Claims (20)
1 . A packaging system for storage of a ready-to-eat food product to limit migration of moisture from said food product, the packaging system comprising:
a substantially rigid tray having at least one gas-flushed compartment for receiving said food product, said compartment having a bottom wall and upstanding peripheral side walls;
a ready-to-eat food product, wherein said food product is further enclosed in a second package comprising a shrinkable thinly formed flexible material and having transverse end seals and a longitudinal fin seal extending between said end seals and having a tear initiator at the fin seal to facilitate tearing of said flexible material at said fin seal to permit removal of said food product from said package, and wherein said package is deposited within said at least one compartment; and a hermetically sealed cover extending over at least the top of the side walls to define a chamber containing said food product and a headspace surrounding said food product.
a substantially rigid tray having at least one gas-flushed compartment for receiving said food product, said compartment having a bottom wall and upstanding peripheral side walls;
a ready-to-eat food product, wherein said food product is further enclosed in a second package comprising a shrinkable thinly formed flexible material and having transverse end seals and a longitudinal fin seal extending between said end seals and having a tear initiator at the fin seal to facilitate tearing of said flexible material at said fin seal to permit removal of said food product from said package, and wherein said package is deposited within said at least one compartment; and a hermetically sealed cover extending over at least the top of the side walls to define a chamber containing said food product and a headspace surrounding said food product.
2. A packaging system in accordance with claim 1 wherein said flexible material is perforated to provide a pattern of openings effective for allowing air within said second package to pass through said openings when said covered tray in which said second package is deposited is subjected to a vacuum and wherein said pattern also is effective for minimizing migration of moisture from within said second package.
3. A packaging system in accordance with claim 2 wherein said food product is a farinaceous food product.
4. A packaging system in accordance with claim 3 wherein said openings are spaced approximately 3/4 inches apart in lines extending longitudinally of the package and said lines are spaced approximately 1 3/4 inches apart.
5. A packaging system in accordance with claim 4 wherein said openings are from about 1/16 to about 1/8 inch at their greatest dimension.
6. A packaging system in accordance with claim 1 wherein said tear initiator comprises a slit in said fin seal.
7. A packaging system in accordance with claim 6 wherein said slit is from about 1/4 to about 1/2 inches long.
8. A package for a cooked farinaceous food product to limit migration of moisture from said farinaceous food product, said package comprising:
a shrinkable thinly formed flexible material having generally parallel first and second edges and generally parallel third and fourth edges positioned generally perpendicular to said first and second edges, wherein said flexible material is wrapped about said farinaceous food product and said first edge is adjacent said second edge;
a fin seal formed along said first and second edges and extending longitudinally of said farinaceous food product;
a pair of transverse end seals, each formed along said third edge and said fourth edge, said fin seal extending between said pair of transverse end seals;
and a tear initiator to facilitate tearing of said flexible material at said fin seal to permit removal of said farinaceous food product from said package, wherein said package is shrunk to fit closely about said farinaceous food product and wherein said closely fitting package limits migration of moisture from said farinaceous food product.
a shrinkable thinly formed flexible material having generally parallel first and second edges and generally parallel third and fourth edges positioned generally perpendicular to said first and second edges, wherein said flexible material is wrapped about said farinaceous food product and said first edge is adjacent said second edge;
a fin seal formed along said first and second edges and extending longitudinally of said farinaceous food product;
a pair of transverse end seals, each formed along said third edge and said fourth edge, said fin seal extending between said pair of transverse end seals;
and a tear initiator to facilitate tearing of said flexible material at said fin seal to permit removal of said farinaceous food product from said package, wherein said package is shrunk to fit closely about said farinaceous food product and wherein said closely fitting package limits migration of moisture from said farinaceous food product.
9. A package in accordance with claim 8 wherein said tear initiator comprises a slit in said fin seal.
10. A package in accordance with claim 9 wherein said slit is from about 1/4 to about 1/2 inches long.
11 . A package in accordance with claim 8 wherein said flexible material is perforated to provide a pattern of openings effective for allowing air within said package to pass through said openings when said package is subjected to a vacuum and wherein said pattern also is effective for minimizing migration of moisture from within said package.
12. A package in accordance with claim 11 wherein said openings are spaced approximately 3/4 inches apart in lines extending longitudinally of the package and said lines are spaced approximately 1 3/4 inches apart.
13. A package in accordance with claim 12 wherein said openings are from about 1/16 to about 1/8 inch at their greatest dimension.
14. A package in accordance with claim 13 wherein said farinaceous food product is one or more waffles.
15. A package in accordance with claim 13 wherein said farinaceous food product is one or more pancakes.
16. A method of packaging a cooked farinaceous food product to limit migration of moisture from said farinaceous food product comprising:
providing a cooked farinaceous food product;
placing said farinaceous food product on a shrinkable thinly formed flexible material having first and second edges, wherein said first and second edges are generally parallel;
wrapping said flexible material about said farinaceous food product so as to bring said first edge adjacent said second edge;
securing said flexible material along said first and second edges to form a fin seal;
securing said flexible material along the remaining edges to form a pair of parallel transverse end seals; and heating the wrapped farinaceous food product to shrink said flexible material to form an essentially closely fitting package around said farinaceous food product.
providing a cooked farinaceous food product;
placing said farinaceous food product on a shrinkable thinly formed flexible material having first and second edges, wherein said first and second edges are generally parallel;
wrapping said flexible material about said farinaceous food product so as to bring said first edge adjacent said second edge;
securing said flexible material along said first and second edges to form a fin seal;
securing said flexible material along the remaining edges to form a pair of parallel transverse end seals; and heating the wrapped farinaceous food product to shrink said flexible material to form an essentially closely fitting package around said farinaceous food product.
17. A method in accordance with claim 16 further comprising perforating said flexible material to provide a pattern of openings.
18. A method in accordance with claim 17 further comprising subjecting said food product to a vacuum so that air passes through said openings in said flexible material.
19. A method in accordance with claim 18 further comprising placing said wrapped farinaceous food product in a gas flushed, hermetically sealed compartment of a meal kit.
20. A method in accordance with claim 16 further comprising providing a tear initiator on said fin seat.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US39938099A | 1999-09-20 | 1999-09-20 | |
| US09/399,380 | 1999-09-20 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2319887A1 true CA2319887A1 (en) | 2001-03-20 |
Family
ID=23579288
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002319887A Abandoned CA2319887A1 (en) | 1999-09-20 | 2000-09-19 | Shrink packaging of food products |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2319887A1 (en) |
| ES (1) | ES2190708B1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7041326B2 (en) * | 2002-03-29 | 2006-05-09 | Kraft Foods Holdings, Inc. | Food package |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ES2283167B1 (en) * | 2004-09-15 | 2008-08-16 | Valentin Masa Alcorlo | PACK FOR PRODUCTS. |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE7802439U1 (en) * | 1978-01-27 | 1978-06-22 | Hoechst Ag | Sealed packaging with tear tape |
| FR2531682B1 (en) * | 1982-08-10 | 1985-12-27 | Venthenat Jehan | FLAT PRODUCT HAVING VARIABLE PERFORATIONS AND ITS MANUFACTURING METHOD |
| FR2558802B1 (en) * | 1984-02-01 | 1986-11-21 | Grellier Jean | NEW PACKING STRIP PACKAGING, AND APPARATUS FOR MANUFACTURING SAME |
| US5077954A (en) * | 1989-09-05 | 1992-01-07 | Bryan Foods, Inc. | Apparatus for packaging food products |
| US5167973A (en) * | 1990-08-14 | 1992-12-01 | Snyder William D | Comestibles container |
| ES2084784T3 (en) * | 1990-11-06 | 1996-05-16 | Mayer Oskar Foods | FOOD CONTAINER THAT HAS A RIGID COMPARTMENTAL BASE TRAY. |
| GB9315937D0 (en) * | 1993-07-31 | 1993-09-15 | Devro Ltd | Collagem film |
| US5747084A (en) * | 1995-11-28 | 1998-05-05 | Kraft Foods, Inc. | Ready-to-assemble, ready-to-eat packaged pizza |
| US6068864A (en) * | 1996-07-12 | 2000-05-30 | Kraft Foods, Inc. | Method of imparting resistance to moisture and texture degradation to a baked product |
-
2000
- 2000-09-19 ES ES200002270A patent/ES2190708B1/en not_active Expired - Lifetime
- 2000-09-19 CA CA002319887A patent/CA2319887A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7041326B2 (en) * | 2002-03-29 | 2006-05-09 | Kraft Foods Holdings, Inc. | Food package |
Also Published As
| Publication number | Publication date |
|---|---|
| ES2190708A1 (en) | 2003-08-01 |
| ES2190708B1 (en) | 2004-12-16 |
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| Date | Code | Title | Description |
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| FZDE | Discontinued | ||
| FZDE | Discontinued |
Effective date: 20040920 |