CA2387349A1

CA2387349A1 - Products, methods and apparatus for fresh meat processing and packaging

Info

Publication number: CA2387349A1
Application number: CA002387349A
Authority: CA
Inventors: Anthony J. Garwood
Original assignee: Individual
Current assignee: SafeFresh Technologies LLC
Priority date: 1999-10-19
Filing date: 2000-10-19
Publication date: 2001-05-03
Also published as: AU774767B2; AU1097701A; EP1226072A1

Abstract

Published without an

Description

DEMANDE OU BREVET VOLUMINEUX
LA PRESENTE PARTIE DE CETTE DEMANDE OU CE BREVET COMPREND
PLUS D'UN TOME.

NOTE : Pour les tomes additionels, veuillez contacter 1e Bureau canadien des brevets JUMBO APPLICATIONS/PATENTS
THIS SECTION OF THE APPLICATION/PATENT CONTAINS MORE THAN ONE
VOLUME

NOTE: For additional volumes, please contact the Canadian Patent Office NOM DU FICHIER / FILE NAME
NOTE POUR LE TOME / VOLUME NOTE:

PRODUCTS, METHODS AND APPARATUS FOR FRESH MEAT
PROCESSING AND PACKAGING
Field of the Invention The present invention relates to products, methods, apparatus, and the products made therefrom used for processing and packaging perishable foods and particularly to processed perishable foods that are packaged in plastic food trays that are overlaid with one or more layers of sealable plastic materials. The present invention also relates to apparatus for processing and pre-treating perishable foods and associated packaging with gases.
Background of the Invention For the entire history of fresh red meat processing for human consumption, where slaughtered, eviscerated, and chilled carcasses are produced in the normal process, improvements in terms of reducing labor and or reducing costs of the process, have been sought. Few major improvements have been achieved in the recent past and it is a purpose of this present invention to expose opportunities and to provide methods, apparatus and products of improving the efficiency and competitiveness of the red meat industry. Such opportunities are epitomized by, for example, the condition that all carcasses contain a great deal of bone and other materials that are not used for human consumption and yet the entire carcass must be chilled prior to further processing, in order to chill those parts that are used for human consumption. Furthermore, the shape of all animals used for human consumption are of irregular and inconvenient profile. Conversely, packaging trays that have been cost effectively and efficiently manufactured, are invariably rectangular and/or square in profile. By adopting procedures disclosed herein it will be seen that costs of chilling are reduced since, for example, the skeleton can be removed before chilling thereby saving costs of such chilling process. Fresh red meat tissue is typically quite soft and easy to cut immediately after the animal has been slaughtered and prior to the natural, "hardening" effects of rigor mortis has occurred. It can therefore be easier and quicker to cut primal portions from animal carcasses, during the normal animal "disassembly" process prior to rigor mortis and chilling. Those fresh red meat primal items, that are intended for human consumption, can then be shaped by placing into molds of a specifically designed and desired profile prior to rigor mortis and then chilled during the natural rigor mortis process. This device will provide a method to change and adjust the shape of fresh red meat primal items so that, for example, fresh red meat primal items can be readily and automatically processed during the slicing and cutting process as required prior to packaging. Furthermore, profiles of primal meat portions can be arranged so as to be more convenient when slices of fresh red meat primal items are loaded into improved packaging, such that more can be loaded into improved packaging while still maintaining a space efficient, appealing and attractive appearance for the consumer at the point of retail display andlor foodservice outlet.
Typical modified atmosphere packages for fresh foods, such as red meats and other perishable foods, having a limited shelf life, typically include a thermoformed tray or other package composed of EPS/tie/PE (barrier foam trays) plastics material or other suitable substantially gas impermeable material, i.e. tray, overlaid with a single transparent web of plastics material that can be heat sealed to the tray. A
typical substantially gas impermeable heat sealable composite web includes a biaxially oriented polyester (PET) layer/tie layer/gas barrier layer (such as PVDC) an adhesive layer/heat sealing layer (such as polyethylene), which in turn is finally adhered by a heat sealer to the tray. The polyethylene layer is a heat sealable layer that is tied to a gas barrier layer such as polyvinylidene chloride which is in turn adhered to polyester. Because of the diverse types of materials that are employed in the foregoing package, it is difficult to reprocess and recycle the post-consumer package. Moreover, the cost associated with post-consumer recycling of multiple layer plastics material renders the process impractical and substantially not economically feasible.
Commonly used modified atmosphere packages for fresh foods such as red meats and other perishable foods having a limited shelf life typically comprise a tray thermoformed from a sheet of EPS (expanded polystyrene) laminated to a web of substantially gas impermeable web material or other suitable substantially gas impermeable material. A lid, such as a single or composite transparent web of plastics material that can be bonded to the flanges of the tray. Both tray and lid materials are typically substantially gas impermeable heat sealable composite structures and cannot be readily recycled. Lid material typically comprises a laminated structure including several layers such as bi-axially oriented polyester bonded to a gas barrier layer (such as PVDC) which is sandwiched between an adhesive or heat sealing layer (such as polyethylene). Because of the diverse types of materials that are employed in the foregoing package, it is difficult to reprocess and recycle the "post-consumer" package. Moreover, the cost associated with post-consumer recycling of multiple layer plastics material, such as the aforementioned, renders the process impractical and substantially not economically feasible.
A further limitation of packaging perishable goods such as fresh red meats in hermetically sealed gas barrier packages results from the need to enclose a relatively large volume of gas, and particularly carbon dioxide, within the package.
Clearly, consumers have no interest in purchasing these gases that accompany the red meat.
Minimizing the size and bulky appearance of such packaging is desirable, therefore it is a goal to reduce the overall size and volume of the packaging to a minimum size.
Additionally, a major proportion of red meat production occurs at locations that are located at a substantial distance from the point of retail sale of red meats to consumers. Most US beef is produced in the central plains around Kansas, Nebraska and Iowa and the major markets are situated on the coastal regions such as New York or California. Costs of shipping these fresh red meat items from the point of production and packaging can be reduced if the packages are reduced in volume.
However, reduction in the volume of gases provided within a package can have a deleterious effect on shelf life of the perishable goods and red meat contained therein.
Typical methods used for production of ground meats and patties, that are substantially composed of fat, muscle tissue, protein and water, have remained unchanged for many decades and are inefficient when compared with other food production methods that are commonly applied in other industries. These inefficiencies that result in large part from poor controls and questionable safety standards, often cause significant and unnecessary wastage of meat in addition to occasional loss of human life.

A limitation of producing perishable goods such as fresh beef patties at the point of source animal slaughter results from shelf life limitations inherent with current packaging systems. A major proportion of beef patties production occurs at locations that are situated at a substantial distance from the point of sale of these products. Beef patties are often produced at locations remote from the point of slaughter due to short shelf life.
The packaging industry has therefore felt the need for simplified individual packaging structures that will provide finished package performance including label requirements for a variety of applications. Additionally, if the packaging can be handled economically both in the pre-consumer handling and in post-consumer recycling, significant economic advantages are available.
With conventional packaging of meats and other perishable type goods, the shelf life is limited due to bacterial growth within the package. The growth can be inhibited when the package contains carbon dioxide gas, however, carbon dioxide will dissolve in liquids such as water contained within the goods in the package.
After time, carbon dioxide can become substantially dissolved in the water and shelf life may be limited by this. After time, discoloration due to formation of, for example, metmyoglobin on the outer surface of the red meat also reduces consumer appeal of the packaged goods. It is also known to provide other gases within the package to enhance the keeping of the packaged goods. In the case of red meat blends of C02 and Nz, in varying proportions and up to 100% of each single gas have been used. When carbon dioxide dissolves into liquids and water, this can cause the package to collapse inwardly. Collapsing causes the appearance of the package to be unacceptable to consumers and can also cause the package to rupture.
In order to extend shelf and storage life of the packaged goods several inventions have been disclosed and examples of known packaging for this purpose are given in the following US Patents:

5,779,832 Kocher Method and Apparatus for making a peelable film 5,629,060 Garwood Packaging with Peelable Lid 5,560,182 Garwood Packaging Method 5,534,282 Garwood Packing Perishable Goods -S-5,514,392 Garwood Packaging for Perishable Goods 5,323,590 Garwood Method of producing food packaging with gas between tensioned film and lid 5,226,531 Garwood Food Packaging with gas between tensioned film and Lid 5,155,974 Garwood Food Packaging with gas between tensioned film and Lid 5,115,624 Garwood Thermoplastic skin packing means 5,129,512 Garwood Packaging The subject matter of the above patents is hereby incorporated by reference.
Prior art as described in USP 5,779,832 to Kocher, discloses a method of making a multilayer peelable film. Kocher discloses a method of co-extruding two webs of material simultaneously in the form of a multilayer film that can be delaminated into a third web and a second web and then after treating the second web to improve gas permeability therethrough, re-laminating the third and second webs together. These two re-laminated webs can be sealed to a first web of gas barrier material and thereby produce a package. The first web may have a depression formed therein into which goods such as red meat can be placed before heat sealing the third and second webs to the first web. Typically, goods will not completely fill the depression and space will remain in the depression in addition to the goods. A
blend of gases or a single gas such as C02 can be provided in the space with the goods and thereby can contact the goods. After storage and prior to retail display at an intended point of sale to consumers, the third web can be peeled from the package allowing atmospheric oxygen to permeate the second web of gas permeable material and to contact the goods. The atmospheric oxygen can then allow generation of a bright red colored substance such as oxymyoglobin thereby providing an appearance attractive to the consumers.
It has been found that when applying the second and third webs extruded in the manner as disclosed in Kocher to packaging as that disclosed in the inventor's own U.S. Patent No. 5,534,282, a dull appearance of the second web can result with reduced clarity when compared with other webs of material that are produced in a single web such as plasticized PVC (pPVC). Furthermore, after removal of the third web, from the re-laminated co-extrusion, by peeling, as described in U.S.
Patent No. 5,534,282, distortions and ripples can appear in the second web. This occurs, partly, as a result of inadequate lateral tension provided in the second web when limited by the inherent limitations of co-extruding the second and third webs simultaneously. This can, therefore, severely detract from the visual appearance of the package in the eyes of consumers.
A further limitation of packaging perishable goods such as fresh red meats in hermetically sealed gas barrier packages results from the need to enclose a relatively large volume of gases, and particularly carbon dioxide, within the package.
Clearly, consumers have no interest in purchasing gases with red meat and minimizing the size and bulky appearance of the package is desirable. Additionally, a major proportion of red meat production occurs at locations that are situated at a substantial distance from the point of sale for red meats. Costs of shipping the goods from point of production and packaging can be reduced if the packages are reduced in size.
However, reduction in the volume of gasses contained within a package can have a deleterious effect on the shelf life of perishable goods and red meats contained therein.
Conventional modified atmosphere "case ready" retail packaged fresh red meats and other perishable type goods experience limited shelf life because of bacterial growth, such as aerobic and anaerobic bacteria, on the packaged goods;
rancidity "off flavors" caused, in part, by oxidizing fats; and discoloration to visible meat surfaces. The growth can be inhibited when goods are treated by exposure to certain agents prior to packaging and then providing certain gasses and/or other agents with the goods within the finished and sealed package. Such a gas, blend of gasses agent or agents may include one or a combination of the following:
oxygen, carbon dioxide, ozone, hydrogen, nitrogen, argon, krypton, neon, helium, xenon, hydrogen peroxide, potassium permanganate, chlorine dioxide, fluorine, bromine, iodine and/or any other suitable substances. However, some gasses such as carbon dioxide gas, for example, can quickly dissolve in substances such as oils and water contained in the goods. After time, carbon dioxide can become substantially dissolved in water which may limit shelf life. Furthermore, when oxygen is present and more particularly when a quantity of approximately 5,000 to 30,000 parts per million of oxygen is present in a gas within a package, discoloration due to formation of metmyoglobin on the visible surface of red meat, reduces consumer appeal of the packaged goods. When carbon dioxide dissolves (into another substance) the combined volume of the residual substances is substantially reduced which can cause the package to collapse inwardly. Collapsing causes the appearance of the package to be unacceptable to consumers and can also cause the package to rupture and render it unfit for use. In compensating for such a deleterious event, several existing packaging systems require large volumes of gas to be packaged with the goods.
However, when large volumes of gas are provided, the resultant "bulky"
condition does not provide for cost efficient shipping and distribution from the location of packaging to the point of retail sale of the packaged goods.
Conventional packages for red meat are produced in one or more sizes.
When packaging red meats or other perishable goods, the package must conform to the goods. Therefore, if a red meat portion is too large for one size of a package, the next larger size must be used. Oftentimes, this will lead to an overly large sized package introducing inefficiency into the process because of the wasted space.
In order to maximize efficient use of the internal space available in a typical road, rail or sea, refrigerated shipping container or trailer, it is important to increase the density and unit weight per unit volume of the packaged perishable goods. The maximized efficient use of the space in the shipping containers can be achieved by adjusting the shape of the inconveniently shaped animal fresh red meat primal portions such that slices of the fresh red meat primal portions will fit and substantially fill the available space within trays of the improved packaging.
High oxygen case ready packages are inefficient, in large part, due to the inherent need to include a quantity/volume of gas that is equal to, or greater than the volume of the package meat contents. For example, a high oxygen package comprising a barrier foam tray and clear barrier film lid, hermetically sealed to flanges of the barrier foam tray and with a 21b quantity of meat sealed therein will require approximately 1 liter of gas to be enclosed and sealed within the package to ensure that an approximate 10 day shelf life extension can be provided. Said gas (referred to as modified atmosphere) will typically comprise 80% Oxygen and 20 Carbon Dioxide but other combinations that may include relatively small quantities (say <10%) of residual atmospheric nitrogen are also typical. The relatively high level of C02 (when compared to ambient atmosphere) is provided to inhibit bacterial growth, and with good storage temperature control a shelf life for sound, fresh meat can be extended to over 10 days from packaging. The bacterial controlling effect is a consequence, in part, of a characteristic of bacteria entering a "lag phase"
when the environment in which it is placed, significantly changes... eventually the bacteria will equilibrate and adapt to the atmosphere that is present and commence normal _g_ reproduction and extended infection. The shelf life extension will vary according to several factors including, for example, the following: storage temperature ie:
the less variation from a minimum temperature of approximately 29.Sdegrees F is optimum, (while ensuring that freezing of the meat, which occurs at about 26 - 27 degrees F, does not occur); the condition and age of the meat at packaging, the conditions at the point of packaging such as hygiene, temperature etc., muscle type and age of animal from which the meat was harvested. Nevertheless, a shelf life extension of 10 days is readily reproducible when conditions are maintained as required. After a relatively short period of time, the C02 provided within the package will dissolve into the water and oils contained in the meat and the oxygen is present to ensure that a consumer appealing/acceptable "bloom: or "redness" is maintained. The "bloom"
is caused by the natural color of oxymyoglobin and oxyhemoglobin that is present in freshly cut meat but when oxygen is present, after approximately 9 to 10 days discoloration such as browning due to increased levels of surface metmyoglobin, will occur, rendering the product unsaleable or requiring a reduction in price to sell to a consumer. Furthermore, the excessive volume of the finished packages, results in excessive packaging material and shipping costs and display case space at retail outlets and also excessive costs incurred for disposal of additional cardboard etc. at the supermarket outlets. Therefore by reducing volume of the retail package, costs for packaging, shipping and display are substantially reduced, which is a purpose of the inventions.
Effective packaging materials for existing, extended shelf life, retail packaged, case ready perishable goods are often relatively expensive and the associated packaging processes are typically labor intensive. The use of EPS
and FP
can provide desirable low cost packaging materials but the inherent cell structure of these materials can retain residual oxygen (from air) within the cell structure, even during and after exposure to very low levels of air pressure (vacuum). When EPS
and FP materials are used in low residual oxygen modified atmosphere packaging, such as described in US Patent Application Serial No. 09/039,150, residual oxygen can diffuse and exchange from the cell structure, and become present as a free gas within the master container thereby elevating the level of oxygen present therein to a potentially undesirable level. As described in the subject matter of US Patent Applications in the name of the present inventor, apparatus for minimizing the level of residual oxygen retained in the cell structure and master containers are disclosed.
However, such a process of gas exchange is problematic and difficult to reliably maintain. Therefore, packaging fabricated from solid plastics sheet, may be more efficiently employed in this application.
Conventional "master container" or "master package" modified atmosphere packaging (MAP) systems include loading perishable goods into trays and then a plurality of loaded trays are subsequently placed into a larger "master container"
which may be manufactured from a suitable gas barrier material. The "master container" is typically evacuated of air and then filled with a gas blend that may include a mixture of any desirable gasses which may include, for example, 40%
carbon dioxide and 60% nitrogen for a low oxygen MAP system. The master container is then sealed with loaded trays to provide an airtight, sealed master container, containing loaded trays and a gas blend with a residual quantity of atmospheric oxygen. Most desirably, for low oxygen MAP systems, the residual quantity of atmospheric oxygen will not exceed an amount of 100 to 300 PPM
(parts per million) with the balance of the gas blend including nitrogen and carbon dioxide and/or other inert or .oxygen free gasses. Low cost packaging materials include foamed polystyrene (EPS trays), however, the choice of material for tray manufacture must exclude materials (unless treated in a manner that will substantially remove atmospheric oxygen from the cell structure), such as expanded (foamed) polystyrene (EPS), that have a capacity to "retain" air, even after exposure to a high vacuum as may occur in packaging processes. Therefore, in order to maintain the residual quantity of atmospheric oxygen at not more than 100 PPM, untreated expanded (foamed) polystyrene (EPS) or FP trays cannot be easily and efficiently used. By way of explanation, EPS trays are typically thermoformed from extruded EPS sheet. A typical method of producing EPS sheet is to "foam" the melted (liquid) polystyrene by injection of a foaming agent, such as nitrogen, carbon dioxide or pentane, into liquid polystyrene thereby causing it to foam (become frothy, with bubbles and/or tiny gas filled cells within the foam) and then extrude the foam through a slot in a flat or annular die. The extruded EPS can then cool and solidify into a sheet that can be slit and wound onto a roll prior to further processing.
Immediately after extrusion of the EPS sheet, cells retained within the foam are filled with nitrogen or other gas (foaming agent) used in the foaming process.
However, such a foaming agent gas, if not retained by other means in the cell structure, can quickly exchange with the ambient air during storage and the cells can become filled with air. When placed within a vacuum chamber and exposed to a high level of vacuum, as is normal in a "master container " packaging process for low oxygen MAP systems, cells can retain a quantity of air, even during and subsequent to evacuation (unless the exposure to vacuum is significantly extended to the extent required). The retained quantity of air in the cells, can subsequently exchange with gas within the sealed "master container" which can, thereby, elevate the residual oxygen content of the "free" gas contained within the "master container" above a desirable level.
A fundamental need that resulted in the development of thermoformed EPS
trays initially arose in the modern supermarket. Fresh meats and poultry were formerly processed and retail packaged at the supermarket immediately prior to retail display and sale. EPS foam trays were developed to meet these supermarket requirements, and have provided a functional and low cost retail package, when "over wrapped" with a low cost web of plastic material such as plasticized PVC.
However, with case ready MAP systems, such EPS trays are now required to be shipped in trucks and other means of transport from the point of packaging, which may be located many hundreds of miles from the point of sale. Abuse and damage can occur to the packaging during this shipping. In an effort to protect against damage, rigid and heavy weight cartons with sheets, cushions and/or columns, made from suitable materials such as chipboard are manufactured and assembled with EPS
trays and goods contained therein. Such protective packaging is expensive, bulky and results in excessive shipping costs. Furthermore, excessive packaging, as required for the sole purpose of protection during shipping, must be discarded at the supermarket thereby creating excessive waste disposal problems with the attendant costs to the environment.
Summar~r of the Invention Methods and apparatus of the present invention are directed at saturating fresh meat with C02 prior to packaging. In this situation, adequate C02 can be dissolved in the tissue of the meat and to such a level that the meat can become a source of COZ after packaging. This can be achieved by lowering the temperature of the meat to a minimum (typically about 29.5 degrees F) and exposing it to relatively high pressure (ambient to 200 psi or more) C02 gas. C02 gas dissolves more readily at lower temperatures and therefore a part of the method is to expose the meat to high pressure C02 at the lowest temperature above freezing and then retail package the meat in a tray, then over wrapped with a highly gas permeable web of material such as pPVC. If an extended shelf life of say not more than 10 days is adequate, then a 3 S barrier pouch master container may not be needed, the C02 gas "entrained"
in the meat tissue prior to packaging will gradually be released immediately after removal from a higher pressure to ambient and as the temperature elevates during delivery to the point of sale and this can be sufficient to inhibit bacterial growth and atmospheric oxygen in unlimited quantities is available to maintain the requisite "bloom".
In this way, shipping, packaging and display costs can be reduced substantially, while providing an extended shelf life which may be sufficient for some industry packers and supermarkets.
Thus, the present invention discloses a method of processing and packaging goods, the method having a step for placing goods in an enclosed vessel containing a gas to enhance the keeping of the goods, a step allowing the gas to contact and dissolve in liquids and oils present in the goods, a step restricting the formation of oxymyoglobin by substantially displacing ambient air, that may otherwise contact the surface of the goods, with the gas, a step providing a retail package including two overlapping webs with a space therebetween with at least one of the webs being gas permeable, a step transferring the meats from the vessel to a position between the two overlapping webs and into the space without allowing significant formation of oxymyoglobin on surface of the meats.
In a preferred embodiment, the method is suitable to use on goods including fresh red meats wherein the gas is a substantially oxygen free gas.
A further embodiment is a method of packaging goods, the method having a step providing four or more overlapping web sections, the two outer, first and second, web sections being gas barrier webs, the inner web sections having folded, third web material with at least one cup-shaped depression therein that restricts nesting of the webs together, and a fourth gas permeable web material with space between the third and fourth web sections, a step providing goods between the folded third web material and the fourth web material, a step for sealing the folded third web material and the fourth web material so as to substantially retain the goods in the cup-shaped depression but allowing gas to pass into and out of the space, a step for sealing the overlapping webs after sealing the third and fourth web material but prior to sealing the first and second webs together at a seal path near the perimeter of the packaging which will provide a hermetically sealed package, a step for gas flushing the chamber means with a gas to enhance the keeping of the goods, a step for sealing the first and second webs together by a sealing means which defines a seal path near what will be an outer perimeter of the packaging and which encloses the third and fourth web material within a hermetically and substantially gas impermeable package with the goods and the gas sealed therein and allowing the gas to contact the goods.
A further embodiment includes one or more packaging tray(s), each fabricated from a single web of thermoformed plastics material web. Said packaging tray having upwardly disposed side walls, defining depressions) with space therein into which goods are placed, a second web of gas permeable material overlapping said first web which may have been stretched over said packaging tray with goods therein and hermetically sealed to fully enclose said packaging tray and goods therein, a third web of gas impermeable material overlapping and hermetically sealed so as to fully enclose one or more of said first and second webs with space therein, a suitable gas in said space, said gas or blend of gases selected for enhancing preservation of the packaging goods by contacting the surface of said goods, a chamber means to enclose said first, second and third webs, prior to sealing said third web, which can be isolated from external atmosphere by valve means, providing a suitable pressure to said gas in said chamber, hermetically sealing said third web.
A further embodiment is a goods packaging tray having a base with upwardly extending side walls that terminate at a flange that extends around a perimeter of the tray to provide a cup-shaped recess. The tray having at least one extension connected to the flange at a hinge. The extension having a cup-shaped flap that can be folded about the hinge and be sealed to at least one of the upwardly extending side walls to provide an enclosed space. The tray having apertures at a base of the side wall of the tray so as to provide communication between the enclosed space and the tray that will allow liquids to pass from the tray cup-shaped recess to the enclosed space.
A further embodiment is an apparatus for producing packaging trays having means for thermoforming plastics sheet to form and trim a packaging tray with a base and upwardly extending side walls that terminate at a flange that extends around a perimeter of the tray to provide a cup-shaped recess with at least one extension connected to the flange at a hinge having a cup-shaped flap that can be folded about the hinge and be sealed to at least one of the upwardly extending side walls to provide an enclosed space. The apparatus further includes a sealer to seal the flap to the tray wall around a perimeter of the flap and a device to optionally provide apertures in the side wall of the tray recess so as to provide a communication between the enclosed space and the tray recess.
A further embodiment includes a method and apparatus for grinding boneless beef directly into an enclosed chamber that has been filled with a suitable gas such as C02 and which substantially excludes oxygen from contacting with the ground beef.
Adjusting temperature of the ground beef to a suitable temperature.
Processing and mixing ground beef (meat), in a vessel or series of vessels substantially excluding oxygen, so as to blend and adjust the relative quantities of fat and muscle in the finished product to a desired ratio. Maintaining the ground beef at a suitable temperature.
Extruding ground beef in a stream of grinds by pumping through an enclosed conduit with an exit end and a selected cross sectional area and profile that is substantially similar to typical beef patty, at a velocity that is adjustable while maintaining pumping at a substantially constant rate. Pressurizing a stream of ground beef in a conduit at a selected pressure and compressing any voids such that C02 gas contained therein dissolves into the stream of ground beef.
Maintaining ground beef at a suitable temperature.
Intermittently adjusting the velocity of stream of grinds so as to intermittently slow or stop its flow as it emerges from the exit end of the enclosing conduit and allow slicing with knife means to provide single beef patties in stacks of a chosen quantity. Intermittent slowing or stopping of flow may exceed 500 cycles per minute.
Interfacing with a packaging system and packaging fresh meat patties without exposure to air while maintained at a suitable temperature.
The present invention provides an efficient method and apparatus for processing fresh red meat products at the point of animal slaughter for subsequent case ready packaging and delivery to the consumer via a typical supermarket or retail sale outlet. The consumer may be located thousands of miles away from the point of slaughter which often results in distribution and delivery that can require a period of time exceeding 20 days.
The present invention provides a most efficient method and apparatus for packaging fresh red meat products at the point of animal slaughter for subsequent delivery to the consumer via a typical supermarket or retail sale outlet.
Consumers, located thousands of miles away from the point of slaughter and packaging often results in distribution and delivery that can require a period of time exceeding 15 days.
The present invention maximizes efficient use of the internal space available in a typical road, rail or sea, refrigerated shipping container or trailer, it is important to increase the density and unit weight per unit volume of said packaged perishable goods. Effective packaging materials for existing case ready packaging systems are often expensive and the associated packaging processes are typically labor intensive.
The present invention provides low cost packaging trays by utilizing various packaging materials such as polypropylene or PET.
The present invention provides improved packaging for perishable goods, an improved appearance of the packaging and a means to increase the level of carbon dioxide dissolved into the liquid and water contained on or with the perishable goods, thereby reducing the total volume of the packages, increasing density for more efficient shipping and subsequent display at the point of sale. The goods includes fresh red meat and a further purpose of this invention is to provide a means of enhancing the keeping qualities of the goods.
The present invention provides several alternative methods of stretching the second web such that after removal of the third web, the second web will be in a substantially "ripple free", clear, smooth, and at least partially tensioned condition.
Additionally, a further description of a method to pre-stretch the second web, before sealing the first web, second web and third webs, within a single chamber sealing means is disclosed. A further description of methods to package goods in a single chamber sealing and packaging machine when the first and second webs are applied separately without having been re-laminated after treatment of the second permeable web.
Therefore in accordance with a first broad aspect of the present invention there may be provided improved packaging for perishable goods including: a tray or first web over which the goods are placed, the goods including oils, fats, protein, liquids and water. The tray having upwardly disposed side walls, defining a depression with space therein, the side walls having been urged inwardly to a controlled and predetermined extent and are tensioned, thereby retaining an outwardly urging force; a second web of gas permeable material overlapping the first web which may have been pre-stretched; a third web of gas impermeable material overlapping the first and second webs; a gas in the space, the gas or blend of gasses (preferably carbon dioxide and nitrogen) selected for enhancing preservation of the packaging goods by contacting the surface of the goods; a chamber means to enclose the first, second and third webs, prior to sealing, which can be isolated from external atmosphere by valves, providing pressure to the gas in the chamber, the pressure being at a level above ambient atmospheric pressure, thereby providing accelerating dissolving of the gasses and carbon dioxide into the liquids and water; and sealing the first, second and third webs together while retaining the side walls of the first web tray in tension with the second and third webs.
In this way, the shelf life of the packaged goods can be extended and when the third web is removed, the tension between the side walls and the second web can cause the second web to be stretched and be substantially flattened with fewer ripples in its surface. Thus the packaging will be pleasing to an intending purchaser.
The invention provides a labor efficient, low cost processing and packaging system for perishable goods that can minimize the presence of undesirable levels of both anaerobic and aerobic bacteria, fungi, virus and residual oxygen, for an extended period of storage time by enhancing the keeping qualities of the perishable goods. The processing and packaging system is disclosed herein, with further disclosures providing details of several package configurations produced from various packaging materials including polypropylene, amorphous polyester, expanded polystyrene (EPS) and foamed polyester (FP).
Additionally, the present invention provides efficient methods and apparatus for delivering fresh red meat products from the point of animal slaughter and retail packaging to the consumer via a typical supermarket or retail sale outlet. The consumer may be located thousands of miles away from the point of slaughter which often results in distribution and delivery that can require a period of time exceeding 14 to 25 days.
The present invention provides methods and apparatus for reducing the processing costs, provide a method to reduce the labor content of the process and separate the carcass into at least two groups of components that can be either used for human consumption or not for human consumption prior to chilling the carcass.
The present invention provides improved and accurate "portion control." For example, a New York Strip primal that includes a strip of muscle with a fat covering on one side, can be substantially shaped into a uniform strip prior to slicing.
Additionally, such primal items as tenderloin that have a tapered profile can be combined and pressed together to form a single tenderloin of uniform cross-section and then sliced to produce uniform slices of equal size and weight. In yet a further embodiment, the present invention provides for the cutting of meat containing deoxymyoglobin in an atmosphere that excludes oxygen and substantially inhibiting and preventing contact of the freshly cut surface with oxygen in the ambient atmosphere.

The present invention provides a labor efficient, low cost processing and packaging system for perishable goods that can minimize the presence of undesirable levels of bacteria, rancidity, discoloration and enhance the keeping qualities of the perishable goods.
Trays and packaging apparatus are disclosed in the present invention that can incorporate either a low oxygen modified atmosphere or alternatively a high oxygen modified atmosphere. A high oxygen modified atmosphere may include a blend of gasses including 20% carbon dioxide, 70% oxygen and 10% nitrogen. Part of this blend of gas may include some residual ambient atmospheric gases.
The tray construction and packaging disclosed in this invention describe ways to substantially eliminate excessive packaging by incorporating multifunctional features in a single tray. The multifunctional features include devices to allow stacking of a plurality of trays in a vertical stack, incorporation of an in-built protective cushion around the perimeter of the tray and a purge absorbing feature.
Additionally, the present invention provides a most efficient means of delivering fresh red meat products from the point of animal slaughter and retail packaging to the consumer via a typical supermarket or retail sale outlet. The consumer may be located many hundreds of miles away from the point of slaughter which often results in distribution and delivery time that can exceed 14 to 25 days.
The present invention increases the volume of carbon dioxide gas within a package without increasing the size and volume of the package. This can be achieved by carbonation and increasing the quantity of dissolved carbon dioxide in the free liquids, oils and water contained in the package with red meat prior to hermetically sealing the package.
In order to maximize exploitation of the benefits of improved packaging as described herein for use with packaging of perishable goods such as cuts of fresh red meat, as detailed herein, a method and apparatus of changing and/or adjusting the shape and profile of the red meat primal, before slicing the primal, such that slices of the primal will have a permanently adjusted shape facilitating more efficient use of the improved packaging, is highly desirable. The description contained herein provides a method and apparatus of achieving an adjustment and or shape of large fresh red meat primal portions and combinations of smaller pieces pressed together.
Brief Description of the Drawin;~s The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIGURE 1 is a perspective view of one package made in accordance with the present invention;
FIGURE 2 is a perspective view of a corner section of the package of FIGURE 1 with the heat sealable layers up turned;
FIGURE 3 is a cross-sectional view of the package of FIGURE 1 taken along section line 3-3;
FIGURE 4 is a schematic view of an assembly line for manufacturing a package such as shown in FIGURE 1;
FIGURE 5 is a schematic view of a master bag method of packaging individual packages for storage and transport in accordance with the present invention;
FIGURE 6 is an alternate embodiment of a tray having a vent hole in accordance with the present invention;
FIGURES 7, 8, and 9 show another embodiment of a stackable tray built in accordance with the present invention;
FIGURES 10-15 show another embodiment of a stackable tray constructed in accordance with the present invention;
FIGURE 16 shows another embodiment of a master package and method for storing and transporting individual packages containing edible materials in accordance with the present invention;
FIGURES 17 and 18 show an alternate valve arrangement to that shown in FIGURES 14 and 15;
FIGURES 19-21 show another alternate valve arrangement;
FIGURES 22-26 show the incorporation of a material for indicating the presence of E. coli bacteria into a tray, constructed in accordance with the present invention;
FIGURES 27-30 show a production line and method in accordance with the present invention for producing a material for indicating the presence. of E.
coli bacteria.
FIGURE 31 shows a perspective view of a tray with flaps constructed according to the present invention;
FIGURE 32 shows a perspective view of the tray of FIGURE 31;

FIGURE 33 shows a cross-sectional view of the tray of FIGURE 32 taken along line 33;
FIGURE 34 shows a finished package constructed according to the present invention;
FIGURE 35 shows a master container constructed according to the present invention;
FIGURE 36 shows the master container of FIGURE 35 with finished packages enclosed therein and sealed with a lid and enclosed in a cardboard box;
FIGURE 37 shows a cross-sectional view of a tray constructed according to the present invention;
FIGURE 38 shows a perspective view of a finished package constructed according to the present invention;
FIGURE 39 shows a cross-sectional view of a tray portion including a flap in the up position;
FIGURE 40 shows a bottom plan view of the flap of FIGURE 39;
FIGURE 41 shows a cross-sectional view of the flap of FIGURE 39 in the down position;
FIGURE 42 shows a schematic view of a tray sealing apparatus constructed according to the present invention;
FIGURE 43 shows a web material constructed according to the present invention;
FIGURE 44 shows a web material constructed according to the present invention;
FIGURE 45 shows a cross-sectional view of a finished package constructed according to the present invention;
FIGURE 46 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 47 shows a perspective view of a finished package constructed according to the present invention;
FIGURE 48 shows a tray portion including a flap in a down position, constructed according to the present invention;
FIGURE 49 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 50 shows a perspective view of a tray with flaps constructed according to the present invention;

FIGURE 51 shows a bottom perspective view of the tray of FIGURE 50;
FIGURE 52 shows a bottom plan view of the tray of FIGURE 50;
FIGURE 53 shows a side plan view of the tray of FIGURE 50;
FIGURE 54 shows a cross-sectional view of a tray constructed according to the present invention;
FIGURE 55 shows a perspective view of a tray constructed according to the present invention;
FIGURE 56 shows a cross-sectional view of a tray portion of FIGURE 55 taken along line 56;
FIGURE 57 shows a cross-sectional view of a tray portion of FIGURE 55 taken along line 57;
FIGURE 58 shows a cross-sectional view of a tray portion of FIGURE 55 taken along line 58;
FIGURE 59 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 60 shows a perspective view of a tray constructed according to the present invention;
FIGURE 61 shows a cross-sectional view of a tray portion of FIGURE 60 taken along line 61;
FIGURE 62 shows a perspective view of stacked trays constructed according to the present invention;
FIGURE 63 shows a cross-sectional view of the stacked trays of FIGURE 62;
FIGURE 64 shows a perspective view of a finished package constructed according to the present invention;
FIGURE 65 shows a perspective view of a tray with flaps constructed according to the present invention;
FIGURE 66 shows a schematic view of a tray portion including a flap constructed according to the present invention;
FIGURE 67 shows a cross-sectional view of a tray portion of FIGURE 65 taken along line 67;
FIGURE 68 shows a cross-sectional view of a tray portion of FIGURE 65 taken along line 68;
FIGURE 69 shows a detailed view of FIGURE 68;
FIGURE 70 shows a cross-sectional view of a tray portion including a flap constructed according to the present invention;

-20- Q 9. 07 1001 FIGURE 71 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 72 shows a cross-sectional view of a detailed tray portion of FIGURE 70;
FIGURE 73 shows a cross-sectional view of a finished package with a pealable label constructed to the present invention;
FIGURE 74 shows a perspective view of the package with label of FIGURE 73;
FIGURE 75 shows a cross-sectional view of a finished package with over wrap web material constructed according to the present invention;
FIGURE 76 shows a perspective view of the finished package of FIGURE 75;
FIGURE 77 shows a cross-sectional view of the finished package of FIGURE 76 with the over wrap in its loose state;
FIGURE 78 shows a cross-sectional view of the finished package of FIGURE 76 with the over wrap in a stretched state;
FIGURE 79 shows a cross-sectional view of a master container containing finished packages, the master container being enclosed within a cardboard box, constructed according to the present invention;
FIGURE 80 shows a portion of the master container of FIGURE 79;
FIGURE 81 shows a portion of the master container of FIGURE 79;
FIGURE 82 shows a perspective view of a tray with flaps constructed according to the present invention;
FIGURE 83 shows a cross-sectional view of the tray of FIGURE 82 taken along line 83;
FIGURE 84 shows a pair of tray pre-forms with ribs that are arranged to provide enclosed pressure vessels after sealing;
FIGURE 85 shows a side elevation of a packaging tray that has been manufactured from a pair of pre-forms shown in FIGURE 84;
FIGURE 86 shows a cross-sectional view of a tray portion of FIGURE 85 taken along line 86;
FIGURE 87 shows a cross-sectional view of the tray portion of FIGURE 86 taken along line 87;
FIGURE 88 shows a three dimensional view of a complete packaging tray comprising a base 6540 with four upwardly extending side walls terminating at a AMENDED SHEET

continuous flange 6542 that follows a path at a perimeter of the packaging tray and surround a cavity 6544;
FIGURE 89 shows a cross sectional view through the packaging tray shown in FIGURE 88;
S FIGURE 90 shows a plan view of a thermoformed pre-form that can be fabricated by folding and bonding to form a packaging tray as shown in FIGURE
88;
FIGURE 91 shows a cross-sectional view of a tray portion of FIGURE 89;
FIGURE 92 shows a plan view of a thermoformed pre-form that can be fabricated by folding and bonding flaps 6700, 6702, 6706, 6714, 6710, and 6712 to form a packaging tray with ca~,rity 6704 as shown in FIGURES 95 and 96;
FIGURE 93 shows two thermoformed and fabricated packaging trays 20 and 21, that are nested and stacked together to provide a stack of trays;
FIGURE 94 shows a cross section through an apparatus that is arranged to seal flaps (such as 6700, 6702, 6706, 6714, 6710, and 6712 shown in FIGURE 92) to the walls of a packaging tray (such as shown in FIGURE 92) to produce trays such as 6828 and 6830 shown in FIGURE 95;
FIGURE 95 shows a side elevation of two packaging trays that are stacked after flaps, such as 6700, 6702, 6706, 6714, 6710, and 6712 shown in FIGURE 92 have been sealed to walls of the tray;
FIGURE 96 shows an end view of two packaging trays that are stacked after flaps, such as 6700, 6702, 6706, 6714, 6710, and 6712 shown in FIGURE 92 have been sealed to the corresponding walls of the tray;
FIGURE 97 shows a three dimensional view of a packaging tray 6900 with ribs 6916, 6914, 6910 and 6908 formed into the profile of flaps and walls of the 2S packaging tray;
FIGURE 98 shows a cross-sectional view of tray 6900 in FTGURE 6 taken along line 98;
FIGURE 99 shows a perspective view of a tray according to the present invention;
FIGURE 100 shows a cross-sectional view of a tray portion of FIGURE 99 taken along line 100;
FIGURE 101 shows a cross~sectional view through a segment of a preferred packaging tray embodiment;
FIGURE 102 shows a cross-sectional view of a tray portion of FIGURE 101 taken along line 102;
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FIGURE 103 shows details of the components used to manufacture a composite tray;
FIGURE 104 shows a plan view of a web material to construct a tray according to the present invention;
FIGURE 105 shows a cross section through an apparatus with housing 7534, and a tapering screw 7508 mounted therein; a piston 7514, with corresponding cylinder 7512, is mounted to housing 7534 and a restricting conduit 7526 is attached to the exit end of housing 7534, grinds 7506 can be transferred into said housing 7534 and screw 7508 may be used for pumping said grinds into a profiled conduit thereby providing an extruded stream of grinds for subsequent slicing and thereby production of patties;
FIGURE 106 shows a cross section through an apparatus intended for use in slicing extruded streams of ground meats to produce patties, a temperature controlled conduit 7560 is mounted adjaccnt to a revolving blade 7542, such that stacks of sliced patties 7544 and 7546 can be produced and transported to a packaging station via conveyor belting 7550 that is driven intermittently by drive roller 7552 in direction shown by arrow 754ti;
FIGURE 107 shows a cross-sectional view of an apparatus portion of FIGURE 105 taken along ~.ine 107;
FIGURE 108 shows a side elevation of an apparatus assembled to produce fine ground boneless beef 7630, from coarse ground boneless beef 7602, after fine grinding into vessel 7618 from grinder 7608, ground beef 7630 is pumped, in the direction shown by arrow 7622, via servo driven positive displacement pump 7628, through conduit 7620 which can be connected directly to conduit 7502, shown in FIGURE 105. Conduit connections 7638 and 7634 are provided to allow injection of gas such as C02 there through and conduit connection 7614 is provided to allow gases to be withdrawn from vessel 7618;
FIGURE 109 shows a side elevation, cross sectional view of an apparatus that is arranged to automatically measure and slice portions of meat primals that have been molded to a predetermined profile corresponding with a temperature controlled conduit 7702 of similar profile, pre-conditioned and tempered primal cuts of boneless meat 7738 are located in an entry end of conduit 7702 followed by a plug such as 7704, electromagnetic driving fixtures 7712 are arranged to intermittently drive and by magnetic bonding to each plug, carry plugs such as 7704, in a forward direction and a distance equal to the selected thickness of a single slice of beef, blade 7732 is AMENDED SHEE ~

controlled to intermittently slice during a single revolution shaft 7734, conveyor 7726 is mounted in an enclosure 7722, and adjacent to the exit end of conduit 7702, so as to conveniently carry slices to a further processing or packing station;
FIGURE 110 shows a cross-sectional view of an apparatus portion of FIGURE 109 taken along line 110;
FIGURE l11 shows a cross-sectional view of an apparatus portion of FIGURE I09 taken along line 11 I ;
FIGURE I12 shows a cross-sectional view of a finished package constructed according to the present invention;
FIGURE 113 shows a perspective view of a finished package constructed according to the present invention;
FIGURE 114 shows a perspective view of a tray with flaps constructed according to the present invention;
FIGURE 115 shows a cross-sectional view of a tray portion including flaps of FIGURE 114;
FIGURE 116 shows a cross-sectional view of a tray constructed according to the present invention;
FIGURE 117 shows a perspective view of a tray with a flap constructed according to the present invention;
FIGURE 118 shows a cross-sectional view of packages stacked atop one another, constructed according to the present invention;
FIGURE 119 shows a top plan view of a tray constructed according to the present invention;
FIGURE 120 shows a cross-sectional view of a tray portion of FIGURE 119;
FIGURE 12I shows a cross-sectional view of a tray portion of FIGURE 119;
FIGURE 122 shows a cross-sectional view of a plurality of stacked trays with flaps, constructed according to the present invention;
FIGURE 123 shows a cross-sectional view of a tray with a flap constructed according to the present invention;
FIGURE 124 shows a cross-sectional view of a finished package constructed according to the present invention;
FIGURE 125 shows a cross-sectional view of a master container containing finished packages constructed according to the present invention;
FIGURE 126 shows a perspective view of a txay portion constructed according to the present invention;
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FIGURE 127 shows a cross-sectional view of a tray portion of FIGURE 126;
FIGURE 128 shows a cross-sectional view of stacked trays in a master container constructed according to the present invention;
FIGURE 129 shows a cross-sectional view of a finished package with a flap constructed according to the present invention;
FIGURE 130 shows a cross-sectional view of a tray with flap constructed according to the present invention;
FIGURE 131 shows a top plan view of a tray portion with flap constructed according to the present invention;
FIGURE 132 shows a side plan view of a tray portion of FIGURE 131;
FIGURE 133 shows a side plan view of stacked trays according to the present invention;
FIGURE 134 shows a top plan view of a tray portion with flaps constructed according to the present invention;
FIGURE 135 shows a perspective view of a tray portion with the flaps folded down according to the present invention;
FIGURE 136 shows a cross-sectional view of a tray portion of FIGURE 135 taken along line 136;
FIGURE 137 shows a cross-sectional view of a tray with flaps constructed according to the present invention;
FIGURE 138 shows a cross-sectional view of a tray with flaps containing iron particles constructed according to the present invention;
FIGURE 139 shows a cross-sectional view of a tray portion of FIGURE .138;
FIGURE 140 shows a schematic view of an apparatus for applying iron particles according to the present invention;
FIGURE 141 shows a cross-sectional view of an apparatus portion of FIGURE 140;
FIGURE 142 shows a cross-sectional detailed view of an apparatus portion of FIGURE 141;
FIGURE 143 shows a schematic view of an apparatus for applying iron particles according to the present invention;
FIGURE 144 shows a top plan view of a web material containing iron particles according to the present invention;
FIGURE 145 shows a cross-sectional view of the web of FIGURE 144 taken along line 145;
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FIGURE 146 shows a schematic view of an apparatus for packaging and forming holes in web materials according to the present invention;
FIGURE 147 shows a side plan view of a tray formed by the apparatus of FIGURE 146;
FIGURE 148 shows a schematic view of a master container sealing apparatus according to the present invention;
FIGURE 149 shows a perspective view of an apparatus portion of FIGURE 148;
FIGURE 150 shows a cross-sectional view of an apparatus portion of FIGURE 149 taken along line 150;
FIGURE 15I shows a schematic view of a packaging, labeling, and weighing apparatus according to the present invention;
FIGURE 152 shows a top plan view of the apparatus of FIGURE 151;
FIGURE 153 shows a top plan view of a register formed according to the presentinvention;
FIGURE 154 shows a cross-sectional view of a vacuum chamber constructed according to the present invention;
FIGURE 155 shows a cross-sectional view of an apparatus portion according to the present invention;
FIGURE 156 shows a cross-sectional view of a vacuum chamber constructed according to the present invention;
FIGURE 157 shows a cross-sectional view of a tray with flaps according to the present invention;
FIGURE 158 shows a cross-sectional view of a tray portion with flap of FIGURE 157;
FIGURE 159 shows a cross-sectional view of a sealing plate constructed according to the present invention;
FIGURE 160 shows a top plan view of a sealing plate according to the present invention;
FIGURE 161 shows a top plan view of a sealing plate according to the present invention;
FIGURE 162 shows a cross-sectional view of the sealing plate of FIGURE 161 taken along line 162;
FIGURE 163 shows a cross-sectional view of a finished package constructed according to the present invention;
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FIGURE 164 shows a cross-sectional view of a tray located in a sealing plate according to the present invention;
FIGURE 165 shows a top plan view of a sealing plate according to the present invention;
FIGURE 166 shows a schematic view of tray walls being bonded when located in the sealing plate according to the present invention;
FIGURE 167 shows a cross-sectional view of a vacuum chamber constructed according to the present invention;
FIGURE 168 shows a schematic view of an apparatus for loading and sealing trays according to the present invention;
FIGURE 169 shows a schematic view of an apparatus for forming a laminated web according to the present invention;
FIGURE 170 shows a schematic view for an apparatus for packaging trays using a laminated web according to the present invention;
FIGURE 171 shows a cross-sectional view of a web material according to the presentinvention;
FIGURE 172 shows a schematic view of a packaging and sealing apparatus constructed according to the present invention;
FIGURE 173 shows a cross-sectional view of a tray with a laminated web;
FIGURE 174 shows a cross-sectional view of a tray with a single web;
FIGURE 175 shows a schematic view of an apparatus for forming master containers according to the present invention;
FIGURE 176 shows a cross-sectional view of the apparatus of FIGURE 175 taken along line 176;
FIGURE 177 shows a cross-sectional view of an apparatus portion of FIGURE 175 taken along line 177;
FIGURE 178 shows a cross-sectional view of an apparatus portion of FIGURE 176;
FIGURE 179 shows a finished package enclosed within a master container;
FIGURE 180 shows an apparatus for grinding and processing meat constructed according to the present invention;
FIGURE 181 shows an apparatus for grinding and processing meat constructed according to the present invention;
FIGURE 182 shows a cross-sectional view of an apparatus portion of FIGURE 181;

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-a7-FIGURE 183 shows a cross-sectional view of an apparatus portion of FIGURE 181;
FIGURE 184 shows a front plan view of a manifold constructed according to the present invention;
FIGURE 185 shows a side plan view of the manifold of FIGURE 184;
FIGURE 186 shows a cross-sectional view of an apparatus for grinding and processing meat according to the present invention;
FIGURE 187 shows a cross-sectional view of an apparatus for processing meat constructed according to the present invention;
FIGURE 188 shows a side plan view of an apparatus portion of FIGURE 187;
FIGURE 189 shows a cross-sectional view of an apparatus portion of FIGURE 188 taken along line 189;
FIGURE 190 shows a cross-sectional view of an apparatus portion of FIGURE 187 taken along line 190;
FIGURE 191 shows a top plan view of a tube structure according to the present invention;
FIGURE 192 shows a cross-sectional view of an apparatus portion having three meat processing tubes, constructed according to the present invention;
FIGURE 193 shows a cross-sectional view of an apparatus for grinding and processing meat;
FIGURE 194 shows a cross-sectional view of an apparatus portion of FIGURE 187;
FIGURE 195 shows a cross-sectional view of a measuring device constructed according to the present invention;
FIGURE 196 shows a top plan view of a packaging and slicing apparatus having a tunnel, constructed according to the present invention;
FIGURE 197 shows a cross-sectional view of the apparatus of FIGURE 196 taken along line 197;
FIGURE 198 shows a schematic view of a meat processing apparatus constructed according to the present invention;
FIGURE 199 shows a schematic view of a meat processing and packaging apparatus constructed according to the present invention;
FIGURE 200 shows a schematic view of a meat processing and packaging apparatus constructed according to the present invention;
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FIGURE 201 shows a schematic view of a meat processing and packaging apparatus constructed according to the present invention;
FIGURE 202 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 203 shows a perspective view of an over wrapping web material constructed according to the present invention;
FIGURE 204 shows a perspective view of an over wrapped package constructed according to the present invention;
FIGURE 205 shows a schematic view of an apparatus portion constructed according to the present invention;
FIGURE 206 shows a top plan view of an apparatus portion constructed according to the present invention;
FIGURE 207 shows a cross-sectional view of a meat blending apparatus constructed according to the present invention;
FIGURE 208 shows a cross-sectional view of the meat blending apparatus of FIGURE 207 taken along line 208;
FIGURE 209 shows a schematic view of a meat processing and conditioning apparatus constructed according to the present invention;
FIGURE 210 shows a cross-sectional view of a meat forming and shaping apparatus constructed according to the present invention;
FIGURE 211 shows a side plan view of an apparatus portion of FIGURE 210;
FIGURE 212 shows a perspective view of a meat forming and shaping apparatus constructed according to the present invention;
FIGURE 213 shows a schematic view of a master container sealing apparatus constructed according to the present invention;
FIGURE 214 shows a cross-sectional view of the apparatus of FIGURE 212;
FIGURE 215 shows a cross-sectional view of a meat forming and shaping apparatus constructed according to the present invention;
FIGURE 216 shows a side plan view of an apparatus portion of FIGURE 215;
FIGURE 2I7 shows a cross-sectional view of a forming and shaping apparatus for several primals, constructed according to the present invention;
FIGURE 218 shows a cross-sectional view of an apparatus portion of FIGURE 216;
FIGURE 219 shows a cross-sectional view of an apparatus portion of FIGURE 218;
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FIGURE 220 shows a cross-sectional view of an apparatus portion for forming and shaping meat primals constructed according to the present invention;
FIGURE 221 shows a cross-sectional view of an apparatus portion for shaping and forming meat primals constructed according to the present invention;
FIGURE 222 shows a schematic view of an equipment layout constructed according to the present invention;
FIGURE 223 shows a cross-sectional view of a master container vacuum chamber constructed according to the present invention;
FIGURE 224 shows a schematic view of an equipment layout constructed according to the present invention;
FIGURE 225 shows a cross-sectional view of a tube apparatus of FIGURE 224 taken along line 225;
FIGURE 226 shows a perspective view of a spool for storing web material constructed according to the present invention;
FIGURE 227 shows a schematic view of a thermoforming oven of FIGURE 224 taken along line 227;
FIGURE 228 shows a schematic view of equipment layout constructed according to the present invention;
FIGURE 229 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 230 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 231 shows a detailed view of web material constructed according to the present invention;
FIGURE 232 shows a detailed view of web material constructed according to the present invention;
FIGURE 233 shows a detailed view of web material constructed according to the present invention;
FIGURE 234 shows a detailed view of web material constructed according to the present invention;
FIGURE 235 shows a detailed view of web material constructed according to the present invention;
FIGURE 236 shows a detailed view of web material constructed according to the present invention;
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FIGURE 237 shows a detailed view of web material constructed according to the present invention;
FIGURE 238 shows a perspective view of a tray treatment apparatus constructed according to the present invention;
FIGURE 239 shows a perspective view of a tray treatment apparatus constructed according to the present invention;
FIGURE 240 shows a cross-sectional view of a tray forming apparatus constructed according to the present invention;
FIGURE 241 shows a cross-sectional view of a tray forming apparatus constructed according to the present invention;
FIGURE 242 shows a cross-sectional view of web material constructed according to the present invention;
FIGURE 243 shows a cross-sectional view of web material constructed according to the present invention;
FIGURE 244 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 245 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 246 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 247 shows a cross-sectional view of formed web material constructed according to the present invention;
FIGURE 248 shows a cross-sectional view of formed web material constructed according to the present invention;
FIGURE 249 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 250 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 251 shows a perspective view of a tray portion with ribs constructed according to the present invention;
FIGURE 252 shows a cross-sectional view of formed web material constructed according to the present invention;
FIGURE 253 shows a cross-sectional view of formed web material constructed according to the present invention;
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~'~ 1.

FIGURE 254 shows a cross-sectional view of a web forming apparatus constructed according to the present invention;
FIGURE 255 shows a cross-sectional view of a web forming apparatus constructed according to the present invention;
FIGURE 256 shows a cross-sectional view of a web material constructed according to the present invention;
FIGURE 257 shows a cross-sectional view of a web aperture forming apparatus constructed according to the present invention;
FIGURE 258 shows a cross-sectional view of a web forming apparatus constructed according to the present invention;
FIGURE 259 shows a top plan view of an apparatus portion of FIGURE 258;
FIGURE 260 shows a cross-sectional view of a formed web material constructed according to the present invention;
FIGURE 261 shows a cross-sectional view of a pressure chamber for removing oxygen from the cell structure of EPS foam constructed according to the present invention;
FIGURE 262 shows a cross-sectional view of an apparatus for removing oxygen within the cell structure of EPS foam constructed according to the present invention;
FIGURE 263 shows a perspective view of an apparatus portion of FIGURE 261;
FIGURE 264 shows a front plan view of the apparatus of FIGURE 262;
FIGURE 265 shows a schematic view of an apparatus with vacuum tubes constructed according to the present invention;
FIGURE 266 shows a schematic view of equipment layout constructed according to the present invention;
FIGURE 267 shows a schematic view of equipment layout constructed according to the present invention;
FIGURE 268 shows a tray with flaps having crests and indentations constructed according to the present invention;
FIGURE 269 shows a perspective view of the tray of FIGURE 268 with the flaps opened upward;
FIGURE 270 shows a side plan view of stacked trays of FIGURE 268 showing a space between the crest and a flap indentation;
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FIGURE 271 shows a perspective view of a tray with flaps constructed according to the present invention;
FIGURE 272 shows a perspective view of the tray of FIGURE 271 with the flaps folded downward;
FIGURE 273 shows a cross-sectional view of a tray portion with substances located within a flap space constructed according to the present invention;
FIGURE 274 shows a cross-sectional view of a tray with flaps having flap spaces.
FIGURE 275 shows a schematic detail portion of the tray flap of FIGURE 92.
Detailed Descriution of the Preferred Embodiment As used herein, the following terms take the following mean, unless otherwise indicated.
The term "case ready" refers to retail packaged fresh meats (that were typically formerly prepared at the supermarket) that has been packaged ready for retail sale from the meat case at a place of production remote from the supermarket.
The term "high oxygen modified atmosphere" refers to a blend of gases that includes some or all of the naturally occurring atmospheric gases but in proportions that are different to air and including a high level of oxygen which may be greater than 40%. Such an example would be a gas comprising 80% oxygen and 20%
carbon dioxide, however in virtually all applications a residual quantity of nitrogen remains in the sealed "high oxygen modified atmosphere" package.
The term "low oxygen'' or "no oxygen" modified atmosphere" refers to a blend of gases that includes some or all of the naturally occurring atmospheric gases (except oxygen) but in proportions that are different to air and including a low (or zero level of oxygen) which may be less than 300-500 parts per million.
The term "MAP" refers to modified atmosphere packaging.
The term "CAP" refers to controlled atmosphere packaging.
The term "Epsilon GMS-40" or "GMS-40" refers to an apparatus that can be used to measure the fat and/or lean content of pumpable ground meats. The GMS-is manufactured and supplied by Epsilon Industries, of Austin, Texas.
Additional information is available on web site: www.epsilon-gms.com.
The term "AVS-ET system" refers to a system that can be used to identify the composition of boneless meats. The system can identify quantities of fat, muscle/lean tissue, contaminants, bone, metal inclusions and other matter that is transferred, in a continuous stream, through a conduit and into and then away from ~~AMENDED SHEET

the AVS-ET system. The system operates preferably when the continuous stream is exclusive of any voids such as pockets of air. The system is manufactured and supplied by Holmes Newman Associates, 4221 Fallsbrae Road, of Fallbrook, CA 92028.
The term "statiflo blending devices" refers to a continuous, static and enclosed material blending device that can introduce gases such as C02 to the blended material. STATIFLO is a registered trademark of Statiflo International, The Crown Center, Bond Street, Macclesfield, Cheshire SK116QS, LTK. Information is available on web site: salesC statiflo.co.uk.
The term "blending devices" refers to a continuous, static and enclosed material blending device that can be used to continuously blend such perishable goods as ground meats that comprise substantially two components of fat and lean meat and may also be used to introduce gases such as C02 to the blended materials.
The term "shelf life" refers to the period of time between the date of retail packaging of perishable goods (that are slowly deteriorating) of acceptable quality and a subsequent point in time or date, prior to the perishable goods having deteriorated to an unaccepta>,le condition.
The term "PP" refers to polypropylene.
The term "EPS" refers to expanded polystyrene.
The term "pPVC" refers to plasticized polyvinylchloride.
The term "PET," polyester or "APET" refers to amorphous polyethylene terephthal ate.
The term "heat activated adhesives (or coating)" refers to adhesives that become active and capable of bonding substances together when heated to a suitable temperature that otherwise, at ambient temperature, will not bond.
The term "OTR" refers to oxygen transmission rate.
The term "perishable goods" or "goods" refers to any perishable foods such as sliced beef or other fresh meats, ground meats, poultry pieces etc.
The term "liquids and oils" refers to water, liquids, blood, purge, liquid animal fats and oils and the like.
The term "master container" generally refers to a substantially gas barrier container that can be filled with finished packages, evacuated of substantially all atmospheric air and filled with any suitable gas. However, said "master container"
may also be gas permeable if so desired.
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. ~ :~.,a The terms "suitable substance", "suitable gas" or "suitable gases" refer to any gas or blend of gasses, provided at any pressure (suitable pressure). A
suitable gas may include a blend of carbon dioxide and nitrogen and oxygen with residual atmospheric gases in any relative proportions. Examples are provided, but are not restricted to any of the following:
1. A blend of gases including argon, carbon dioxide, nitrogen and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).
2. Air that has been filtered to remove substantially all oxygen therefrom.
3. Carbon dioxide and nitrogen in any relative proportions.
4. Carbon dioxide and oxygen where oxygen does not exceed 5% and is not less than 5 PPM.
5. Carbon dioxide and a quantity of oxygen that does not exceed S% and is not less than 5 PPM (parts per million).
6. Nitrogen and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).
7. A blend of inert gasses and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).

8. A blend of pentane and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).

9. A blend of propane and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).

10. A blend of butane and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).

11. A blend of a CFC and nitrogen in any relative proportions and a quantity of oxygen that does not exceed S% and is not less than S PPM (parts per million).

12. A blend of an HCFC and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).
AMENDED SHEEN' 13. A blend of methane and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).

14. A blend of hydrogen sulfide and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM
(parts per million).

15. A blend of carbon monoxide and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM
(parts per million).

16. A blend of sulfur dioxide and nitrogen in any relative proportions and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts per million).

17. A gas including 100% carbon dioxide 18. A substance or agent including one or more of the following:
isoascorbic acid, ascorbic acid, citric acid, erythorbic acid, lactic acid, succinic acid or mixtures of salts thereof. Glycerol monolaurate, potassium sarbate, sodium sorbate, sodium iodoacetate, potassium acetate, iodoacetomide, potassium iodoacetate, sodium acetate or mixtures or acidic solutions thereof.
The term "suitable gas pressure" or "water pressure" refers to any pressure that is suitable for the application and may be controlled within any of the following pressure ranges, or any other suitable pressure:
Suitable gas pressure:
gas at a pressure of 1 PSI to 14 PSI.
gas at a pressure of up to 13 PSI.
gas at a pressure of 13 PSI to 50 PSI.
gas at a pressure of 50 PSI to 80 PSI.
gas at a pressure of 80 PSI to 120 PSI.
gas at a pressure of 120 PSI to 200 PSI.
gas at a pressure of 200 PSI to 500 PSI.
gas at a pressure above 500 PSI.
Suitable water pressure:
water at a pressure of 1 PSI to 14 PSI.
water at a pressure of up to 13 PSI.
water at a pressure of 13 PSI to 50 PSI.
water at a pressure of 50 PSI to 80 PSI.
-~~'~ AMENDED SHEET

s water at a pressure of 80 PSI to 120 PSI.
water at a pressure of 120 PSI to 200 PSI.
water at a pressure of 200 PSI to 500 PSI.
water at a pressure above 500 PSI.
The term "suitable gas temperature" or "suitable water temperature" refers to any temperature that is suitable for the application and may be controlled within any suitable temperature ranges for any suitable period of time, or at any other suitable temperature. Suitable temperature also includes a temperature range which may be a pasteurizing temperature range such as maintaining a product such as a beef primal within a temperature range of not less than 138.5 degrees F to 140 degrees F
and for a suitable period of time.
Bond or Bonding refers to sealing or welding of two or more surfaces together by any suitable means such as with any suitable adhesive, RF welding, ultrasonic welding heat sealing, or any other suitable means.
Hermetic seal refers to a seal or bonding of two or more surfaces of any suitable material together by any suitable means to provide an enclosed space and wherein said enclosed space is rendered fully enclosed in such a manner that will substantially inhibit the passage or communication of any substance such as gas, air or liquids from within said enclosed space to and with the exterior of said enclosed space.
Pre-Form refers to a thermoformed or suitably fabricated packaging component that has been arranged with one or more hinged flaps that can be folded and bonded to produce a useful packaging tray or container for goods.
"Fat" content is a component of meat and may mean the measured fat content of a quantity of boneless meat harvested from any species of slaughtered animal such as beef.
"Meat" can mean any meat harvested from any species of slaughtered animal wherein the meat comprises several components but generally including water, fat, oils, and protein in relative quantities that are not precisely known at the time of harvesting and must be measwed to determine the precise ratio of each component.
Trays with Peelable Lids In accordance with the present invention, trays having peelable lids are disclosed herein. Perishable goods packaged in trays with peelable lids have extended shelf life. A peelable lid provides a method of delaying the exposure of ~' AMENDED SHEET

fresh meat contained within a package to ambient air at a predetermined period, preferably at the point of sale.
Refernng first to FIGURES 1, 2, and 3, a preferred package 100 made in accordance with the present invention includes a tray 102 into which meat 104 (FIGURE 3) or other perishable food product is placed. A first layer 106 and second layer 108 of heat sealable material are then placed over the tray 102 and heat sealed to the upper horizontal flange 110 that extends outwardly from the upper periphery of the tray 102. By draftsman's license used in accordance with the present invention, the layers 106 and 108 are shown separated. In actuality, they are in intimate contact throughout their entire length and width. The layers 106 and 108 are also shown to be heat sealed to each other by cross hatching shown in the drawings at locations 112 between the two layers and between the bottom layer 106 and the tray flange 110. In actuality again, there is no substantial thickness at the heat sealed locations, but in fact, the materials are in intimate contact with each other andlor the flange 110 of the tray 102. Thereby substantially expelling/removing air or gas from therebetween.
Depending upon the particular design and use of the tray, the first layer 106 can be composed of a substantially gas impermeable barrier layer or a substantially gas permeable layer. Similarly, the outer layer 108 can either be substantially gas impermeable or permeable. Substantially gas permeable materials include plasticized polyvinyl chloride (pPVC) and polyethylene (PE). Preferably, these are more typically used in thicknesses from 0.0004 inches to 0.001 inches. Preferably, suitable barrier layers (substantially gas impermeable) are composed of amorphous polyethylene terephthalate (Al'ET) unplasticized polyvinyl chloride (uPVC) and a composite material such as a biaxially oriented polyester/tie/polyvinylidene chloride/tie/polyethylene. Other suitable materials known to those of ordinary skill can also be employed in accordance with the present invention. The trays are preferably made of polyester (APET, amorphous polyethylene terephthalate often referred to as polyester), polyvinyl chloride or other suitable food grade polymers.
As used herein, a web is a sheet of material that may have one or a plurality of layers or zones of differing compositions. Also, when the terms "substantially gas permeable" or "substantially gas impermeable" are used, they are intended to reflect the fact that no practical heat sealable material is totally gas permeable or impermeable. Materials disclosed herein as substantially gas impermeable will serve as a barrier layer to the transfer of significant amounts of gas over time.
Likewise ~Ig.AMENDED SHEET

-3 $-substantially gas permeable materials will not function as a burner but will allow ready diffusion of gas therethrough.
Method for Producing_Peelable Lids A method is disclosed fox producing the peelable lids disclosed above which include a label.
Referring now to FIGURE 4, a side elevation of a package sealing arrangement for assembling a package of the type disclosed in FIGURE 1 is shown.
Trays 102 are loaded with perishable edible material 104 and placed in conventional carrier plates on a conveyor {not shown) and conveyed toward a heat sealing station 114. A roll 116 of heat sealable material is supplied above the conveyor. The sheet of material that will become the inner web 106 from the roll 116 travels downwardly and wraps around a roller 118 and then traverses horizontally in a left-to-right direction along with the trays 102 being conveyed by a conveyor (not shown). A label dispenser 118 positions a label 120 on the upper surface of the inner web 106 of heat sealable material. The outer web 108 of sheet material is then drawn from roll 122 downwardly around another roller 124 and traverses horizontally from left-to-right, where the label 120 is captured between the inner and outer webs 106 and 108. The two webs and the label are then run through a pair of nip rolls 126 to cause the two webs and the label to come into intimate contact and also substantially removing air from between the webs. The webs of heat sealable material 106 and 108 are then positioned at the heat sealing station 114. Corresponding tray 102 is positioned in the lower portion 162 of the heat sealing chamber. The lower portion of the heat sealing chamber 162 is then raised upwardly toward the upper portion 160 of the heat sealing chamber wherein the webs 106 and 108 are sealed to each other and to the upper surface of the flange/lip portion of the tray 102 around the periphery at the flange. At the same time, a knife incorporated into the mechanism trims the excess material neatly around the outer edge of the tray flange 110. The scrap material 128 is then passed around a roller 130 and onto a scrap retrieval roll 132.
The tray 102 is then moved onto another conveyor where the finished packages are moved from left to right to a transportation and/or storage station.
Apparatus for Forming Peelabl ~ Lids Referring to FIGURES 42-44, a schematic side elevation view through a section of a package is shown. A schematic view is provided so as to clearly disclose an example of a preferred peelable seal mechanism that will facilitate peeling of the third web from the package while the second web remains substantially intact and AMENDED SHEET

sealed to the first web. The example is provided to show preferred plastics materials that will seal as required when used according to the present invention. Other selected materials may also be used in similar manner without departing from the general ambit of this invention. First 1002, second 1004, and third 1006 webs are shown where, in this instance, first web 1002 preferably includes a thermoformed tray produced from a multilayer co-extruded material including first, outer layer 1088 of Eastman 9921 about 0.008" thick and a second inner layer 1086, about 0.004"
thick, including a blend of about 50% PETG 6763 and about 50% Eastman 5116 (or Eastman PM14458 or equivalent shown in FIGURE 42). Second web 1004 preferably includes a web of pPVC with a thickness of about 0.0008". Referring to FIGURE 43, third web 1006 preferably includes a two layer co-extruded web with a first outer layer 1082 of Eastman PET 9921 about 0.003" in thickness and a second inner layer 1084 about 0.003" thick including a blend of about 16% Eastman PETG 6763 and about 84% Eastman PET 9921. Referring now to FIGURE 42, preferably, a water cooled clamp 1104 is shown in position above the flanges of first, second and third webs and two separate heat seal bars 1106 and 1008 are arranged adjacent thereto and all are separated by space and are each independently activated and controlled and moved. Preferably, heat seal bar 1106 can have a set temperature of about 385 degrees F and heat seal bar 1 I08 can have a set temperature of about 370 degrees F. Third web second inner layer 1084 will heat seal to second web when the temperature at the interface of second and third webs reaches about 385 degrees F and abcve. Preferably, second web will heat seal to second inner layer 1086 of first web 1002 when the temperature of the interface between the first and second webs is about 370 degrees F and above.
Preferably, the water cooled clamp 1104 is mounted to an independently activated pneumatic driver, providing downward pressure such that the water cooled clamp can clamp against first., second and third webs so as to hold them firmly against the rubber seal 1110 located beneath the first web flange portions 1072 and 1074. Preferably, heat seal bars 1106 and 1108 are independently attached to pneumatic drivers for applying pressure thereto so as to facilitate a method to seal third, second and first webs together under independently selected pressure.
Preferably, heat seal bar 1106 heat seals the third, second and first webs together at 1112 and 1114 and heat seal bar 1108 heat seals the second web 1004 to the first web 1002 at 1116 but does not heat seal the interface between the third 1006 and second 1004 webs. When the package is assembled and sealed in the foregoing ~2(L AMENDED SHEET

manner, the third web 1006 can be peeled from the package without rupturing the second web 1004. Preferably, second web 1004 may be perforated so that after seals 1112, 1114 and 1116 have been provided, the second 1004 and third 1006 webs can be separated to provide a space 1118 therebetween.
Seals at 1112, 1114, and 1116 have been shown as heat seals, however, effective sealing can be achieved with use of ultra sonic devices or alternatively latex rubber adhesives when applied at the interfaces of the webs at 1112, 1114, and 1116, or with any other suitable method of sealing. Such sealing can provide improved economics while still providing an effective peeling mechanism as required and described above. w Stackable Trays, Trays with Valves Conventional thermoformed trays are shaped in a mold which have sides that generally are inclined to facilitate separation between the mold and the tray.
Thus, making them cumbersome to stack when filled, because the smaller area at the bottom cannot be suitably supported by the larger opening at the top. Trays constructed according to the present invention include members, in the form of flaps that provide a suitable resting area for the lower portion of the tray when stacked atop one another.
Embodiment 1 Refernng now to FIGURES 7-9, a preferred embodiment of a stackable tray 202 constructed in accordance with the present invention is illustrated.
Referring first to FIGURES 7 and 8, a tray 202 has a recessed bottom 204 so as to form peripheral legs 206 on which the tray rests. The longitudinal edges of the tray each include a flange 208. The outer flange 208 is coupled to an inner flange 210 of the tray by a hinge member 212. The inner flange is integral with and extends outwardly from the upper edge of the tray 202. A recessed platform 214 is formed across the corner of the tray at diagonal corners of the tray. The bottom of the platform 214 is lowered slightly relative to the level of inner flange 210.
The platform 214 in the edge of the tray carries a small depression 216, the bottom of which is perforated. During evacuation and flushing, gases can rapidly enter through the perforation in the 3epression 216, travel through the recess formed by platform 214 into the interior of the tray and vice versa. Adjacent to the recessed platform 214, the flange 208 includes an outwardly extended flap 218. In the unfolded position shown iti FIGURE 7, the flap carries a concave dimple 220 (viewed from the top). The dimple is located relative to the hinge 212 such that AMENDED SHEET
~gi~

when the flange 208 is folded over on top of the flange 210, the dimple 220 resides directly above and central to the depression 216. When desired, the dimple can be depressed from the upper side so as to reverse its concavity. When the concavity is reversed, it extends downwardly into depression 216 to close off the perforation in the cavity and thus seal the container.
Referring now to FIGURE 8, a first and second web 222 and 224, respectively, of heat sealable material overlay the upper portion of the tray 202 and are heat sealed to the upper surface of the flange 210. First web 222 may be incorporated by deleting web 224. A label 226 or other indicia bearing material can be sandwiched between the heat sealable layers 222 and 224. The method for incorporating a label between a first and second web has been described above.
The label 226 sandwiched between heat sealable webs 222 and 224 is optional and can cover the entire surface of the tray 202. Alternatively, the Label can cover only a portion of the product contained in the tray. The label can carry graphics that, for example, show the contents in a fully prepared and cooked condition to suggest to the consumer how the product will look when cooked, yet allowing the consumer to see at least a portion of the fresh product in the tray. For example, if the tray contained fresh beef patties, the label could cover half of the exposed upper surface. The label may be arranged with a straight cut or opening running the full length of the package. Alternatively, the label could be positioned on one side of a diagonal through the package, while the portion of the package on the opposite side of the diagonal would be open for viewing the fresh, packaged product.
Refernng again to FIGURE 7, the remainder of the longitudinal extent of the flanges 208 include lateral reinforcing ribs 228 that extend upwardly from the flanges 208 when folded over the top of flange 210. The reinforcing ribs 228 have a recess 230 that receives the legs 206 of an identical container stacked on top of a first container as shown in FIGURE 9. The recesses inhibit lateral movement of one tray relative to another. Thus, these containers are stackable for use for example in the master bag evacuation technique which will be described below in conjunction with FIGURE 5.
Embodiment 2 Referring now to FIGURES 10-13, another embodiment of a stackable tray 300 constructed in accordance with the present invention is illustrated.
The tray in plan form is generally rectangularly shaped. The tray includes first and second ,,~2:-'s AMENDED SHEET

sidewalls 302 and first and second end walls 304. Walls 302 and 304 are generally upright and slope inwardly from their upper portion toward the tray bottom 306 to facilitate separation from a mold. The bottom 306 has a raised central portion that slopes downwardly towaxd the bottom of each end wall 304. The upper end of the sidewalls 302 and end walls 304 terminate in an outwardly extending horizontal flange 310 that extends cornpletely around the tray 300. The raised center portion 308 creates a cavity 312 in the bottom of the tray. When the trays are filled and stacked, the contents extend above the flange 310. The cavity 312 will accommodate the raised contents without compression in a stacked arrangement.
Referring to FIGURES 10-13, a horizontal platform 314 is formed in diagonally opposed corners of the tray. The platform 314 is positioned at an elevation slightly below that of flange 310. A wall segment 316 extends downwardly from the inner edge 318 of the platform 314 and has edges that join the sidewalls 302 and end walls 304. The platform 314 and the wall 316 form a recess on the outside of the tray. An aperture 320 is formed in the center portion of platform 314 and allows gas communication between the inside of the tray and the outside of the tray via the recess when a web is sealed over the tray to flange 310.
Referring now to FIGURES 14 and 15, the tray 300 also has movable flanges 322 that are hinged via a hinge 324 to the outer edges of the portions 310 of horizontal flanges 310 that extend outwardly from the end walls 304. The flange 322 when open carries a hemispherical shaped dimple 326. The center of the dimple is on a line perpendicular to the hinge 324 which line also runs through the center of aperture 320. The centers of the aperture 320 and the dimple 326 are equidistantly spaced from the hinges. Thus, as shown in FIGURE 14, when the movable flange 322 is folded over the flange 310, the dimple 326 resides over the aperture 320. Referring to FIGURE 14, when a web 328 of material is heat-sealed over the top of the tray 300, the interior of the tray 300 remains open to the atmosphere through the space between platform 314 and web 328 through aperture 320. As will be better understood below, it is many times desirable to close the aperture 320. This is done by pressing downwardly on the exterior of the dimple 326 forcing it to reverse itself as shown in FIGURE 15 and extend downwardly and fill the aperture 320, thus closing it and sealing the inside of the tray 300 from the external atmosphere.
Embodiment 3 AMENDED SHEET

Refernng now to FIGURES 17 and 18, another embodiment of a stackable tray with tray valve constructed according to the present invention is shown.
In this embodiment, a web 400 of substantially gas permeable material is heat sealed at 402 to the top of the peripheral flange 404 of a tray 406. A frustoconical tube S extends upwardly from ledge 410 and terminates in an opening 412 that is slightly above the level of the outer flange 404. After heat sealing web 400 to the flange 404, the web 400 overlying the opening 412 contacts the upper edge of the frustoconical member thus forming an effective valve to close the interior of the containers from the atmosphere. During evacuation of the master pack, the portion of the web 400 over the frustoconical member 408 will elastically extend away from the aperture until the gas inside the package is completely withdrawn, allowing full evacuation of the individual container. This occurs because the air/gas pressure inside the package is greater than the air gas pressure outside the package 406 during evacuation. When gas flushing occurs, which immediately follows evacuation, the web at the opening 412 will again be elastically extended and lifted off the rim of the frustoconical member 408. This again occurs because a partial vacuum remains in the recess of the dome 414 overlying the frustoconical member. Moreover, during gas flushing, at least the initial pressure in the container is less than that on the outside thus allowing gas pressure on the outside to distend the web 400 away from the opening 412. After equilibration, the tension of the web 400 over the rirn of the frustoconical member 408 remains so as to effectively close it and prevent ingress of undesirable material into and/or egress of juice or matter from the container 406.
Embodiment 4 Referring now to FIGURES 19-22, another alternative arrangement for a valve structure similar in operation to that shown in FIGURES 17 and 18 includes a tube 700 that extends upwardly from the upper surface of ledge 702. The tube is connected to the ledge 702 by a concentric bellows structure 704 that allows the tube 700 to move upwardly and downwardly relative to the ledge. In practice, the upper lip of the tube (which forms an opening into the tray from the outside) is in contact with the web. The dimple 710 resides over the upper edge of the tube 700.
During evacuation and gas flushing, the web 708 will distend away from the lip of the tube in the same manner as described in conjunction with FIGURES 17 and as shown in FIGURE 20. however, the tube may be more permanently closed by depression and reversal of the dimple 710. Full reversal of the dimple 710 would push the tubes 700 downwaudly against the resistance of the bellows structure F24, AMENDED SHEET

thus, forming a very tight closure between the upper lip 700 of the tube and the bottom surface of the reversed dimple 710.
Embodiment 5 Referring now to FIGURE 6, another embodiment of a tray with valve constructed in accordance with the present invention is shown. In this embodiment, the tray 146 has an upper peripheral flange 148 that extends outwardly from the entire upper periphery of the tray 146. The tray sides extend downwardly to the horizontally disposed bottom. A downwardly extending recess 150 is cut in the tray corners. The edges of the recess 152 communicate with the interior of the tray. At the inner portion of the recess, the recess and the wall of the tray terminate in an opening 154 having its upper edge at the same level as the upper surface of the flange 148. The opening 154 functions in a similar manner as the apertures in the tray 202 shown in FIGURE 7. However, in this embodiment, if the tray is tipped, undesirable juices can flow into the recess 150 and hack out through the edges of the recess 152. In this manner the undesirable juices/liquids will not easily exit the package through the opening 1~4.
Trays constructed in accordance with the present invention provide a closeable ventilation mechanism. In addition, trays constructed according to the present invention provide for ledges which allow the trays to be stacked in a convenient fashion in master bag or master containers as shown in FIGURE 5.
Further, valves according to the present invention may be one way only valves.
Master Containers, Master Baas Packaged trays constructed according to the present invention can be stacked in master containers, evacuated and flushed with desirable gases, and the master container can be sealed to enhance the shelf life of the packaged goods.
A description of the master container method of packaging perishable good according to the present invention will now be described with reference to FIGURES 5, 10-13, and 16.
One of the aforementioned trays make suitable packages for use with the master container method provided the tray includes foldable flaps and channels providing communication from the interior of the package to the exterior surrounding environment, for example the tray of FIGURE 10. Referring now to FIGURE 11, the package can be used to store and transport red meat 330, for example, ground beef.
In accordance with the present invention, the ground beef 330 may be ground in a conventional grinder. The grinder may be modified so that preconditioned carbon AMENDED SHEET

dioxide at a predetermined temperature is injected into the grinder head for two purposes. The first is to cool the grinder head; the second is to allow the carbon dioxide to mix with the ground beef 330 and become dissolved in the liquid therein.
The dissolved carbon dioxide will aid in preservation of the ground beef during the storage period. A web 328 of substantially gas permeable material is then placed over the tray 300 and heat sealed to the flange 310 in a conventional manner as shown in FIGURE 12. The web is taut over the top of the red meat to prevent its movement about the tray during handling. A label 332 may be applied to the upper surface of the web 328 if desired. Alternatively, a dual web can be employed as shown in FIGURE 1 and a label sandwiched therebetween: Thereafter, the flaps or movable flanges 322 are folded over the top of the flange portions 310 so that the dimples 326 reside over the apertures 320. However, any of the aforementioned trays with valves can be used. The flaps 322 are then further heat sealed along their outer edges to the flanges 310 at a second heat sealing station to form a completed package as shown in FIGL))~ 13.
Referring now to FIGURE 16, a preferred embodiment of a master container constructed according to the present invention is shown. The master container can be thermoformed from substantially gas barner materials such as unplasticized PVC or alternatively a coextruded material including amorphous polyethylene terephthalate and polyethylene glycol. The material can be formed with the polyethylene glycol layer on the inside of the tray allowing exposure to the web of PVC material for heat sealing. The master container 334 includes flange 336 located around the periphery of the ~:pper portion of the container 334. The master container containing finished packages 300 with perishable goods therein are evacuated and flushed with a gas of suitable composition. The master container can be sealed by a web of material to the flange 336.
As shown in FIGURE 16, a plurality of trays 300 may then be positioned in a master tray 334. For example, in a 3 high by 4 wide array. In accordance with the method of the present invention, the master tray 334 can then be evacuated and flushed with substantially oxygen free gases. At the same time, the individual packages 300 are evacuated through the apertures 320 and flushed with inert gases that enter the individual pacl~:uges through apertures 320 as well. A package formed in accordance with the present invention allows the use of relatively large aperture 320, which in turn enables very rapid evacuation and gas flushing of the individual packages. With the disclosed system it is estimated that only a few AMENDED SHEET

seconds will be needed to completely evacuate and gas flush the master tray 334 and individual trays 300. After the containers are evacuated and flushed, a master web 338 is heat sealed to the top of the master tray 334. To form a completed master tray 334, if desired, an oxygen absorber may be inserted in the master tray 334 so that it is assured that the residual oxygen content in the package will stay below about 0.05%. This low level of oxygen is required to prevent irreversible oxidation of the deoxymyoglobin in the red meat and forming of metmyoglobin.
Once the package reaches its destination, it can be stored for several days in a sealed condition. When it is time to display the meat, the master web 338 is removed i0 from the master tray 334 and the individual packages can be weighed and labeled.
At that time, oxygen reenters the individual packages 300 through the aperture 320 as well as through the substantially gas permeable web 328. The oxygen converts the deoxymyoglobin in the red meat to oxymyoglobin, giving the meat a very fresh red appearance. Before placing the package in the display case, the dimple 326, one embodiment of which is shown in FIGURES 14-15, is depressed so as to close the aperture 320 which prevents the entry of undesirable elements such as insects into the package, and also substantially seals the package so that juices from the red meat cannot escape from the container if it is tipped on end.
Refernng now to FIGURE 5, a preferred alternate master bag container constructed according to the present invention is illustrated. Trays constructed according to the present invention can be stacked conveniently atop one another because the trays have been provided with flaps which fold inwardly to provide a ledge for a tray resting atop another tray can rest. Once trays are placed inside a master container as shown in FIGURE 5, the gas inside the master bag and trays can be evacuated through opening 140, because trays constructed according to the present invention include valves which allow the interior of sealed trays 136 to also be evacuated, and then flushed with a gas of desirable composition. The gas is preferably inert and substantially oxygen-free so as to reduce oxidation of the edible products in the packages 136 during storage. The number of cycles which are necessary to lower the level of the undesirable gas will vary. Once the master bag reaches an intermediate processing station prior to delivery to the location of point of display, it can be opened and flushed with high oxygen atmosphere containing 80% 02 + C02. The packages can be weighed and labeled. Then the dimples may be depressed to close the perforations in depressions at this station or alternatively left open. In some alternates of the present invention, the trays are AMENDED SHEET

provided with one-way valves which eliminates the need for dimples. Other alternates of trays may have no valves, because these packages will have been packaged in a low oxygen atmosphere. After this step, the trays can then be replaced into a master bag at which time the interior can be partially or completely evacuated and flushed with a high oxygen content gas such as 80% 02 + C02. The master bag can then be heat sealed again. In this way, extra days of shelf life can be obtained because the CO2 will tend to inhibit bacterial growth.
This method of packaging can be advantageously used for other types of higher value products such as tomatoes, grapes, peaches and the like.
Referring again to FIGURE 5, an alternative to -evacuating - the -bag 138, includes an oxygen absorber such as an iron compound that can be placed in a container 142 in the master bag 138. Thus, instead of or additionally to evacuating and flushing with an inert or substantially oxygen free gas, the oxygen-absorbing compound quickly absorbs all remaining oxygen in the bag leaving only nitrogen and other inert gases that will not adversely affect the condition or value of the food or red meat products in the containers.
In practice it is possible that all features described above will be incorporated into individual retail package structures. With the valve arrangement, free passage of air and/or gas through the aperture is essentially restricted. In addition, small microperforations in the overlying web may be employed to allow more rapid gas/air exchange than would otherwise occur through a normal substantially gas permeable material such as plasticized polyvinyl chloride. Such microperforations would facilitate more rapid reoxygenation of the deoxymyoglobin and generation of a desirable bright red meat color.
Soaker Pads Soaker pads provide absorptive materials to absorb liquids exuded by the packaged goods. Soaker pads constructed according to the present invention include bacteria sensing materials.
Referring now to FIGURE 22, a tray constructed according to the present invention is shown. Tray 800 is configured similarly to that of the tray shown in FIGURE 10, and carries a soaker pad 802 that lies on the bottom of the tray. A
plan side view of soaker pad 802 is shown in FIGURE 24 and a cross-sectional view 25 is shown in FIGURE 23. The ground beef 804 or other edible material is positioned on the soaker pad and first and second webs 806 and 808 of heat sealable material are placed over the tray and sealed to the horizontal flanges 810 that extend outwardly '~g~ AMENDED SHEET

from the upper edges of the tray. The label 812 is included of a special polymeric material that has the capability of indicating the presence of E. coli bacteria. This material may be laminated into a three-layer web including polypropylenelE.
coli sensor material/polypropylene or polyethylenelsensor material/polyethylene.
The polymeric material employed is of the type disclosed in the paper entitled "A
Litmus Test for Molecular Recognition Using Artificial Membrane," Charych, D. et al.
Chemistry and Biology, Vol. 3, No. 2, February 1996, 3:113-120, expressly incorporated herein by reference. The lower web 806 may be microperforated in the region of the label 812 so that juices from the ground beef 804 can penetrate the web and contact the label 812. The label 812 will change color in the presence of E. cola bacteria. The upper surface of the label can also be treated so that it may be printed with instructions relating to the E. coli test and/or information relating to the ground beef 804 or other edible product. A detail of the webs 806 and 808 carrying the litmus test label 812 is shown in FIGURE 25.
Alternatively, as shown in FIGURES 24 and 25 (a cross-section of FIGURE 24 along section line 25) shows that the container for the soaker pad can be made of the laminated three-layer web described above containing as the middle layer the litmus test sensor material. In this embodiment, the absorbent material 814 in the soaker pad 802 is encased in an upper web 816 of the tri-layer test material and a lower web 818 of the same test material. It is heat sealed around the entire periphery 820 and placed in the bottom of the tray 800 (FIGURE 22).
Both webs 816 and 818 are microperforated so that juices from the red meat 804 can penetrate to the absorbent layer 814. The presence of E. coli will be shown by a change in color of the test material in the web 816 and 818.
FIGURE 26 illustrates a tray 800 similar to that shown in FIGURE 22.
However, this tray carnes a plurality of ground beef patties 822 that are interleaved with layers 824 of the test material. In this manner, the presence of E. coli bacteria can be ascertained at a variety of locations in the package.
Apparatus and Methods for the Manufacture of Soaker Pads Referring to FIGURES 27-30, a side elevation (FIGURE 27) and a plan view (FIGURE 28) of an apparatus for manufacture of soaker pads with the engineered polymerized molecular film of the type that detects E. coli and indicates its presence by a change of color [EPMF] attached to an inner surface of a side of the soaker pad is illustrated. A roll of coextruded transparent, perforated, plastics materia1900, including a rolled length of web 902, is mounted on an unwind stand 904 and the end AMENDED SHEET

of the web is "threaded" around a series of drive and idler rollers, 906, 908, 910, 912, and 914 such that when drive rollers 908 and 914 are driven, the web 902 is pulled over the drive roller 908 so that the inside surface of the web 902 contacts the surface 922 of the water 918 flowing through the trough 920. The trough 920 is connected to a conventional Langmuir-Blodgett water trough in such a manner as to cause water 918 to flow, from the Langmuir-Blodgett water trough, horizontally, underneath and parallel to web 902 and at a similar rate of flow to the speed of the forward movement of the web 902 as controlled by the rate of revolutions of drive roller 908. The Langmuir-Blodgett water trough is provided to generate sufficient quantities of EPMF as required by the process. The EPNiF floats on the surface of the water 918 and is carried with the flow of water at a similar speed.
When the web 902 contacts surface 922, the EPMF is transferred from the water surface to the web 902 and travels adjacent to a drying section 924 that evaporates any surplus water.
The web 902 is transferred from a vertical disposition across drying section 924 to horizontal by way of movement over the idler roller 910. Soaker (absorbent) pads 942 are positioned onto the surface of the web 902 and a further perforated web 930 is unwound from roll 932 mounted on unwind stand 934. The two webs, with absorbent pads therebetween, are transferred, between two drive rollers, 914 and into a heat sealing station 936. The heat sealing station seals the two webs 902 and 930 together by applying pressure through two sets of temperature controlled heat sealing bars 9362, 936b shown in FIGURE 30. The pressure applied is sufficient to distort the EPMF layer 960 and allow direct contact of the web 902 and 930 surface layer material (SURLYN is a registered trademark of Dupont), which is an ionomer resin and the SURLYN readily bonds together. Webs 902 and 930 are composites which include an outer and inner layer, 962, 964, 966 and 968, respectively. The longitudinal slitting station 938 slits and separates the sealed soaker pads into continuous strips and the lateral cutting station 940 cuts across the webs thereby separating the complete soaker pads.
Trays_ with flaps. Trays with Channels Trays with flaps and trays with channels which are constructed according to the present invention provide sturdier stackable trays which are able to be evacuated of air and flushed with inert gasses and additionally provide channels and spaces to retain any liquids exuded from the processed goods.
AMENDED SHEET

Embodiment 1 Refernng now to FIGURE 31, a preferred packaging tray 3000 with flaps, is shown in a three dimensional drawing. The tray and flaps 3002 can be thermoformed from suitable materials such as polystyrene, polyester and polypropylene in a solid or S foamed sheet. The tray 3000 is most preferably thermoformed from an expanded polystyrene sheet of suitable thickness. Tray 3000 includes a base with perforations 3004. Four upwardly extending sides terminate at a common flange 3006. Flaps 3002, 3050, 3052 and 3054 are attached to flange 3006 at the external edge of flange by way of hinges at a hinge lines as shown. Flap 3002 is provided with a profile that mirror images flap 3052, and flap 3050 is provided with a profile that mirror images flap 3054. Flaps are attached to the outer edge of flange rim at hinges as shown, such that flaps 3002, 3050, 3052 and 3054 will fold downwardly and intimately contact outer surfaces of the tray walls. The cross-sectional profile of flaps 3002, 3050, 3052, 3054 are similar, flap 3002 and flap 3052 being of substantially similar dimensions, and flap 3050 and flap 3054 being of substantially similar dimensions. Flaps are formed with a rim 3008 that follows a continuous path around the perimeter of the flaps. Flaps include a profile which includes a flap base 3010, a flap flange wall 3012 and external flap vertical walls 3022. Buttresses 3016 are formed into flap profile and connect flap flange wall 3012 to flap base 3010. Horizontally disposed ridges 3018 and 3020 provide horizontal channels that connect buttresses 3016 with continuous communication to openings at each end of flaps in flap vertical walls 3022. Apertures 3014 are provided between the ridges. Apertures 3014 thereby provide communication through flaps at locations between the buttresses. Apertures 3026 are provided in upwardly extending walls of tray at points adjacent to buttresses such that when flaps are folded into a vertically disposed position relative to tray, apertures 3026 provide direct communication through tray walls to buttress recesses 3024.
Referring now to FIGURE 32, a three dimensional sketch of the tray 3000 with flaps folded downwardly, is shown. Flaps are folded to a downwardly position, such that flap flange wall 3012 is in contact with the underside of flange 3006. In this position, flaps are located in close proximity and in contact with upwardly extending tray sides. Flap base 3010 is substantially horizontally disposed relative to tray and provides an extension to base of tray such that when tray with flaps folded as shown in FIGURE 32 is placed directly above a similar tray, flap base is adjacent to and resting on flange 3006. It should be noted that while packaging shown in 3yAMENDED SHEET

FIGURE 31 includes a tray with four flaps, any number of flaps from one to four may be provided according to preference and any specific requirements of a particular application.
Referring now to FIGURE 33, tray base 3028 is shown with perforations therein. Perforations 3004 may extend directly through tray base or partially therethrough from either side. Perforations can provide absorption of liquids that may accumulate adjacent thereto, by the open cell structure of the tray base material, such as when the tray has been thermoformed from expanded polystyrene sheet which is, at least in part, of open cell structure. A space 3030 is shown which can be provided if desired. Space 3030 can be provided after tray with flaps is inserted into a pre-formed shrink bag that is then exposed to elevated temperature that can cause the shrink bag to shrink around the tray with flaps. Alternatively, tray with flaps profile can be arranged such that space 3030 is substantially minimized when the tray base is in direct and intimate contact with the shrink bag. Shrink bags may be printed as required with information of interest to any person interested in purchasing the finished package. Such shrink bags are manufactured for example by Robbie Manufacturing Inc., and are well known by the name PromoBag TM. Shrink bags can be printed and fabricated from a clear, biaxially-oriented, heat shrinkable, anti-fog, polyolefin film material manufactured by E.I. Dupont De Nemours and known as Clysar AFG anti-fog shrink film. Clysar is a registered trade mark of Dupont, details of which can be obtained from Dupont or on the Internet at www.clysar.com.
Refernng now to FIGURE 34, a finished package is shown. The finished package may contain perishable goods such as fresh red meats or fresh ground meats.
Apertures 3032 can be provided at optimized locations and/or as shown, in the outer cover shrink material 3034 of the finished package 3036. Apertures 3032, which may be provided in the bag or web of shrink material before or after package assembly, thereby providing direct communication from external atmosphere through space 3038, apertures 3032, buttress recess 3024 and apertures 3026, and into the tray cavity 3040. A plurality of finished packages can be located inside a barrier master container as shown in FIGURE 35 or any other master container/bag previously described above. Such barrier master container may be thermoformed from a substantially gas barrier plastics material, such as a co-extruded multi-layer sheet of nylon//PVDCI/polyethylene. After inserting finished packages into the barner master container, the master container can be located inside a vacuum chamber and substantially all atmospheric gases can thereby be evacuated from 32:' AMENDED SHEET

within the barrier master container, and within the finished packages. A gas or blend of suitable gases such as carbon dioxide, nitrogen, oxygen and any other suitable gases, can be provided into the barner master container and the finished packages prior to hermetically sealing a substantially gas barrier lid to flanges of the barrier master container. A plurality of barner master containers can then be positioned into a suitably sized shipping case as shown in FIGURE 35, prior to shipping to another location.
Referring to FIGURES 35-36, in yet another preferred embodiment, the master container 3226, with one or more finished packages, 3224, contained therein and including a "loaded master container", may be located inside a pressure vessel that is also arranged to operate as a vacuum chamber with gas flushing. After location of the "loaded master container" inside a pressure vessel, the pressure vessel is closed and sealed from atmospheric air and substantially all air is evacuated to a desired and predetermined level. Following evacuation, the pressure vessel can be filled with a desired gas such as carbon dioxide to a predetermined, controlled and maintained pressure, above atmospheric pressure, such as 12 psi or up to 250 psi or higher, and held at a predetermined pressure for a period of time that will allow sufficient carbon dioxide gas to dissolve in the perishable goods contained in the finished packages in the master container. Carbon dioxide gas can be held at the pressure, for a period of time, as required to prolong the subsequent storage life of the perishable goods. Folluwing the period of time, the gas pressure may be lowered to a pressure equal to that of the prevailing atmospheric pressure and a gas barrier lid then hermetically sealed to the flanges of the master container prior to opening the pressure vessel and removing the master container. The aforementioned process may include the steps of:
i) Locating a master container, 3226 with finished packages such as those shown as 3224 contained therein, into a suitable pressure vessel.
ii) Closing and sealing the pressure vessel so as to isolate it from atmospheric air.
iii) Evacuating substantially all air from within the pressure vessel.
iv) Providing a gas such as carbon dioxide in the pressure vessel at a pressure above atmospheric pressure.
v) Holding the pressurized carbon dioxide provided in the pressure vessel for a period of time sufficient to enhance the keeping qualities of the perishable goods contained i~~ the finished packages 3224 , for an extended period.
x,_f AMENDED SHEET

vi) Lowering the gas pressure within the pressure vessel, to a level equal to the prevailing atmospheric pressure.
vii) Hermetically heat sealing a gas barrier lid to the flanges of the master container so as to substantially exclude oxygen gas from inside the master container.
viii) Removing the master container from the pressure vessel automatically.
ix) Locating another master container in the pressure vessel by automatically and repeating steps l). to viii). in an automatic fashion.
x) Placing and sealing the master container into a finished shipping case as shown in FIGURE 36 which may be constructed of cardboard material with a crush test rating of 44. lbs. per inch.
xi) Shipping the finished container to another location.
xii) Removing the finished packages from the finished shipping case and allowing atmospheric air to penetrate through the apertures in the finished package.
xiii) Repeating any or all of the above steps as required to maximize the keeping qualities of the perishable goods.
Refernng again to FIGURE 33, it can be seen that by manufacturing packaging in this manner, any liquids that may accumulate within the tray cavity 3040, such as blood, will be substantially restricted from escaping through apertures 3032 shown in FIGURE 34. This restriction is provided due to the arrangement of flaps and apertures therein, and the location of the apertures.
Furthermore, perforations 3004 provide for retention of the liquids within the package.
Embodiment 2 An alternate embodiment of a tray with flaps constructed according to the present invention is shown in FIGURES 37-41. The tray of FIGURE 37 includes four flaps as the tray of FIGURE 31, with modifications as described herein.
FIGURE 37 shows the cross-sectional detail of a tray. The tray walls are perforated in sections shown as incision section 3526 and incision section 3528, shown in FIGURE 39. Perforations may be in the form of small holes or incisions that extend fully through the tray walls, but may be only provided within the limits of regions shown as incision sections 3526 and 3528.
Referring now to FIGURE 37, a cross-sectional view of finished package 3514 is shown. Finished package 3514 includes a packaging tray 3556 with perishable goods located in tray cavity with an outer cover 3516. The outer ~~4AMENDED SHEET
~,A~u~.,:

cover 3516 includes an envelope of material that completely covers and encloses the packaging tray and the perishable goods and is heat sealed to provide a sealed package. The outer cover 3516 may be manufactured from a shrink material such as Clysar, manufactured by DuPont, and can be printed such that all surfaces are rendered opaque leaving a transparent window 3522 on the upper surface only, as shown in FIGURE 38 of the finished package. Clysar outer cover shrink material is then heat shrunk such that the outer cover shrinks, holding the flaps against the tray walls. Apertures 3518 are provided on the four vertical faces of the finished package when the base 3520 of tray is horizontally disposed.
i0 Referring now to FIGURE 39, a detailed section of a packaging tray 3556 with base 3520, tray wall 3524 and flange rim 3512 attached to flap 3508 at a hinge 3532, is shown. The relative position of flap 3508 and the section of tray is in the "open position". Flap 3508 is attached at hinge 3532 to flange rim 3512, however flap 3508 is not folded downwardly.
Referring now to the flap portion 3508 of FIGURE 39, a cross-section is shown including a first and second raised peaks 3534 and 3536, respectively, and a flat area shown as face 3538 and face 3540; also shown are a ridge 3542; and gussets 3544, with connecting sections therebetween. Packaging tray includes a base 3520, flange rim 3512 with tray wall connecting base of tray to the flange rim.
Tray wall includes recess 3546, a first incision section 3526, recess 3548 and a second incision section 3528. FIGURE 40 shows a view of flap from the direction of arrow 3608. Flap 3508 includes a perimeter 3530 including hinge 3532, face and end flanges 3550 that are connected together to provide the continuous flat perimeter. Referring now to FIGURE 40, depressions 3552 may be provided in the flap section between peak 3534 and ridge 3542 but do not perforate the section to provide direct communication therethrough. Apertures 3554 are also provided in face 3540.
Refernng now to FIGURE 41, an enlarged view of a tray portion of FIGURE 37 is shown. Flap and the tray wall are in intimate adjacent contact and ridge 3542 and recess 3546 are engaged. Faces 3538 and 3540 as shown in FIGURE 41, are in direct and intimate contact with the tray wall. Face 3540 is located in recess 3548, thereby closing apertures 3554 when in this position.
Spaces 3560 and 3558 are directly adjacent to first and second incision sections 3526 and 3528. Shrink film 3516 holds flap firmly and tightly against the tray wall providing sealed contents within the finished package. The package may be AMENDED SHEET

colorized to prevent translucency. An adhesive such as a cold seal latex is provided between the continuous perimeter 3530 of the flap as shown in FIGURE 40. The tray wall is inwardly flexible such that when a vacuum is provided within the tray cavity, the recess 3548 and face 3540 will separate to provide direct communication from within the tray cavity via perforations or incisions at first and second incision sections 3526 and 3528 through apertures 3554, and through apertures 3518 in outer cover shrink film 3516.
A plurality of finished packages 3514 of this embodiment can, as well, be stacked and placed inside a gas barrier master container inside a vacuum chamber.
Substantially all the air may be evacuated from within the gas barrier container and .
from inside the finished packages. Air is evacuated from within the packaging tray cavity through perforations andlor incisions in the tray wall at first and second incisions 3526 and 3528 into space 3560 and 3558, created when the fjap is placed adjacent the tray wall, the air flows through apertures 3554 and apertures 3518. A
suitable gas or gas blend such as nitrogen and carbon dioxide can then be provided into the vacuum chamber. The desired gas can be provided in a reverse flow direction into the finished packages by way of direct communication through apertures 3518, apertures 3554 into spaces 3560 and 3558, through perforations at incision sections 3526 and 3528 and thereby fill all free space within the finished packages and the gas barrier master container. A gas barrier lid can then be hermetically heat sealed to the opening of the gas barrier master container and the finished packages in the hermetically sealed master container can then be stored at a controlled temperature for a desired period of time prior to opening the master container and removal of the finished packages for retail sale.
In this way air and gasses can be removed from the finished and sealed packages by evacuation and then replaced by gas flushing with a desired gas, while liquids such as blood cannot readily escape.
Embodiment 3 Referring now to FIGURE 271, another preferred packaging tray with flaps constructed according to the present invention is shown in a three dimensional sketch. The packaging tray of this embodiment as with the packaging trays of previous embodiments is similar in operation, but with an alternate configuration of the channels through which evacuation and flushing is accomplished. The tray with flaps can be thermoformed from suitable plastics materials such as polystyrene, polyester and polypropylene in a solid or foamed sheet. The present packaging tray AMENDED SHEET

is preferably thermoformed from expanded polystyrene (EPS) sheet. T'he EPS
sheet may include an "open cell" structure with a surfactant added prior to extrusion of the sheet such that the finished tray will have a capacity to absorb water and other liquids such as "purge" or blood. The EPS sheet may be extruded with a "skin" on what will become the in-side of the finished tray. The "skin" can be arranged so as not to absorb the liquids. The non absorbent "skin" may be provided on both surfaces of the extruded sheet.
The EPS sheet may b~ a multi-layer extruded sheet including three layers.
The three layers may include two outer layers of closed cell EPS foam with an inner layer of open celled EPS foam. The outer layers may be close celled and resistant to liquids such as blood and/or purge. The inner layer of open celled >r'YS roam can be extruded with a suitable surfactant contained therein that will enhance the liquid absorbing qualities of the open celled EPS foam.
The tray with flaps, shown in FIGURES 271-272, is most preferably I5 thermoformed from expanded polystyrene sheet of suitable thickness, of preferably from about 0.01" to about 0.15", and most preferably about 0.090" and including at least two layers including a "skin" that will not absorb the liquids and an adjacent layer of open cell structure that will absorb the liquids. FIGURE 271 shows detail of the packaging tray with flaps extended and including a tray with tray cavity and four flaps shown as flap 7002, flap 7004, flap 7006, and flap 7018. Flap 7002 is provided with a profile that mirror images flap 7006, and flap 7004 is provided with a profile that mirror images flap 7018. Flaps 7002, 7004, 7006 and 7018 are attached to the outer edge of flange rim 7010 at hinges 7012 as shown, such that flaps 7002, 7004, 7006 and 7018 will fold downwardly and intimately contact outer surfaces of the tray walls. FIGURE 272 shows the packaging tray with flaps folded downwardly. The cross-sectional profile of flaps 7002, 7004, 7006 and 7018 are similar. Flap 7002 and flap 7006 being of substantially similar dimensions, and flap 7004 and flap being of substantially similar dimensions, but can be longer or shorter than flaps 7002 and 7006. Referring yet again to FIGURE 271, the packaging tray includes a base with four upwardly extending tray walls terminating at a continuous flange rim 7010. The tray walls can be perforated with openings directly therethrough with the perforations arranged in sections shown as a first incision section 7014 and a second incision section 7016. The perforations may be in the form of small holes or incisions that extend fully through the tray walls, but are preferably provided within the limits of regions shown as first and second incision S7' AMENDED SHEET

sections 7014 and 7016, respectively. Apertures provided in sections 7014 and preferably extend into spaces between flaps and tray walls. Apertures 7020 provide a passage for evacuating and flushing the tray in a master container, as previously described.
Embodiment 4 In another embodiment shown in FIGURES 45-49, a gap 4126 is provided between the flap at openings 4128 and the tray wall. The flap 4106 is in a folded down position and a gap 4126 is arranged between openings 4128 and the tray side wall. Spaces 4130 and 4132 are directly adjacent to incision sections 4118 and 4116.
The shrink film holds the flap firrrily and tightly against the tray wall. An adhesive such as a cold seal latex, or any other suitable adhesive may be provided between the flaps and the tray walls so as to cause sealing and bonding where contact between the flaps and the tray walls occurs. FIGURE 46 provides details of a cross-section through a section of the tray wall and the flap that are in direct contact. A
"skin" 4134 is shown on the outer surfaces of the section directly adjacent to EPS
foam that is bonded together by adhesive layer 4146 causing a secure bonding and sealing of the tray wall and the flap together. The sealing and bonding can be arranged so as to provide a completely sealed and "liquid tight" condition such that any liquids contained in the spaces 4130 and 4132 will be retained within the spaces.
As shown in FIGURE 49, an adhesive layer 4142 can be provided between base and outer cover 4120 so as to bond the outer cover 4120 to the base 4138.
Referring now to diagram FIGURE 47, an elevation of finished package 4118, is shown. Toe finished package 4118 includes a packaging tray as shown in FIGURE 45 with perishable goods located in tray cavity with an outer cover 4120. The outer cover 4120 includes an envelope of material that completely covers and encloses the packaging tray and the perishable goods and is heat sealed to provide a sealed package. The outer cover 4120 may be manufactured from a shrink material such as Ciysar, manufactured by DuPont, or alternatively a stretch wrapping material such as Mapac -M, a plasticized polyvinyl chloride web material manufactured by AEP Industries, Inc. The outer cover 4120 can be printed such that all surfaces are rendered opaque leaving a transparent window 4122 on the upper surface as shown in FIGURE 47. Clysar outer cover shrink material is then heat shrunk such that the outer cover shrinks, holding flaps against the tray walls.
Alternatively, if the Mapac -M, pPVC material is used, heat shrinking may not be required and the Mapac -M material is stretched over the tray with flaps such that 3$ AMENDED SHEET

flaps contact the tray walls. Apertures 4124 are preferably provided on the four vertical faces of the finished package. The apertures are conveniently located in such a location so as to minimize the probability of any liquids, such as blood or "purge", escaping therethrough.
The EPS material, which may contain a suitable surfactant, used in production of the packaging tray may be manufactured so as to have a capacity to absorb liquids such as blood. Incisions and/or perforations provided in sections of the packaging tray can enhance the capacity of the EPS material to absorb the liquids such as blood.
Referring now to FIGURE 48, an enlarged view of a cross section of the tray of FIGURE 45 is shown. The flap and the tray wall are in intimate contact and a gap 4126 is arranged between openings 4128 and the tray side wall. Spaces 4130 and 4132 are directly adjacent to incision sections 4118 and 4116. A suitable adhesive can be applied between the flap and the tray at all direct points of contact therebetween causing a secure bonding and sealing of the tray wall and the flap together. The sealing and bonding can be arranged so as to provide a substantially sealed and "liquid tight" condition such that any liquids contained in spaces 4130 and 4132 will be retained. The shrink film, outer cover 4120 holds the flap firmly and tightly against the tray wall. Referring now to FIGURE 49, a cross-section of the tray base portion and outer cover 4120 are shown to be in adjacent disposition. An adhesive layer 4142 can be provided so as to completely bond the outer cover to the base of tray 4138.
Furthermore, when the outside-surface of foam is arranged to have a capacity to absorb liquids, such liquids can be retained and substantially prevented from escaping from within the finished package. Additionally, a suitable adhesive can be provided between the tray flange rim 4144 and the outer cover 4120 where the continuous flange rim 4144 is in contact with the outer cover 4120 so as to cause bonding in a substantially liquid tight fashion therebetween. The openings at sections 4116 and 4118 in the tray wall, openings 4128 in the flaps and apertures 4124 in the outer cover 4120 provide a passage and direct communication from the tray cavity to the outside of the finished package such that when the finished package is exposed to a vacuum, air and gasses can be removed from within the package and replaced with a desired gas or mixture of gasses through the passage.
3g AMENDED SHEE r Embodiment 5 FIGURES 50-54 show yet another embodiment of a tray with flaps constructed according to the present invention. The tray 8208 of this embodiment is similar in operation to the trays described above. Refernng to FIGURE 50, a tray is S shown whereby flaps 8202 and 8206 can be arranged so as to have no openings therein, and flaps 8200 and 8204 can be arranged to have openings 8210 therein.
Tray 8208 as shown in FIGURES SO-54 can be over wrapped with a web of pPVC to produce a finished package. The web of pPVC can be printed on the inner surface with a heat activated coating that can provide a method of bonding the web of pPVC
~ to faces 8212 on flaps 8202 and 8206 and face 8214 on flaps 8200 and 8204.
The heat activated coating can be applied to the web of pPVC by typical offset printing process and applied in those areas of pPVC that will come into contact with the faces 8206 and 8214 after over wrapping the tray 8208 with the web of pPVC in such a manner that when heat is applied to the pPVC in contact with the faces 8212 and 8214 the web of pPVC will become bonded to the faces 8212 and 8214. The web of pPVC will thereby cover recess 8216 and recess 8218 in flaps 8200 and 8204 but will not fully enclose and isolate the recesses leaving openings at openings 8220.
The web of pPVC can also thereby cover recess 8222 and recess 8224 in flaps 8206 and 8202 but will not fully enclose and isolate the recesses leaving openings at openings 8226. In this way a path of direct communication from internal space of the tray to external atmosphere is provided through apertures 8228 into space shown in FIGURE 274 through apertures 8210 in flaps 8206 and 8202 only into recessed 8222 and recesses 8224 and through openings 8226 into space between the pPVC outer cover and tray through space 8230 and therefrom through openings into recesses 8216 and 8218 and finally through apertures that are provided in the outer cover pPVC adjacent to the recesses 8218 in flaps 8200 and 8204 to external atmosphere.
The tray 8208 may be thermoformed from any suitable material such as expanded polystyrene EPS materials as shown in FIGURES 242-246 and FIGURES 71-72. The EPS materials may include several layers of co-extruded material that are arranged so as to allow any liquids that may enter space 8230 of FIGURE 274 through apertures 8228 to be absorbed into the open cell structure of EPS materials through surface perforations 8250 that can be provided into the surface of the EPS materials that are adjacent to space 8230 only. Liquids can thereby be concealed within the layers 4502 or 4508 as shown in FIGURES 229-230.
e:..
~c~AMENDED SHEET

The pPVC outer cover can be bonded to the underside of the tray 8208 by any suitable method, such as heat sealing or adhesive bonding, so as to follow contours of recess 8232 shown in FIGURE 51. The pPVC outer cover can also be bonded, by any suitable method, such as heat sealing or adhesive bonding, to flange rim along the full length and perimeter thereof so as to inhibit liquids from passing between the flange rim 8234 and the pPVC over wrapping web of material after the bonding.
In this way liquids that may accumulate in internal space of tray are restricted from escaping from within the finished package, while providing a path to allow extraction and injection of suitable gasses into and out of the internal space of tray.
In another preferred embodiment the flaps may be extended as shown in FIGURE 54, flap 5056 to provide additional cushioning around the perimeter.
The additional cushioning can provide protection of the package and the package contents during shipping from the point of production of the finished packages and a point of sale to consumers such as a supermarket. FIGURE 273 shows a tray flap with a space wherein substances 8250 may be added, such as wax-coated iron particles.
FIGURE 274 shows a cross section of a tray with flaps, wherein the flaps form a plurality of spaces between the tray wall and the flap (outer wall).
Embodiment 6 Refernng now to FIGURE 55, yet another preferred packaging tray 5200 with flaps, is shown. The flaps are shown folded into a desired position and bonded to the tray base and/or walls. The packaging tray with flaps can be thermoformed from suitable plastic materials such as polystyrene, polyester and polypropylene in a solid or foamed sheet. The present packaging tray is preferably thermoformed from expanded polystyrene (EPS) sheet. The EPS sheet may include a single or multi-layer construction as shown in FIGURE 59. Any suitable sheet of EPS material may be used but most preferably the sheet includes 3 layers 5204, 5206, and 5208.
The layer 5204 preferably includes a layer of solid plastic material such as polystyrene sheet with any suitable thickness, preferably about .001" and is laminated to layer 5206. Layers 5206 and 5208 preferably include "closed" or "open cell"
structures either with or without a surfactant added prior to extrusion of the sheet such that the finished tray may have a capacity to absorb water and other liquids such as "purge" or blood. The EPS sheet may be extruded with a "skin" covering on a surface that will become the in-side of the finished tray. The "skin" can be arranged so as not to absorb the liquids. The non-absorbent "skin" may be provided on both t~~, zl~AMENDED SHEET

surfaces of the extruded sheet. The layer 5204 may contain a white or other suitable pigment, such as white titanium dioxide in such a quantity so as to prevent visibility of any discoloration that may be caused by blood or purge absorbed by layers or 5208. In this way the layer 5204, which will be visible, will not show substantial discoloration as a result of blood or purge that has been absorbed by any of the other layers.
Tray 5200 with flaps is most preferably thermoformed from sheet material of suitable thickness, preferably about 0.01" to about 0.15" but preferably about .090"
and includes a tray with tray cavity and four flaps. Two flaps are shown as flap 5210 and flap 5212. Flap 5210 is an end flap and flap 5212 is a side flap. The construction of tray 5200 with folded and bonded flaps, allows for production of suitably rigid finished trays even though the thickness of the sheet material from which the tray is formed, is substantially thinner than would otherwise be required in conventionally formed packaging trays that do not have "flaps".
Flap 5210 can be provided with a profile that is a mirror image of 5214 (not shown), and flap 5212 can be provided with a profile that is a minor image of flap 5216. Flaps 5210, 5212, 5214 and 5216 are attached to the outer edge of flange 5218 at hinges as shown by the hinge lines, such that flaps 5210, 5212, and 5216 can be folded downwardly and intimately contact outer surfaces of the tray walls at locations as required. One or more flaps may be provided and folded to provide an enclosed space 5222 and/or cavity 5220 shown in FIGURE 58. The cross-sectional profile of flaps 5210 and 5214 axe similar. The cross-sectional profile of flaps 5212, and 5216 can be similar.
Referring again to FIGURE 55, the packaging tray includes a base with four upwardly extending tray walls terminating at a continuous flange 5218. Tray walls can be perforated with openings 5224 directly therethrough with the perforations arranged so as to communicate between the tray cavity and space 5222. The apertures 5224 can be located so as to allow any purge that may be present in the tray cavity 5226 to pass therethrough and into space 5222. The perforations 5224, may include small holes, slots or incisions that extend fully through the tray walls. The flaps can be bonded to the tray walls so as to retain any liquids that enter therebetween and into space 5222. Any suitable liquid absorbing medium may be attached to one or more of the flaps so that when the flaps are folded and bonded the liquid absorbing material will be enclosed within space 5222. The liquid absorbing 4~' AMENDED SHEET

material could therefore absorb any liquids that may enter the space 5222 during use of the tray.
Referring again to FIGURE 55, recesses 5228 and 5230 are shown in flap 5212. Slots 5232 are shown in flap 5212 and are located in recess 5228.
Perforations 5234 are provided in flap 5212 and are located in recess 5228.
Recesses 5238 and 5240 are shown in flap 5210. A suitable adhesive is provided at the interface between flaps and tray walls so as to provide a bonding of flaps to tray walls. Bonding of flaps and tray walls is provided in such a manner so as to ensure complete bonding of flaps to the tray wall along strips that follow a path close to what will become a perimeter of the flaps. FIGURE 58 shows a cross-section through flap 5212 and tray wall showing enclosed space 5222. Space 5222 is enclosed between the flap and the tray wall in a substantially liquid tight manner.
Iron powder deposits 5244 can be applied to locations on the tray walls and flaps adjacent to space 5222 and also to the underside surface of the tray base. The iron powder deposits 5244 may include iron powder particles that have been fully coated with a special coating material, such as wax. The coating can be arranged to prevent direct contact of the iron particles with ambient air or any gas that may be present, until such direct contact with the air or gas is required. The coating may have physical andlor chemical properties that can be activated by exposure to microwaves, radio waves or a magnetic field. For example, when using wax as a coating, microwaves will cause the iron particles to heat up, thereby melting the wax and exposing the iron particles. The coating may also contain an adhesive that is heat activated and otherwise does not bond with other matter until activated and/or heated by exposure to any suitable microwaves, radio waves, magnetic field or any suitable electrically or sonically induced waves or field. The coated iron particles 5244 can be deposited on the surfaces by apparatus shown in FIGURE 140 herein. The coated particles can be coated with a substantially gas barrier substance that is altered when exposed to suitable microwaves or an electrically induced magnetic field.
Exposure to the waves, field or microwave can cause the coating gas barner substance to physically or chemically alter and become gas permeable, in such a manner that will cause the iron particles to immediately or subsequently react with any gases such as oxygen that may be present. The quantity of iron particles 5244 provided and attached to the tray and flap selected surfaces can be measured and controlled in an amount having an equal or greater capacity that may be required to absorb ~~' AMENDED SHEET

substantially all oxygen gas that may be present andlor become present by permeating into the finished package.
Refernng now to FIGURE 64, a plurality of finished packages that may be conveniently stacked as shown in FIGURE 62 may be placed in a gas barrier master container which can then be evacuated of substantially all air. Ambient air that may be present within the finished package tray cavities and spaces such as 5222 shown in FIGURE 58 will be evacuated through apertures 5306 and replaced with a suitable gas. The air can be replaced or displaced with any suitable gas prior to hermetically sealing the master container to provide a single container with finished packages enclosed and sealed therein. At a convenient time after sealing the sealed master containers may be exposed to a suitable level of microwaves or magnetic field or other suitable source of energy that will selectively alter the gas barrier coating on the iron particles so as to render it permeable and further activate iron particles to oxidize with any residual oxygen that may remain within the master container.
The substance "IPD" 5244 may include any suitable substance that can be applied in any convenient manner to the trays 5200 so as to remain inactivated until exposed to the microwave and/or magnetic field in such a manner as to render the IPD
activated.
When the IPD is selectively activated by any suitable source of energy that is applied before or after the trays are loaded with goods, the IPD can react with and thereby absorb any residual oxygen gas remaining within the finished packages, in such a manner so as to inhibit the formation of metmyoglobin that may otherwise be formed as a result of available oxygen that has been released during reduction of any oxymyoglobin that may be present in the finished package after sealing the master container.
The IPD can be applied in any suitable manner to selected surfaces of the tray and/or flaps so as to not directly contact but to be in close proximity to goods that is subsequently loaded into the cavities of trays. Ground or sliced red meats may have been exposed to ambient oxygen, after grinding or slicing and prior to packaging, for such a period of time that d~oxymyoglobin present in freshly cut red meats has reacted with ambient atmospheric oxygen to form oxymyoglobin. Fresh meat with oxymyoglobin may be then packaged in a substantially oxygen free gas package such as a barner master container tlmt has been evacuated and filled with any suitable gas that may contain less than 500 PPM oxygen. After packaging, the oxymyoglobin will reduce to deoxymyoghbin thereby releasing oxygen gas into the spaces in the master container. The released oxygen can then react with the deoxymyoglobin to AMENDED SHEET

form metmyoglobin. The metmyoglobin is brown in color and is undesirable and consumers are unlikely to purchase meat that is brown in color. The IPD
substance can be provided within the finished packages in such a manner so as to substantially absorb, and thereby render inactive, the oxygen that has been released by reduction of the oxymyoglobin to deoxymyoglobin, after hermetically sealing the finished packages. In this way the formation of undesirable metmyoglobin can be inhibited and/or minimized. In order to enhance the absorption of oxygen gas by the substance IPD, any suitable method to cause circulation and movement of any gas inside the finished package can be incorporated. Such methods may include shaking or suitable movement of the finished and sealed master containers in such a manner so as to cause gas to circulate through apertures 5306 from the spaces in the tray cavities and more particularly near and over the exposed surfaces of the goods.
In another alternate embodiment, the present invention provides capsules of suitable size but most preferably having a diameter or widest/longestldeepest dimension of less than 0.25", wherein capsules have a generally rounded, spherical or oval profile with a continuous capsule wall of any suitable thickness but most preferably approximately 00.060" thickness, with a cavity enclosed within the continuous capsule wall and wherein each enclosed capsule cavity contains a suitable quantity of any selected agent, substance or material, such as, for example, a bactericide, a water absorbing gel, a C02 generating agent. The capsule wall may be manufactured from a material such as wax or a flexible waxy plastics material that is affected by micro waves, RF (radio frequency) or a magnetic field that is generated from a controlled source and with such an intensity that it can cause the capsule walls to rupture or soften or dissolve and to such an extent that the contents of the capsule cavities will be expelled or allowed to escape from within the enclosed capsule cavity. A suitable quantity of capsules or combination of capsules containing separate quantities of several agents, with any selected agents) contained therein may be enclosed, for example, within the cavity(ies) of any suitable packaging tray prior to use in a packaging application. At any time during or after assembly of such a tray with capsules contained therein, it may be exposed to the appropriate source and intensity of micro wanes, RF (radio frequency) and/or a magnetic field and in such a way so as to cause the release of any agents contained within the cavity of the capsules. In this way, for example, a bactericide may be held until required for use within the package walls or base and after assembly of the package such as a tray containing fresh red meat, at which time the bactericide can be released and thereby AMENDED SHEET

made available to substantially kill bacteria, fungi, virus or any undesirable life form that may be dangerous to human or animal life.
Referring now to FIGURE 64, a finished package 5300 is shown with a seal 5324, that extends continuously around a horizontally disposed perimeter of the finished package. Seal 5324 is provided so as to bond an over wrap 5326, which is positioned above the seal 5324, to an over wrap 5328 which is located below the seal 5324. The seal 5324 can be provided by any suitable method such as by heating and is arranged to be a complete and continuous and gas tight seal along the full length of the seal 5324. The over wraps 5326 and 5328 may be either both clear and transparent or alternatively printed but most preferably the 5328 over wrap will be printed as desired. 5326 and 5328 may be produced from a substantially gas barner material such that when sealed along seaI5324 a hermetically sealed finished package is produced. Alternatively gas permeable plastic materials may be used to produce the over wraps. The profile of over wrap 5326 and 5328 may be provided by a thermoforming method prior to assembly of the finished package whereby a loaded tray 5300 is located into a thermoformed over wrap 5328 prior to sealing a thermoformed over wrap 5326 thereto at seal 5324. Alternatively, both over wraps 5326 and 5328 may be produced from a web of "stretched" material such as pPVC. The web of pPVC may be held taut above a depression where the depression is similar in profile to the lower section of tray 5300 but slightly larger so as to allow a neat location of tray 5300 therein. A vacuum can be applied in the depression so as to stretch the pPVC web therein and thereby provide a lower over wrap 5328.
Tray 5300 can be located into the stretched pPVC depression and heat sealed at to an over wrap 5326 that can be formed in a similar manner by stretching into an inverted depression, of suitable size, that is located directly above and aligned therewith so as to allow such sealing at seal 5324. Apertures 5306 may be provided in the over wrap 5328 or alternatively, over wrap 5328 may be maintained without apertures so as to provide a complete finished and substantially gas barner package.
In another preferred embodiment, iron powder that has been completely coated with a substance, such as a special type of wax, can be included in one or more layers of a tray thermoformed from a one, two, three or more layer sheet of co extruded EPS foam. The special type of wax coating can be arranged so as to prevent contact of undesirable substances such as water, with the powdered iron that is completely covered by the special type of wax coating, until a suitable time. The special type of wax coating can be arranged so as to melt or otherwise change when AMENDED SHEET

exposed to an electromagnetic field, microwaves or other suitable medium. The melting or change to the special type of wax coating can allow the powdered iron to become exposed and thereby react with oxygen gas that may be present, after exposure to the electromagnetic field, microwave or suitable medium. In this way trays, formed from the EPS foam with coated iron powder contained therein, can be used to package perishable gouds and when the tray with perishable goods has been over wrapped with a gas permeable web of plastics materials, can be located in a master container with a suitable gas, and all hermetically sealed so that the master container contains the over wrapped tray with perishable goods and a suitable gas.
Immediately after hermetically sealing the master container, the master container can be exposed to an electromagnetic field, microwave or other suitable medium, so as to change the coating and thereby expose the iron powder and allow reaction of the iron powder with any oxygen gas that may be generated within the master container as a result of reduction of oxymyoglobin.
Immediately prior to or after loading goods such as ground or sliced meats into the tray cavities, the trays 5320 can be exposed to a suitable level of microwaves or a magnetic field sufficient to cause coating SCM to be altered and thereby allowing the IPD to react with any oxygen that is present and in contact with the IPD.
In this way and due to the close proximity of the IPD to the oxymyoglobin, the oxygen that is released by reduction of the oxymyoglobin, can be quickly absorbed by the iron powder IPD as soon as it contacts therewith.
Pre-conditioning of the goods, prior to loading into the trays can reduce the quantity of oxymyoglobin formed immediately after slicing or grinding of the goods but before packaging and sealing in the master container. The pre-conditioning can include the process of exposing the goods to carbon dioxide or any suitable gas at any suitable pressure or high pressure immediately after and/or during slicing and/or grinding. The goods can be exposed to the gas at high pressure in such a manner that the gas becomes highly soluble in liquids and oils present in the goods, and dissolves in the liquids and oils. The goods can be exposed to high pressure gas for an adequate period of time to allow saturation of the liquids with soluble gas.
Saturation of liquids and oils will therefore occur at the high pressure. Therefore, when goods are removed from exposure to high pressure gas and returned to exposure to normal ambient atmosphere for subsequent packaging into finished package andlor master container, gas (or gases) that have dissolved in the liquids and oils will be then exposed to a lower gas pressure. Gas that has dissolved under the high pressure into AMENDED SHEET

liquids will be "released" and return to a gaseous condition. The release of gas will occur at the surface of goods and during this event, any oxygen that is present in atmospheric air will be inhibited from contacting the surface of the goods.
This procedure can therefore provide a method to slice and package goods while reducing and minimizing the formation of oxymyoglobin immediately prior to packaging and consequently minimizing the otherwise corresponding formation of metmyoglobin after packaging in the manner described herein. The pre-conditioning process can also include the method of lowering the temperature of the goods to any suitable "pre-conditioning" temperature that may be 28 degrees F prior to slicing and/or subsequent immersion in high pressure gas with exposure thereto.- After removal of the goods from immersion in and exposure to high pressure gas at a lower temperature the goods will be exposed to ambient atmospheric conditions which will be at a higher temperature and lower gas pressure. After packaging the goods in the finished package and/or master container, the packaged goods can be stored and 1S maintained within a suitable temperature range that may be higher than the "pre-conditioning" temperature. The pre-conditioning temperature may be maintained within a range of approximately 29 to 32 degrees F. The suitable post conditioning temperature range may be maintained between 33 to 36 degrees F. The difference between the pre-conditioning temperature and the post conditioning temperature may be less than 15 degrees F. Goods may be pre-conditioned by passing through a first tube at a suitable pressure where the first tube has a diameter of 'X' and is centrally located within a second tube that has a diameter of 'X' + I inch or more and thereby providing a space between the outer surface of the first tube and the inner surface of the second tube. A temperature controlled liquid such as brine or glycol can be provided in the space between the first and second tubes and thereby provide a cooling or heating devices that will allow temperature controlling of goods that are present in the first tube. A specified and controlled quantity of, any suitable gas at any suitable temperature and pressure can also be provided in the first tube with goods so as to provide a controlled devices of dissolving suitable gasses into the goods. The goods with the gas can be held in the first tube for a suitable period of time so as to allow the gas t~ dissolve into the liquids and oils in the goods at a suitable temperature. The first tube can be filled with compacted goods in such a manner so as to restrict any gas, that is provided therein, from escaping or leaking there from. The first tube may be provided with mixer therein to allow mixing of 3S goods contained therein. i he first tube may be fitted with scraper and substantially 4~ AMENDED SHEET

remove any solids, such as frozen liquids, ice and/or solids that may accumulate on the internal surfaces thereof.
Refernng now to FIGURE 56, a cross-sectional view through tray wall and flap 5212 is shown. For illustration purposes, a section of web material 5246 is shown bonded to plane 5248. Recesses 5236, and 5230 are therefore shown as enclosed channels. Cavity 5220 is fully enclosed and sealed from external communication save through perforations 5234 by bonding at interface 5242.
Gases can therefore communicate through the perforations 5234 and into the cavity and recess 5236. The gases can therefore come into direct contact with deposits 5244. The deposits 5244 are preferably applied to tray and flap surfaces that will not come into contact with any goods that are subsequently located in the tray cavity.
Referring again to FIGURES 57-58, a cross-sectional view through crest 5260 is detailed in FIGURE 57 with hinge 5252 between the flap 5210 and flange 5218. In FIGURE 58, tray 5200 is shown in a horizontal disposition with the opening in tray cavity facing upwardly. The tray base is profiled so as to be higher at the center of the tray base than at the lowest point of the tray cavity (at a radius connecting the tray base to the upwardly extending tray wall) and a clearance, designated by arrow 5254 is shown. The clearance 5254 is the distance (clearance) measured from the lowest point of the tray 5200, at the side flaps and the highest point of the under surface of the tray base. The clearance 5254 is arranged so as to suitably accommodate and "mate" with the crest 5260 when another tray (not shown) is located above and placed onto a lower tray 5200. In another alternate, the clearance 5254 may be enclosed by over wrap material to provide a cavity into which purge may enter through suitably located apertures in the tray. Suitable liquid absorbing material with a suitable capacity may be provided between the over wrap and underside of the tray base. The crest 5260 and clearance 5254 prevent the base of a stacked tray from contact with an overwrap on the bottom tray. In this manner, the goods are prevented from touching the base of an adjacent tray.
Embodiment 7 Refernng now to FIGURES 60-61, another preferred embodiment of a tray 5300 with flaps is shown. Tray 5300 has similar features to tray 5200;
therefore, those features ill be alluded to by the same reference numerals. Tray 5300 with depression therein is shown after over wrapping with overwrap web 5302.
Web 5302 may include a plastic web of material such as pPVC. The depression may yg AMENDED SHEET

be substantially filled with goods such as ground beef prior to over wrapping with the over wrap 5302. Over wrap 5302 may be stretched in such a manner as to contact the goods in the depression. The web of materia15302 may be printed with information that gives detail of the contents of the over wrapped tray.
Further more the inner surface of the over wrap 5302 may have been processed and a heat activated coating applied thereto, by any suitable method, and in those areas that will come into contact with planes 5258 and 5256 as shown in FIGURE 55. A suitable heat source can be provided to activate the heat activated coating so as to cause bonding of the web 5302 to flaps 5212 and 5210 at planes 5256 and 5258 and at locations showm as shaded sections 5304. Alternatively, the areas shown as 5258 and 5256 may be coated, by any suitable method, such as by "ink jet", with any suitable bonding material such as a heat activated coating. Apertures 5306 may be provided as shown. Apertures 5306 can be provided after bonding of the web to plane such that communication directly into recess 5238 is provided. A cross-sectional view is shown in FIGURE 61 through where web 5302 has been bonded to plane 5256 thereby providing space 5308 and recess 5310. Apertures 5312 in flap, apertures 5314 in wall of trzy and apertures 5306 in web 5302 are provided. In this way a communication is provided between the tray cavity to the outside of the over wrapped tray following a path that will readily allow gases to communicate therethrough but will restrict escape of liquids such as purge. The communication follows a path through aperture 5314 into space 5316, through aperture 5312 into recess 5310, through recess '310 to space 5308, through space 5308 to recess 5318, through recess 5318 to recess 5238 and through aperture 5306.
Referring now to FIGURE 62, a stack of 4 finished packages of the tray shown in FIGURE 60 is shown. A cross-sectional view is shown in FIGURE 63, through the stack of packages. It can be seen that with this arrangement an upper tray is in contact and rests on the flange of a lower tray. As can also be seen, clearance provided in the underside of the base of tray mates with the upper profile of a lower tray whereby the contents of a lower tray are located in close proximity to the upper tray but are not in contact with the underside of the upper tray.
Embodiment 8 Referring now to FIGURE 65, a preferred packaging tray 3200 with flaps, is shown. FIGURE 65 shovrs a flap 3202 attached to a tray 3200 by a hinge 3204 to flange 3206. Tray can also be provided with sinvlar flaps attached by hinges to all AMENDED SHEET

four sides of the tray at hinge lines between flaps and flanges. However, shows a tray that has two flaps, on opposing sides, where one only flap can be seen.
Packaging tray 3200 includes a substantially flat base that may have depressions, ridges, apertures and/or penetrations provided therein, with upwardly extending walls terminating at a continuous flange 3206. A ledge 3208 is provided in two of the four walls in a horizontally disposed position and level, across the face of the side wall and between the flange and the base of tray. The other two walls have flaps 3202 attached thereto, at a hinge connecting the flaps to the flange.
Apertures 3210 provided are provided in ledge 3208. Tray 3200 with flaps 3202 may be thermoformed from a sGitable material such as solid or foamed polystyrene (EPS), polyester, polypropylene or other suitable material. Apertures 3212 are provided in flaps at optimized locations that will restrict passage of solid or liquid matter therethrough. An alternative aperture construction is also shown as slot 3234 cut through a compressed section 3240 of tray in cross-section FIGURE 68 and in an enlarged view, FIGURE 69, showing details of the slot 3234 provided in a section of the flap along ridge 3214. Slots may also be located at other locations. The region surrounding the slot is compressed to provide a section of thinner cross-sectional thickness. Slot 3234 includes an incision in the compressed section of the ridge and may be provided with ar. "H" profile. The slot with "H" profile provides two adjacent flaps, 3236 and 3238, respectively, that can open when a differential in gas pressure is provided on opposite sides of the flap, however, when the gas pressure differential has equalized the two adjacent flaps shown as "H" flaps, can close to the former condition before opening.
Flaps 3202 are folded downwardly, against the upwardly extending adjacent tray walls 3216 as shown in end view of flap in FIGURE 66, prior to over wrapping.
Flaps 3202 can be provided with a fastening lug 3242 that is profiled so as to "mate"
with a corresponding fastening recess 3244 provided in tray 3200. The fastening lug 3242 and fastening recess 3244 holds flap 3202 in a downwardly located position in convenient readiness to be inserted into a bag prior to sealing and shrinking.
Flaps 3202 may otherwise prevent automated loading of the tray with perishable goods therein, into the bag.
Perishable goods such as fresh ground beef can be placed in the tray cavity prior to tray and perishable goods being over wrapped and shrink wrapped with a material such as Clysar AFG Anti Fog Polyolefin Shrink Film. Shrink film may be in the form of a preformed fabricated printed pouch (or bag) or alternatively, unrolled AMENDED SHEET

from a continuous web of rolled material that is formed into a tube on a machine such as a flow overwrapper, and cut into convenient sized sections that can be heat sealed (or cold sealed), so as to completely cover the assembled packaging tray and contents, prior to heat shrinking. The assembled tray with flaps, perishable goods and sealed overwrap are then passed through a heat shrink tunnel that causes the overwrap material to shrink and provide a taut and relatively tight cover over the packaging tray and goods. Flap 3202 is provided with a continuous rim 3246.
The.
continuous rim 3246 is provided in such a manner so as to contact the inner surface of the outer cover 3218. Rim is in continuous contact around the perimeter of the flap and substantially restricts passage of matter between the rim and the outer cover 3218 as shown in FIGURE 112.
Refernng now to FIGURE 112, a cross-section through the tray with flaps is shown after outer cover 3218 has been heat shrunk into a finished position.
Apertures 3220 are provided in the outer cover. A space 3222 is provided between the flap and the outer cover such that apertures 3220 provide direct communication between the space 3222 and external atmosphere. A finished package 3224 is shown in FIGURE 113. A plurality of finished packages can be assembled in a group that may include a total of twelve finished packages in three adjacent stacks of four finished packages. The group of twelve packages can be transferred by automatically into a thermoformed, substantially gas barrier, outer master container as shown in FIGURES 35-36. The barner master container 3226 containing the finished packages may be located within a vacuum chamber and substantially all air evacuated from the vacuum chamber and from within the finished packages and the barner master container. In this way, substantially all atmospheric air can be removed from within the finished packages via a route that follows a path through apertures 3210 (FIGURE 65) into space 3228 (FIGURE 66), through apertures 3212 (FIGURE 65) into space 3222 (FIGURE 112) and through apertures 3220 (FIGURE 112). The vacuum chamber may then be filled with a desired gas such as any single, oxygen free or oxygen enriched blend of gases including nitrogen, carbon dioxide and/or any other suitable gases. The gases will therefore substantially fill all voids and spaces within the barrier master container and the finished packages contained therein, by following the reverse route of the path along which atmospheric gases had previously been evacuated. In this way, finished package 3224 provides a suitable package with space therein that can be filled with desired gases as required, ~~~. AMENDED SHEET

while restricting the escape of liquid or solid matter, from within the finished package, to external atmosphere.
Referring again to FIGURE I12 and FIGURE 113, it can be understood that when a plurality of finished packages are assembled in a stack, the base of tray 3230 S with adjacent flaps will be in intimate contact with the upper surface of the finished packages. The flaps will be in adjacent contact with the flange regions of the lower package, thereby supporting the weight of packages stacked above. Therefore, the perishable goods contained in any package located beneath a package stacked above, will be protected from damage.
Embodiment 9 Refernng now to FIGURE 114 an isometric projection of a finished package 2500 constructed according to the present invention is shown and a cross-section through an empty package 2500 is shown in FIGURE 116. Tray 2502 is thermoformed from a suitable material such as expanded polystyrene. Flaps 2504 are connected to the tray by way of hinges 2506. Flaps can rotate about the hinges such that upper surface of flanges 2508 can contact directly and in alignment with flanges 2510 of the flaps.
Refernng now to FIGURE 115, a perishable goods 2600 such as ground meat is located in tray 2502 and a web 2512 is positioned directly above and over the tray and perishable goods. Web 2512 includes a transparent sheet of a suitable material such as plasticized PVC that has been coated with a heat activated adhesive covering the areas of the web that will come into contact with flange 2508 thereby providing a method of sealing web 2512 to the flanges 2508. After the web has been heat sealed to the flanges 2508, it is severed along the perimeter of flanges 2508. The web is hermetically sealed around the full flange extending around the perimeter of the tray.
Flaps 2514 and 2504 can then be rotated about hinges 2506 and flanges 2510 of flaps are sealed to flanges 2508 of the tray as shown in FIGURE 114.
Refernng again to FIGURE 115, flanges 2516 and 2518 are conveniently formed into a portion of the end walls of the tray. Web 2512 can be sealed to the flanges 2516 and 2518 as shown. Aperture 2520 can be provided in the location shown such that direct communication between the gas contained between the tray and the web 2512 and external atmosphere is enabled. The location of aperture inhibits the egress of any liquids that may accumulate within the package from escaping therethrough. Additionally or alternatively, aperture 2522 is also shown. A
plurality of finished packages can be stacked together such that face 2524 engages AMENDED SHEET

with face 2526. Such engagement of faces provides a secure method of stacking finished packages.
Embodiment 10 Refernng now to FIGURE 117, another preferred embodiment of a finished package constructed in accordance with the present invention is shown. The package 2544 includes a tray 2526 and a tray cover 2528. Tray and cover can be formed from suitable materials such as expanded polystyrene (EPS). Cover 2528 has a window 2530 cut therein as shown and web 2532 is stretched taut and heat sealed to flanges 2534. Tray 2526 and tray cover 2528 are hermetically sealed together at flanges 2536 and 2538. Walls of tray and the cover can be printed directly thereon with information describing the contents of the package with all legally required information, pricing, weight of contents and cost per unit weight. Recesses (four) in ridge 2542 are conveniently provided to allow for evacuation of air from between stacked packages. Recesses 2540 can also provide for location of bands of i5 printed paper that may provide further information and details of package contents.
Referring now to FIGtTRE 118, a cross-section through the end section of two stacked and finished packages 2544 of FIGURE 117 is shown. The perishable goods contents of the packages have been omitted for clarity. Faces 2546 and 2548 engage between the stacked finished packages. Engagement of the faces causes the outward urging of ridge 2550 of the lower package. The weight of the upper package is thereby transferred through the walls of the lower tray cover while inhibiting the inward displacement of flange 2552. Such an arrangement minimizes the likelihood of undesirable pressure being applied to the perishable goods contents of the lower tray by depressing the flange 2552 downwardly.
FIGURES 119-121 show an enlarged section of flange 2552, including side elevation, FIGURE 120, and a plan view FIGURE 119, of the underside of FIGURE 120, and a further end view, FIGURE 121, is shown with grooves and slots that allow direct communication between the inside of the finished package and atmospheric gases on the outside. Web 2554 is heat sealed along a continuous seal path 2556 and intermittent seals 2562 are shown with slots 2558 therebetween.
Slot 2560 is therefore in direct communication with slots 2558 and 2564 and grooves 2566. Apertures 2568 are located adjacent to slot 2560 and directly between continuous seal 2556 and intermittent seats 2562. Web 2554 can include a sheet of plasticized PVC and is tensioned prior to sealing as shown thereby providing a transparent cover across the window. In this way direct communication from within AMENDED SHEET

the package to atmosphere is provided through apertures 2568, slot 2560, slots 2558, slot 2564, and grooves 2566, while minimizing the possibility of any accumulated liquids escaping that may be present within the package.
Refernng now to FIGURE 122, three empty packages 2608 with web sealed thereto, are shown stacked together. A section through a finished package 2610 is shown in FIGURE 124, and a section through an individual package is shown in FIGURE 123.
Referring now to FIGURE 125 three finished packages 2570 are stacked together within a flexible gas barrier container 2572. A gas barner lid 2574 is hermetically heat sealed to gas barne: container 2572 after substantially all air has been evacuated and replaced with a suitable gas that may be substantially oxygen free.
Embodiment 11 Referring now to FIGURE 126, another alternative embodiment of a tray with flaps constructed according to the present invention is shown. Tray 2578 includes a first 2576 and second flap (not shown). Flap 2576 is attached to tray 2578 by hinge 2580. Ridges 2582 are formed in flap and corresponding ridges 2584 are formed in tray such that when flanges of flap and tray are in contact, portions of ridges are also in contact. Web 2586 is heat sealed to flanges 2588 and 2590.
Apertures 2592 and 2594 are provided in the web such that when flanges of the flap and tray are parallel to each other and in closest proximity, apertures are in alignment providing direct communication therethrough. Concentric depressions 2596 are shown in FIGURE 126 and in the detail of cross-section FIGURE 127. Tray 2578 may be formed from a three layer construction of expanded polystyrene where the inner layer includes an "open" cell structure that will absorb liquids such as water and blood. Depressions are provided on the inner surface of the tray, to allow contact of liquids, that may be present in the tray, with the inner cells of the tray and allowing absorption of liquids by the open cell structure.
Embodiment 12 Referring now to FIGURES 128-130, another preferred embodiment of a tray with flaps constructed according to the present invention is shown. FIGURE 130 shows a cross-section through a tray 2400, FIGURE 129 shows a cross-section through a tray 2402 that contains ground meat with a web 2404 stretched over the ground meat and sealed to flanges 2406, 2408 and edge portion 2410. FIGURE 128 AMENDED SHEET

-7 Jr-shows a cross-section through a portion of a master container 2412 with finished packages 2414 stacked therein. A flap 2415 is shown that has been severed from tray 2402 and web 2404 is also sealed to flap 2416. A space 2418 is provided between web 2404 and inner surface of the flap 2416 providing direct communication between recess 2420 and aperture 2422. Flap 2416 and tray 2402 are therefore attached together by web 2404 and a gap 2424 is provided between flap 2416 and the tray 2402. An aperture 2422 is provided in web 2404 at flap portion and an aperture 2426 is also provided in web 2404 at tray portion.
Recesses 2420 are provided in the flap 2416 such that when web 2404 is sealed thereto recess 2420 provides direct communication therethrough from atmosphere to the space between the flap 2416 and web 2404. Recesses 2420 are conveniently located in wall of flap 2416 between flange 2406 and horizontal edge portion shown in FIGURE 129. Severing of flap 2416 is optional and alternatively a hinge may be provided by compressing flange 2428 with a profile so as to facilitate easy hinging of flap 2416 and tray 2402 relative to each other.
Flap 2416 is arranged such that it can be "hinged" about the gap 2424 such that flanges 2406 and 2408 contact directly with web 2404 material therebetween.
Flanges can then be sealed together through web 2404 such that web 2404 material seals together in a desired manner. The apertures 2422 and 2426 are positioned such that they become aligned after sealing of the flanges. Web 2404 material is then most likely to become lightly bonded together around the perimeter of apertures 2422 and 2426. An adhesive may also be applied to the contacting surfaces of web around the perimeters so as to cause substantial bonding and providing a substantially liquid 'tight' seal there around so as to inhibit escape of any liquids therebetween. This arrangement provides a direct communication from space 2418 to any atmosphere external of the package, via apertures 2422 and 2426, space and recesses 2420. The location of apertures 2422 and 2426, space 2430 and recesses 2420 are arranged such that any liquids (or solid matter) that may accumulate within the package are inhibited from escaping from space 2418.
With this arrangement, gasses can communicate directly between space 2418 and while liquids and other solid matter is substantially restricted and held within space 2430 or 2418.
Tray can be formed from foamed polyester or from expanded polystyrene foam (EPS). Web 2404 may include a suitable grade of plasticized PVC (pPVC) which may be printed with various colors and graphics and a heat activated, or 6~' AMENDED SHEET

pressure sensitive adhesive may also be applied during the printing process or separately as desired and required to provide sealed finished packages.
Completed packages 2434 can be stacked into master container 2412 until it is filled. A lid including a gas barrier web can be then sealed to the flanges of 2412 as described in U.S. Patent Application Serial No. 09/039,150. Packages 2434 are stacked such that the ridg: s 2436 on the base of a first package "nest"
adjacent to ridges 2438 of a second package. A space can therefore be maintained between the bottom of the second package and the web and contents of the first package.
In a further embodiment, 2412 can be located within a chamber such as is shown in FIGURE 148 prior to sealing the gas barrier web to the flanges of 2412.
Embodiment 13 Referring now to FIGURE 70, another embodiment of a tray with flaps constructed according to the present invention is shown. FIGURE 70 shows a cross-sectional through tray detaili~.~g a preferred profile. Rib 7920 is formed in flap 7922 adjacent to recess 7924. Rib 7920 is formed so as to contact wall of tray as shown when flap is folded into position. Recess ?926 is formed in the flap 7922 with an aperture or slot therein but does not contact the outer surface of the wall of tray and is provided with space 7928 therebetween. A suitable adhesive such as a solvent is applied to the surfaces of the flap 7922 and the wall of tray such that when flap 7922 contacts the wall of tray, both parts bond together. The bond between the flap and the wall of tray can be arranged to follow a continuous path close to the perimeter of the flap 7922 and thereby provide a substantially liquid "tight"
seal around space 7928. Each flap (4) can be applied with adhesive in a similar manner to that described for flap 7922 then, in Iike fashion, bonded to walls of tray to produce a finished tray. Apertures 7930 can be provided in the lower section of the wall of tray such that liquids that may accumulate within the tray can pass through apertures 7930 and enter space 7928. Slots, slits or holes can be provided in recess 7924 such that direct communication through recess 7924 into space 7928 and through apertures 7930 can be provided. The surface of the flap and the wall of tray in direct contact with space 7928 can be treated so as to absorb liquids such as water, purge and blood.
Referring now to FIGURES 71-?2, an enlarged cross-section through a portion of EPS sheet is shown and an enlarged cross-section through EPS sheet, after thermoforming and assembly of tray and flaps in finished and bonded position, are detailed. In FIGURE 71, a cross-section through a portion of sheet EPS foam with ~7- AMENDED SHEET

skin 7932 and skin 7934 is shown. EPS sheet, as shown in FIGURE 71 can be extruded in normal production such that skin 7932 and skin 7934 is substantially nonporous and will resist absorption of liquids, while the inner layer of EPS
foam 7936 can be produced so as to absorb liquids. In a preferred embodiment, the EPS sheet with skin 7932 and skin 7934 can be extruded and wound onto rolls in readiness for use in thermoforming and production of trays with flaps as shown in FIGURE 52. In another preferred embodiment, the EPS sheet material may include three layers of expanded polystyrene sheet where an inner layer of open celled foam, that has been arranged to absorb desired liquids, is "sandwiched" between two outer layers of closed cell expanded polystyrene sheet that will resist absorbing of the liquids. After thermoforming the trays with flaps, from the three layer material or alternatively from material with outer skin 7932 and 7934 a solvent or other suitable agent, can be applied by spraying, or any other suitable method, to selected areas of flaps) and wall{s) of tray such that only those selected surface areas, that will become enclosed between the flaps and the trays, after folding and sealing into the required position, will have the solvent applied thereto. The solvent, or other suitable agent, can be applied in sufficient quantities to the selected surface areas, so as to dissolve the skin 7932 or 7934 at surfaces 7938 and 7940, shown in FIGURE 72 thereby exposing the inner, liquid and water absorbing EPS foam, for subsequent contact with any liquids that may enter space 7928. In this way a finished tray, with flaps folded and sealed into the desired configuration, can be produced so that only the surfaces adjacent to and in contact with the space 7928 will be substantially liquid and water absorbing. It can be seen that any liquids that may be present on the inside of the tray can pass through apertures 7930 and into space 7928.
Liquids can then be absorbed by the exposed EPS foam in contact with the space 7928 however, due to the liquid absorbing resistance of skin 7932 and 7934, the liquids may not be visible to any person looking at the tray with flaps from outside the space 7928.
Embodiment 14 Referring now to FIGURES 73 and 74, another embodiment of a tray with flaps constructed according to the present invention is shown. A cross-section through a finished package in shown in FIGURE 73 and a three dimensional view of a finished package 3400, is shown in FIGURE 74. The finished package 3400 includes a tray 3402 with perishable goods contained therein and an outer cover of a substantially gas barrier shrink material 3404. Apertures 3406 are provided in the gas barrier outer cover and a oeelable, gas barrier label 3408 is hermetically sealed x~g, AMENDED SHEET

_')g_ over the apertures 3406. The finished package 3400 has spaces 3410 and 3412 and other space contained within the outer cover 3404. A substantially oxygen free gas including any suitable gas, selected to extend the keeping qualities of the perishable goods, such as a blend of carbon dioxide and nitrogen, can be provided in the spaces inside the package 3400 after evacuating other gasses contained therein, such that all the spaces are filled with oxygen free gas. The finished package can be stored for a period of time and then the gas barrier label 3408 on the tab 3414 can be removed by peeling, thereby allowing atmospheric gas to enter through the apertures 3406 and 3416 and into the spaces around the perishable goods and contact the perishable goods.
Embodiment 15 Refernng now to FIGURE 76, another embodiment of a finished package constructed according to the present invention is shown. A cross-sectional view with details of a preferred configuration including a tray with flaps that are folded into the finished position and extend below the base of tray is shown in FIGURE 75. As described in earlier embodiments of this present specification, a tray with flaps may include a rectangular flat base with radiused corners and upwardly extended walls that terminate at a flat horizontally disposed, common flange. A space or cavity is therefore defined between the walls. Flaps are connected directly to the peripheral edge of the common flange at a hinge along a hinge line. A single flap may be attached to a single wall or alternatively up to four flaps may be attached, one to each wall. The packaging tray with flaps can be thermoformed from suitable plastics materials such as expanded polystyrene (EPS) sheet. Flaps of various configurations have been described herein with apertures conveniently provided to allow gas or air 2S exchange therethrough while inhibiting and restricting the escape of other matter such as liquids including blood therethrough. Such apertures and configurations allowing gas exchange therethrough can be provided in this present embodiment if desired, however, the purpose of the description of this present embodiment is to disclose an improved packaging that will also protect the perishable goods contents of the finished package when stacked together in a master container as shown in FIGURE 16.
Referring now to FIGURE 75, a loaded tray 3700 with flaps 3702 is completely covered with an outer cover 3704 and it can be seen that the outer cover 3704 is domed upwardly and is stretched over the upper surface of the perishable goods 3706 such that the uppermost part of the perishable goods 3706 is b~E AMENDED SHEET
..~E .:>

extended above the common flange 3708 under the outer cover 3704. In this manner the perishable goods 3706 are held firmly to the base 3710 of tray 3700 by applying tension on the outer cover material. An adhesive 3712 may be provided between the outer cover 3704 and the common flange 3708 so as to seal, hermetically or otherwise, the outer cover 3704 to the common flange 3708 along a path that will become an outer edge of the finished package. Additionally and as shown, adhesive 3712 may be provided between the flaps 3702 and the tray walls 3714 so as to seal the flaps 3702 in position to the walls as may be desired, hermetically or otherwise. Adhesive 3712 may also be provided between the underside of the base 3710 and between the base and the inner surface of the outer cover 3704.
Outer cover 3704 may include a suitably printed, heat shrinkable, stretchable, sealable, transparent, oxygen and gas permeable web of material with a "memory" that may be applied after loading the perishable goods into the tray cavity. The outer cover 3704 may be applied directly from a continuous web or roll of the material or alternatively may be fabricated into suitably sized bags, such as those supplied by Robbie Manufacturing, Inc., prior to sealing over the loaded tray with flaps. The outer cover 3704 may be suitably perforated with apertures to allow gas and/or air exchange therethrough and can be heat shrunk after sealing over the loaded tray with flaps by passing through a suitably adjusted heat tunnel. Alternatively, the outer cover 3704 may be applied from a continuous web and stretched during application thereof and then sealed to provide a sealed outer cover 3704 that is stretched taught around and over the loaded tray with flaps as shown in FIGURE 75.
FIGURE 77 shows a cross-section of a tray after the application of the outer cover 3704,. that may be manufactured from any transparent suitable material, but before stretching by depressing the outer cover 3704 into the recess 3716 as shown in FIGURE 78. FIGURE 78 shows the same cross-section as in FIGURE 77 after outer cover has been depressed so as to contact the adhesive between the base of tray and the inner surface of the outer cover 3704. By a mechanical device, the outer cover 3704, that is located adjacent to the underside of the base 3710 of tray, can be depressed and stretched so as to contact the adhesive 3712 located between the inner surface of the outer cover 3704 and the under surface of the base 3710 of tray so as to provide bonding therebetween. A recess 3716 can therefore be provided as shown.
In this way, the outer cover 3704 can be stretched over the entire surface of the tray 3700 with perishable goods contained therein. Therefore, when another finished package of similar configuration is located and stacked above and onto a similar 60,x' AMENDED SHEET

lower package, the underside of the finished package will not contact the upper surface of the dome of the lower package. In this way the lower packages are protected from damage when stacked and transported or when displayed in stacks at a point of sale to consumers.
Referring now to FIGURE 79, a cross-sectional view through an assembled and finished master container 3722 is shown inside a closed and sealed corrugated cardboard carton 3724. Two finished packages 3726 and 3728 are shown inside the master container 3722. As can be seen, the extended flaps of the upper finished package provide a recess to accommodate the upper surface dome of the lower finished package thereby providing protection to the perishable goods contained therein. The master container 3722 may be thermoformed from a web of flexible, substantially gas barrier, plastics material such as Curlon Grade 9315-II as manufactured by Gurwood of Oshkosh, Wisconsin and can be provided so as to tightly hold the finished packages. A substantially gas barner lid 3732 that is provided from a web of plastics material such as Curlam Grade 2500-K as manufactured by Curwood of Oshkosh, Wisconsin, is shown heat sealed to the flange of the master container 3722. The seal 3734 between the lid and the master container will, most desirably, be a peelable seal that can be peeled with relative ease by any person wishing to open the sealed master container. A desired gas 3736 is contained within the hermetically sealed master container and an oxygen scavenger 3730 is located therein. Further, the lid of a master container may contain a relief valve to allow escape of any excess gas that may be released from solution in the meat and to accommodate for an expansion of the master container.
The sealed, gas barrier, master container 3722 is located in a corrugated cardboard carton 3724. The corrugated cardboard carton 3724 may be manufactured by the Weyerhaeuser Corporation, of Tacoma, Washington from 69/40/69, 5100 flute corrugated cardboard and such a construction will withstand substantial loading.
An enlarged view of the seal arrangement is shown in FIGURE 80 and an alternative configuration showing flange of container in position after folding inwardly is shown in FIGURE 81. In this embodiment the corrugated cardboard carton is just large enough to contain the master container but the flange of the master container is folded inwardly to allow the sides of the master container to be in close contact with the inner surface of the carton, thereby reducing the size of the carton to a minimum.
'.6.1. AMENDED SHEET

-a l-The size of the master container and the corresponding size of the carton can be suitably arranged to contain one or more finished packages.
Embodiment 16 FIGURE 131 shows another embodiment of a tray constructed according to S the present invention. The tray 1902 includes flap 1900. Flap 1900 is attached to tray 1902 along an outer edge 1904 of tray flange 1906 and a further flap (not shown) can be attached to the outer edge along the opposite side of the tray which is parallel with the first flap and is similar in operation thereto. After sealing of second and third webs to flanges 1906 and 1908, flap 1900 can be folded downwardly so that radius 1910 in FIGURE 132 engages with recess 1912. Flap 1900 includes a hinge that can be folded along a hinge line through an arc shown more clearly in FIGURE 132. Radius 1910 and recess 1912 "mate" and can be arranged so that they "snap" into a matingly engaged position, thereby holding the flap 1900 firmly.
Refernng now to a cross-sectional view of the stacked trays in FIGURE 133, flap base 1918 is shaped so as to correspond with profile of flanges 1906 and 1908 and a ridge 1926 is located along the external edge of flap base 1918 such that when a finished package is stacked above another similar package they will "nest"
together and the upper tray is prevented from contacting the contents of the lower tray. The base of the tray can be formed with a profile providing an upwardly extending depression that extends above the highest point of the contents in the lower tray. In this fashion, the finished packages can be stacked within cartons for distribution and shipped long distances without causing damage to contents of the trays in the lower position. First web tray 1920 has recessed base to clear goods in the tray below.
Lip 1928 can be heat sealed after folding of the flap by heat seal bars 1930 to ensure that flap 1900 is retained ir. folded position as shown in the stacked finished packages FIGURE 133. Ridges 1932 can be formed into flaps to improve rigidity and stability of the finished pack.
Embodiment 17 Referring to FIGURE 8?, another embodiment of a tray, 3100, with flaps is shown. A cross-section is shown in FIGURE 83, where both flaps are folded inwardly and the package hay been inserted into a Clysar AFG shrink bag 3114.
The tray can be "stretch-wrapped" with PPVC as an alternate to a PP bag as shown in FIGURE 83.
AMENDED SHEET

Tray 3100 includes a base with four upwardly extending walls, terminating at flanges 3104. Two flaps 3102, 3103 are provided such that they can fold inwardly.
Recesses 3106 are provided in the flaps to allow communication of gasses therethrough. Tray 3100 further includes a base rim 3108 that extends around the perimeter of the base. Depressions 3110 and perforations 3112 can be provided at the tray base 3126. Apertures 3116 are provided in shrink bag 3114. Tray 3100 may be thermoformed from any suitable material. Apertures 3116 provide direct communication from external atmosphere through space 3118 and recesses 3118 to tray cavity. Perishable goods can be located into tray cavity and flaps 3102 folded inwardly. Assembled tray and perishable goods can then be located within a polypropylene shrink bag, such as Clysar AFG shrink bag 3114 which is then heat sealed and heat shrunk around the tray and goods to form a finished package. A
plurality of finished packages may be assembled and stacked together to provide a group of assembled finished trays which is then hermetically sealed within a substantially gas barrier master container as described in US Patent Application 09/039,150 with a gas barrier lid. When the finished packages are stacked, the base rim 3108 of one pack will rest directly above flaps 3102. In this way, finished packages can be stacked together without causing undesirable damage to the contents of the package. Perforations 3112 absorb liquids as described herein.
Alternatively, in a preferred embodiment, the Clysar AFG shrink bag 3114, may be replaced with a stretch wrap material such as plasticized PVC.
Referring now to FIGURE 135 wherein a view of a section of tray, after folding and banding of the flaps to the tray wall, is shown. A plan view of the scrap view section, prior to folding and bonding of the flaps, is shown in FIGURE
134. A
preferred method for production of trays with flaps includes a thermoforming process and a "cut in place" procedure. The term "cut in place" is a common term used by those skilled in the art of tooling manufacture and use of thermoforming equipment.
This term describes a thermoforming production method including the use of a thermoforming tool with a cutting devices incorporated into the tool so as to permit cutting of the subject thermoformed component from a web of plastics material immediately after forming and before ejection and removal of the components) from the thermoforming tool. The scrap view section shown in FIGURES 134-135 details a single corner section of a four cornered tray such as the tray of FIGURE 55, however, all four corners of the tray with flaps are similar. Referring again to FIGURES 134-135, flaps 5268 and 5270 are shown attached to a tray 5272 at a AMENDED SHEET

hinge 5274. The tray with flaps is shown in FIGURE 134 prior to folding flaps and bonding. The tray with flaps is shown in FIGURE 135 after folding of flaps and bonding. The flaps can be printed by ink jet devices, prior to folding and bonding in the manner disclosed above with reference to FIGURE 55. Adhesives can also be applied by ink jet printers to the flaps and tray. Hinge lines 5276 and cut lines 5278 are all parallel and in the same plane. The cut lines 5278 and hinge line 5276 terminate at points 5280 and 5282. If desired a further hinge line 5284 provides devices to fold sections 5286, which can be folded and bonded to the base of tray.
Panels 5288 and 5290 can be printed with any information or graphics as may be desired and are arranged to be elevated and angled so as to be more easily visible by an intending purchaser of the tray with goods therein.
Referring now to FIGURE 136, a cross-sectional view through a corner of the tray with flaps, after the flaps have been folded and bonded, is shown. The "cut in place" forming method allows a method to provide walls 5292 and 5294 that can contact each other, as shown, and be bonded together after folding the flaps into the finished position. In this way, a substantially more rigid tray structure can be provided that would otherwise require a heavier wall section for trays that have not been provided with flaps as herein disclosed. With ink jet application of adhesives, as described herein, an efficient devices of economically applying the minimum quantity of adhesives is provided. In this way, adhesives can be applied in a pattern that allows for maximum surface area bonding of trays and flaps while minimizing the quantity of adhesive material required.
In yet another preferred embodiment, packaging including a combination of features disclosed in any of the trays above may be combined to construct a finished package. For example, a package including a tray with any of the flaps disclosed herein may be constructed to provide desired features and inserted into either a Clysar AFG shrink bag or alternatively a stretch wrapped in a pPVC stretch film over wrap or shrink wrapped with printed Clysar AFG anti fog shrink film.
In yet another preferred embodiment, packaging including a combination of features disclosed above may be combined to construct a finished package.
However, perforations may be provided in depressions to allow any free liquids to pass therethrough to a space between the base of tray and the outer shrink bag.
Indentations may be provided in the under (or outer) surface of the tray that can allow open cells, that may be present in the EPS structure of the tray, to absorb the liquids.
AMENDED SHEET

Any of the foregoing trays with flaps will be used in a method to automatically or manually performing the following steps:
Providing a tray with flaps, that has been thermoformed from expanded polystyrene (EPS). The tray having dimensions that will provide for the efficient use of the internal dimensions and capacity of typical, refrigerated road and rail transport vehicles.
Trays will retain a substantially oxygen free gas within cell structure of the tray and/or exposing the tray andlor the tray material prior to and/or during thermoforming and production of the tray, to a gas that excludes oxygen and allowing the gas to exchange with any gasses contained within the cells of the EPS
thereby substantially displacing any atmospheric oxygen from the cells or otherwise ensuring that gasses contained in the cell structure substantially excludes oxygen.
Providing perishable goods onto the base of the tray. The perishable goods having been treated and processed to enhance the keeping qualities thereof.
Over wrapping the tray with goods therein with a web of gas permeable material such as pPVC, to produce a finished package and then seal the over wrapping web of gas permeable material to portions of the tray by a heat sealer or other suitable adhesives and then perforate the over wrapping web of gas permeable material at desired locations.
Placing the finished package or a plurality of similar finished packages into a gas barner master container.
Displacing substantially all atmospheric gas, and particularly atmospheric oxygen, from within the master container, with a suitable gas or blend of suitable gasses.
Sealing a lid over the opening in the master container to form a hermetically sealed package containing the trays with perishable goods and suitable gas.
Placing the master container inside a carton such as can be manufactured from corrugated cardboard and enclosing the master container.
Locating a plurality of closed cartons onto a standard (GMA specified) pallet (Dimensions of 40" x 48") so ~s to maximize the efficient use of the upper surface area provided by the pallet thereby producing a loaded pallet.
Storing the loaded pallet for a period of time in refrigerated space.
Delivering the finished pallets to a point of sale such as a supermarket.
Performing all aspects of the process in temperature controlled conditions f 65~ AMENDED SHEET
~., .~

Embodiment 18 Referring first to FIGURE 88, a tray is shown in a three dimensional disposition. The tray is arranged with a base 6540 and four upwardly extending walls terminating at a flange 6542 with a cavity 6544 surrounded by the walls.
Each of the walls may be rigidly fabricated by bonding together, two or more layers {shown as 6536, 6552 and 6560 in FIGURE 89). Each layer is attached directly together or in series to the flange 901, of the tray, via hinges that allow folding of each layer together and against each other, prior to bonding the layers together, to provide rigid wall{s). In this way the tray walls can be rigidly constructed with higher compression resistance and at a lower cost than would otherwise be incurred for a single layer wall of a similar compression resistant rigidity.
Referring to FIGURE 90, a plan view of a thermoformed pre-form is shown which can be manufactured from any suitable material, of any suitable thickness but is most preferably thermoformed from extruded polypropylene sheet with a thickness of approximately 0.018". The polypropylene sheet is then thermoformed to produce a pre-form, which is constructed so that it can then be folded and bonded into a stackable tray profile. The pre-form consists of a cavity 6617, with a series of semi-rigid flaps, all connected by at least a single hinge to the flange 6542. Cavity 6617 has a base 6540 with four upwardly extending walls terminating at a continuous flange 6542. Flange 6542 may be arranged with four straight sections connected via rounded corners but the other packaging tray configurations may be fabricated. At the outer perimeter of flange 6542, adjacent flange flaps, 6536, 6574, 6598 and 6582 are attached via hinges shown as 6618, 6614, 6612 and 6594 respectively. Located at each corner of flange 6542, and between each adjacent pair of adjacent flange flaps, additional flaps are provided.
Between adjacent flange flaps 6536 and 6574 a pair of generally triangular adjacent flaps 6552 and 6564 are located but severed completely from direct attachment together by cut 6628.
Flap 6552 is attached to adjacent flange flap 6536 via hinge 6626 and flap 6564 is attached to adjacent flange flap 6574 via hinge 6568. Similarly, flap 6576 is attached to adjacent flange flap 6574 via hinge 6570 and flap 6580 is attached to adjacent flange flap 6582 via hinge 6592. Additionally, flap 6580 is attached to adjacent flange flap 6582 via hinge 6584 and flap 65x0 is attached to adjacent flange flap 6598 via hinge 6588.
Finally, flap 6606 is attached to adjacent flange flap 6536 via hinge 6604 and flap 6610 is attached to adjacent flange flag 6536 via hinge 6624. The pair of flaps 6610 and 6606 are severed along cut 6608, the pair of flaps 6552 and 6564 are severed along cut 6628, the pair of flaps 6576 and 6580 are severed along a cut 6578 and the pair of flaps 6580 and yS6~ AMENDED SHEET

6590 are severed along cut 6588. Said flaps 6552 and 6610 can be folded toward each other until they contact what becomes the inner surface of adjacent flange flap 6536, and adjacent flange flap 6536 can then be folded toward adjacent tray cavity wall 6636 until the surfaces of flaps 6552 and 6610 contact a surface of adjacent cavity wall 6636. This can be repeated simultaneously, separately or in correspondingly opposite, adjacent flange flaps such that all flaps are folded and held together for bonding at any and all contact points between the corresponding flaps and generally as detailed in FIGURE 89.
Referring now to FIGURE 89, a side wall of packaging tray shown in FIGURE 88 is detailed, after folding of flaps shown therein which can be bonded, by any suitable bonding means, at contac: points 6562, 6558, 6556, 6554 and 6550.
Bonding can be arranged to follow a path near what becomes a perimeter of adjacent flange flap 6536 so as to hermetically seal space 6548 therein.
Referring now to FIGURE 91, a cross section through flange 6542, cavity wall 6636 and adjacent flange flap 6536, details a preferred embodiment wherein hinge 6618 is located parallel to hinge 6630 with an additional flap section 6632 between hinges 6618 and 6630. Adjacent flange flap 6536 is bonded to wall 6636 at 6634.
Referring again to FIGURE 90 in a preferred embodiment, an additional flap 6572 is shown attached to adjacent flange flap 6574 via hinge 6566 and additional flap 6602 is shown attached to adjacent flange flap 6598 via hinge 6600. Flaps may also be similarly attached via hinges to adjacent flange flaps 6536 and 6582 if so desired. In this arrangement pairs of flaps 6576 and 6580, 6564 and 6552, 6610 and 6606, 6580 and 6590 can be deleted, allowing flaps 6572 and 6602 to be folded respectively against what become internal surfaces of adjacent flange flaps 6574 and 6598 prior to bonding there together to provide a structure generally similar to that shown in FIGURE 89.
Referring now to FIGURE 92, a plan view of a preferred pre-form is shown, wherein a centrally located cavity 6704 is connected via hinges 6716, 6708, 6720 and 6718, to flaps 6702, 6706, 6710 and 6714 respectively. Additional flaps 6700 and 6712 are attached via hinges to flaps 6702 and 6710. Ribs can be provided to all parts of the tray cavity, walls and flaps and can be arranged in any suitable profile so as to maximize rigidity of the finished tray but are shown only in flaps 6700 and 6712.
Refernng now to FIGL:RE 93, two pre-forms are shown stacked and nested together. In this way pre-forms can be manufactured and then conveniently stacked in a nesting configuration, minimizing the volume of space required during storage and shipping thereof. Pre-forms can then be fabricated at the point of use for packaging 3 S goods.
AMENDED SHEET

Referring now to FIGURE 94, a cross section through a tray assembly fixture arranged to fold and bond pre-forms in an enclosed chamber is shown. Only one view of the assembly fixture is shown which is rigidly constructed from suitable materials wherein a base frame 6814 is connected to a platen 6816. Base frame 6814 and platen 6816 can be securely connected there together by any suitable means but most preferably by way of a quick release arrangement so as to allow the rapid separation of the two components. In a preferred embodiment, several similar assembly fixtures can be attached to a horizontally disposed continuous conveyor and arranged to operate automatically as a complete machine and this will be generally described in a later part of this disclosure. Platen 6816 is securely attached to a profiled fixture 6812, which is shaped to correspond with the internal, cavity surface profile of a pre-form such as shown in FIGURE 92. A pre-form 6820 is shown in position and mated with fixture 6812. Part 6818 is hing~;d at 6811 and part 6806 is hinged at 6810.
Parts 6818 and 6806 are arranged to dimensionally correspond to the flaps of pre-form 6820, and can be attached to a suitable driving arrangement such as pneumatic cylinders that will drive each part to close in a sequence as required. Part 6818 is shown in an open disposition whereas pact 6806 is shown in a closed position and firmly holding a flap of pre-form 6820 against a wall thereof. A source of vacuum may be attached to fixture 6812 or single chamber (6804 and 6802) so as to assist in securely holding the pre-form in place during folding and bonding of flaps. After flaps have been bonded into position the vacuum may be released to allow easy removal of the folded and bonded tray. Additional hinged parts (.not shown), similar to 6818 and 6806, may be attached to other sides to fixture 6812 as may be required to correspond with additional flaps that may be attached via hinges to pre-form 6820. A typical pre-form is shown in FIGURES 92 and 93. All hinged parts 6818, 6806 and any others can be arranged to fold flaps against the side walls of pre-form 6820 and to hold there against securely during bonding of flaps to correspondingly adjacent side walls. A single chamber is shown in two parts, 6802 and 6804, that can be opened and closed as required to allow pre-forms such as 6820 to be located on fixture 6812 and sequentially unloaded by any suitable means in an automated and continuous process. The single chamber (6802 and 6804) is attached to a shaft 6800, which in turn is attached to a drive such as a pneumatic cylinder, which can provide alternating upening and closing of the chamber. Ports can be provided in the single chamber with valves arranged to allow any suitable gas at any suitable pressure therein and connection to a suitable source of vacuum. The single chamber can be arranged to close over fixture 6812 after locating a pre-form (6820) thereon and a '..6$~ AMENDED SHEET

_8g-seal such as 'O' ring 6822, can be installed along the contacting face between the single chamber (6802 and 6804) and platen 6816. In this way, an enclosed and substantially gas tight enclosed space 6808 can be provided. Prior to closing the single chamber against platen 6816, hinged parts 6818 and 6806 can be activated by driving air driven cylinders. After closing the single chamber, space 6808 can be substantially filled with any suitable gas at any suitable pressure via valves and pons (not shown) and to ensure that cavities between flaps and cavity walls are filled with the selected gas and thereby substantially excluding atmospheric oxygen. Hinged parts 6818 and 6806 can be arranged to carry any suitable sealing mechanism, such as RF welding and arranged to bond flaps to side walls of pre-form 6820 directly. In this way cavities such as space 6548 described above and in association with FIGURE 89 can be filled with any suitable gas at any suitable pressure. In summary, a preferred sequence of apparatus operation, as shown in FIGURE 94 can be as follows:
A. Provide a pre-form 6820, locate on fixture 6812, and apply a vacuum source to hold the pre-form securely to fixture 6812.
B. Apply any suitable adhesive to selected surfaces of flaps of pre-form and fold hinged parts such as 6818 and 6806 so as to fold and close flaps against the side walls of the pre-form. [Hinged parts 6818 and 6806 may be arranged with a means to partially close and thereby allow substantially complete evacuation of air or gas therefrom prior to bonding].
C. Close single chamber over pre-form and seal chamber against platen 37.
D. Evacuate space 6804 and provide any suitable gas at any suitable pressure therein.
E. Seal flaps to side walls of pre-form.
F. Open chamber and allow removal of pre-form with flaps bonded to side walls.
Referring again to FIGURE 94, assembly fixture detailed therein can be arranged in groups wherein each assembly fixture is attached, via quick release connection, to a pair of parallel horizontally disposed, continuous chains, with a driving motor such as a servo electric motor, horizontally disposed to provide a conveyor. In this way a complete machine can be arranged with the upper section thereof, enclosed and a suitable gas provided in enclosure, such that when pre-forms are located on fixtures {6812), if so desired, the gas in contact with pre-forms is oxygen free.
-6~' AMENDED SHEET

Referring now to FIGURE 95, a side view and end view of two finished packaging trays 6828 and 6830 stacked together are shown. Ribs 6824 and 6826 locate interlock with the base of the upper tray.
Referring now to FIGURE 97 and FIGURE 98, another preferred packaging tray (6920) embodiment is shown with a cross sectional view 98 therethrough. Tray may be manufactured from any suitable material but in this instance a material such as polyethylene is preferable. A cavity 6918 is surrounded by upwardly extended side walls 6912, 6906, 6902 and 6900 all terminating at flange 6900. Flaps 6906 and 6912 are visible and ribs 6910 and 6906 are shown in flap 6906 and ribs 6916 and 6914 are shown in flap 6912. Flaps, 6907 and 6912 (including those not visible), have been hermetically bonded to side walls of tray. Refernng now to section 98 in FIGURE 98, a cross section through ribs 6910 and 6908 is shown. Hinges 6922 and 6924 are arranged to allow folding of flap 6906 against wall 6930. Hermetic seals are shown at 6926, 6932 and 6936. Hermetic seals shown as 6926 and 6932 follow a path completely around the perimeter of rib 6910 and hermetic seals shown as 6932 and 6936 follow a path completely around the perimeter of rib 6908. In this way a spaces 6928 and 6934 can be completely enclosed and hermetically sealed separately from each other.
However, prior to bonding ribs so as to enclose and hermetically seal spaces 6936 and 6934, any suitable gas such as carbon dioxide at any suitable pressure but most preferably at a relative high pressure, such as 80 psi, can be provided therein. In this way a rigid tray can be manufactured with reduced material content and therefore at relatively lower cost.
Referring now to FIGURE 99, a tray 7100 with lateral ribs arranged in a similar manner to those (6916, 6914, 6910 and 6908) disclosed in FIGURE 97 is shown. Section 100 shows spaces 7116 and 7122, enclosed and hermetically sealed within ribs 7118 and 7124, along seals 7114, 7120 and 7126 which can be filled with high pressure gas such as C02. Hinges 7108 and 7112 are located so as to provide an outwardly extending flange, after folding flap against wall 7140, and to which a web of material shown as lid 7142 can be hermetically sealed so as to fully enclose cavity 7138. Apertures such as 7136 can be provided to allow liquids to enter cavity 7128 and seal at 7132 prevents escape of such liquids from space 7128.
Ribs such as 7130 can be provided.
Referring now to FIGURE 84, two thermoformed trays 6500 and 6514 are shown in a partially nesting disposition. The profile of tray 6500 is arranged with upwardly extending walls terminating at flange 6502 with ribs 6506 and 6508, formed into the walls. Ribs formed in tray 6500 such as 6506 and 6508 extend '~Q' AMENDED SHEET

inward toward the center of cavity 6504 and ribs such as 6512 and 6510 in tray extend outwardly away from a centrally disposed cavity.
Refernng now to FIGURE 85, the two trays 6500 and 6514 in FIGURE 84 are shown sealed together to form a single tray 6518. Flanges 6502 and 6516 are hermetically sealed together around the full length of what has become a path close to the tray perimeter. FIGURES 86-87 show details of enclosed spaces such as 6526, 6530 and 6528. Ribs are also hermetically sealed such that ribs formed in the walls of the inner tray are sealed against the corresponding rib in the outer tray to provide fully enclosed spaces such as 6530 shown in FIGURE 87, that can be filled with high pressure I O gas. Seal paths 6522 and 6524 are shown as examples of hermetic sealing and enclosing of spaces such as ti530. FIGURE 87 shows rib 6508 hermetically sealed to rib 6520, at 6532 and 6534 enclosing space 6530.
Referring now to FIGURE 101 a cross section through a tray similar to tray 6500 shown in FIGURE 84 is detailed in a preferred embodiment wherein a tray with a base 7312, and upwardly extending walls 7308 terminating at flange 7300 is provided with rib 7308 formed therein. A separately formed rib 7314 is shown adjacent to rib 7308 in a position prior to bonding and also after bonding to tray wall along seal path 7310. A hermetically sealed and enclosed space 7306 can be filled with high pressure such as C02. In FIGURE 102, a cross section through ribs and 7308 is shown with space 7306 enclosed therein.
Referring now to FIGURE 103, a thermoformed tray, 7408 is shown in a three dimensional view located above a form cut blank, 7414. Ribs are provided in the base 7404 and walls, 7402, 7406, 7412 and 7416 in a vertically disposed arrangement. Any suitable rib configuration may be provided in the walls and base 2S of any suitable size tray, but most preferably rigid ribs such as 7410, as shown in FIGURE 103, are provided with the recess accessible from the outer side of each wall, with the ridge extending inwardly. Trays 7408 and blanks 7414 can be manufactured in any required size, from any suitable material but most preferably would be produced from mono-layer extruded polyethylene terephthalate (PET) sheet. PET sheet may be extruded with multiple layers and both or a single outer layer may be provided with enhanced heat or RF (radio frequency(RF) or micro wave) sealable properties. Enhanced RF sealability may be provided by including any suitable additive such as suitable metallic elements or compounds in the outer layers, by blending into the polymer prior to extrusion.
?1~' AMENDED SHEET

Hinges shown at 7434, 7420, 7432 and 7426 are arranged so that flap portions 7418, 7422, 7425 and 7430 are all attached, thereby, to central rectangular portion 7424. In this way flap portions can be folded upwardly about hinges so as to contact the walls of tray 7410. Flap and base portions of blank 7414 can then be sealed to the walls of tray 7408 so as to provide a hermetic seal around the perimeter of each rib after providing gas such as C02 at an elevated pressure in the recess of each rib. In this way a rigid tray can be manufactured with substantially less material content than would otherwise be required for a tray manufactured from a single component.
Embodiment 20 Refernng now to FIGURES 268-270, a preferred tray with flaps is shown.
Tray 7202 includes a crest 7200 constructed on the perimeter of the tray opening on a wall of the tray 7202. A similar crest is also constructed on opposite sidewall so as to form two convex areas having a first radius. Referring now to FIGURE 269, a flap is shown with a flap base 7204 having a concave indentation 7204 of a second radius. When folded, as in a finished package, flap base 7204 is substantially level with the tray base 7216. Preferably, two such flap bases are provided, each in opposing sides from the other. Referring now to FIGURE 270, a plurality of finished stacked packages using the trays of FIGURE 268 is shown. Preferably, the flap base concave indentation radius is smaller than the radius of tray crest, so that when stacked, flap base of upper tray 7212 makes contact with tray crest of lower tray 7214 at two locations 7208 and 7210. In this manner, trays are prevented from rocking back and forth if only one contact point is provided. Preferably, a space is provided between upper tray 7212 and lower tray 7214 which is also shown in FIGURE 270. In this manner, the underside of tray base 7216 is prevented from touching the sealed or overwrapping web on lower tray. The sealed or overwrapped web material substantially holds the fresh meat portions to the tray base.
Preferably, the web material is oxygen permeable. Finished packages can thus be stored and packaged in any of the master containers disclosed herein. The disclosed tray profile allows stacking of several layers of trays in a vertical stack, wherein each loaded and over wrapped tray is located directly above and in contact with a lower tray to maximize density of a finished master container. Preferably, the profile of the flaps is an upwardly arched base that corresponds with the profile of the tray upper flange profile. Preferably, ground meat is extruded with a profile that corresponds to the inner profile of the cross section across the length of the tray such that when loaded AMENDED SHEET

into the tray, the upper surface of the extruded grinds portion is in firm contact with the tray over wrap so that it holds it in place and slightly below the upper edge of the flanges. The end flanges are arched to match the arched base and end flap profile of the lower tray profile. Continuous bonding of each flap around it's perimeter to ensure that the end edge butts up and contacts the adjacent flaps provides for maximum structural stability and minimum twist after fabrication and bonding.
Thus, the double walls (inner cavity and outer flap) improve crush resistance.
Trays with Iron Powder Powdered iron is often used as an agent for scavenging free, residual oxygen gas in packaged perishable, foods; for example Keplon Co., Ltd. of Kariagawa, Japan have manufactured deoxidizers such as Keplon - TY for this purpose. As exemplary of the application of the method to the present invention, reference will be made with regard to FIGUP.E 49, but it should be readily apparent that the method herein described can be eas~.ly applied to any of the trays made from the present invention. Powdered iron may be applied to the inner surface of the outer cover 4120, in such a manner so as to become activated by water that may be provided in the adhesive layer 4142. Furthermore when the outside-surface of foam 4138 (see detail in FIGURE 49) is arranged to have a capacity to absorb liquids, such liquids can be retained and substantially prevented from escaping from within the finished package. Additionally, a suitable adhesive can be provided between the tray flange rim 4144 and the outer cover 4120 where the continuous flange rim 4144 is in contact with the outer cover.
Powdered iron can be used as an oxidizing agent and removal of oxygen gas from within a hermetically sealed, gas barrier package. Powdered iron may be applied, in combination with other suitable sealing substances and agents, to the surface and most preferably to an inner surface, of the outer cover 4120 at locations that will become in direct contact with underside of the base of tray. The iron powder can be applied to outer cover 4120 in such a manner so as to allow subsequent activation by water that may be contained in the adhesive layer when applied to the under surface of the base of tray, at the time of over wrapping the tray with perishable goods therein, and when cover 4120 contacts the base of tray.
Prior to application to the inner surface of the outer cover 4120, the powdered iron particles may be coated with a suitable coating including a suitable protecting substance or blend of protecting substances, that can provide a protecting layer over the complete outer surface of the iron powder particles thereby protecting and 7~' AMENDED SHEET

_yJ_ isolating the iron powder particles from direct contact with water or other substances that may cause the iron powder to oxidize. The protecting layer can thereby remain in the protecting condition until the coating is altered to allow water to permeate therethrough or otherwise contact the iron particles. The coating may be altered at, for example, a convenient time after complete or partial assembly of the finished packages by exposing to an electromagnetic field of such intensity or in such a manner as to induce generation of heat in the particles of iron. Generation of heat in the iron particles by, for example, exposure to an electromagnetic field, rnay be induced by a suitable frequency of alternating electric current. Generation of heat in IO this manner may cause the protecting coating to release water or allow water from adhesive layer to contact and thereby activate the powdered iron to oxidize.
Oxidation of iron powder in this way can result in absorption of residual oxygen that may be present inside the maser package. Any suitable coating that possesses the required chemical and physical properties may be used to coat the iron powder.
In this way the iron powder particles can be maintained in a protected and "dormant"
condition until required to absorb oxygen such as after sealing of the package and when enclosed within a master container.
In this way air and gasses can be removed from the finished and sealed packages by evacuation and then replaced by gas flushing with a desired gas, while liquids such as blood cannot readily escape. Furthermore, gasses can readily flow through the communicating passage from inside to outside of the package (but still inside the master container) to enable rapid equilibration of gasses when oxygen gas is released by reduction of orymyoglobin after sealing of the master container. Any residual oxygen that may remain present in the sealed master container can be absorbed by the oxidizing ir.~n particles after activation with the electromagnetic field, causing release of water or other suitable substances and direct contact with the iron particles.
Referring now to FIGURES 137-139 three cross-sectional views of selected sections of EPS trays with flaps are detailed. FIGURE 137 shows a section of a tray with a flap attached at a hinge and where the flap is "open" and not folded so as to be in contact with tray 5501. FIGURE 138 shows a flap folded into a finished position and contacting tray 5501. The :'lap may be formed with a recess 5506 that can be a arranged to be a continuous recess that follows a path close to the perimeter of the flap. The tray can be arranged to have a ridge 5508 that follows a path corresponding to the recess 5506 such that when the flap is folded about the hinge so as to ~y.T
:?4AMENDED SHEET

intimately contact the tray wall and base, the ridge 5508 will mate with the recess 5506, as shown in enlarged view of FIGURE 139. Accordingly, the flaps with heat activated adhesive applied in recesses 5506 can be folded, as shown in FIGURE 138, so as to cause intimate contact with the tray base 5512 and/or walls 5514 thereby providing a tray with folded flaps. The tray with folded flaps can be held in such a folded condition so as to hold ridges 5508 firmly against adhesive and in continuos contact with 5516 along the full length of the ridge and recess. The tray with folded flaps can be transferred automatically into and through a microwave oven source of heat such that adhesive 5516 is activated by exposure to a suitable level of microwave heat source. and thereby bond the flap and tray together at _.
ridge 5508 and recess 5506. The bond can be arranged along a continuous path and enclose the space between the flaps and the tray so as to provide a substantially liquid tight seal. Selective heating of adhesive 5516 can be provided by microwave or magnetic field devices so as to cause bonding without application of excessive heat that could otherwise cause undesirable distortion to the EPS tray. Any suitable heat activated adhesive may be provided by any suitable device. In another preferred embodiment the heat activated adhesive may be provided in the recess 5506 by computer controlled robots such as in the form of a heated and softened continuous extruded bead that may be subsequently heated so as to provide good bonding in the recess, followed by cooling thereof to provide hardening of the heat activated adhesive. Heat activated adhesives may be applied to the tray with flaps or any other suitable packaging materials by any suitable method prior to bonding.
Subsequent exposure to microwave or other suitable source of heating, that can be selectively applied in such a manner so as not to cause undesirable damage or distortion to the packaging materials, can produce a package according to the present invention.
A
suitable device for adhesive application to selected surfaces of packaging may be provided by the known process of ink jet printing.
Any suitable substances for enhancing the keeping qualities of goods can be provided into the spaces between the flaps and the tray walls. Water, liquid and purge absorbing substances can be provided in those spaces which may be arranged so as to be non absorbing prior to exposure to and capable of absorbing liquids only after exposure to microwaves or a magnetic field.
Apparatus for Appl~g. Adhesives and Iron Powder to Tray Trays constructed according to the present invention may have one or more features which lends itself to be stackable or allows the channeling of gases, while 7~ AMENDED SHEET

retaining liquids. Trays with flaps are preferably constructed with adhesives to form the finished tray. This description therefore provides a method and apparatus for applying adhesives and other substances to the trays.
Referring now to FIGURES 140-142, an apparatus constructed according to the present invention that can be used to apply substances to the surface of packaging materials, such as EPS trays, for bonding thereto is shown.
In FIGURE 140 a cross-sectional view through a diagrammatically represented apparatus is shown where a horizontally disposed motor driven conveyor 5400, can be intermittently indexed by driving for a set distance or movement.
Magnets 5402 can be located in the conveyor 5400 in convenient positions. A
web of tray 5404 impressions can be arranged to mate with the conveyor 5400 and can thereby be earned by the conveyor. The distance traveled by the conveyor in each movement or index is equal and can be arranged so as to carry a single tray impression a distance equal to the machine direction length of each consecutive tray impression. Such an arrangement can therefore position each tray impression adjacent to a station or processing device for a desired period of time followed by further movement of the tray impression to a subsequent station to allow further processing. FIGURE 140 shows a first, second, and third station which are marked 5406, 5408 and 5410, respectively. Station 5406 is arranged to apply an adhesive 5414 by a nozzle spray device 5412 to an exposed surface of the tray impressions. Station 2 is arranged to dispense iron powder 5416 or other suitable substance, from a conveniently located hopper 5418 with valve 5420, directly above an exposed surface of a tray impression that has had adhesive applied thereto.
Magnets 5402 which may be arranged as permanent or as electrically induced (electromagnets) magnets, are conveniently located in the conveyor such that when iron powder 5416 is dispensed from hopper 5418, it will be attracted toward the magnets 5402 and be deposited in a pattern on the exposed surface of the tray impressions. The pattern of iron powder deposits can be determined by the profile/shape of the magnets 5402 which can be adjusted as required to provide a suitable pattern. The powder 5416 may be then bonded by adhesive to- the tray impression 5424. Third station 5410 can be arranged to apply drying or curing, such as a radiant heater 5422, to the adhesive sprayed and tray impressions 5424 and thereby cause setting and/or drying of the adhesive applied at the first station 5406 with iron powder 5416 thereto. The iron powder applied at second station 5408 can thereby be suitably bonded to the tray impression 5424. Additional stations may be AMENDED SHEET

arranged, adjacent to the conveyor 5400 so as to apply additional layers of adhesive and/or additional substances as may be required.
Referring now to FIGURE 141, a cross-sectional view through a section of a diagrammatically represented apparatus is detailed and showing a profiled vacuum plate mating with a section of an EPS tray that is located between a manifold and a vacuum plate 5428. Manifold and the vacuum plate can be attached to moving devices such as pneumatic cylinders that can be operated as desired to move the vacuum plate and the manifold toward and away from each other in an automated cycling and repetitive sequence. The vacuum plate and the manifold can be closed together so as to conveniently clamp an EPS tray {or other material) therebetween for a period of time. The EPS tray can be arranged with perforations 5430 therein.
The perforations can be located in a recess shown as 5432 in the enlarged view in FIGURE 142. The vacuum plate can be provided with vacuum ports 5434 therein and located so as to provide connection between the under surface of EPS tray and a suitable vacuum source 5436. In this fashion a vacuum source can be applied to the under surface of the EPS tray with communication through the perforations 5430.
The manifold can be provided and arranged with suitable openings that connect selected exposed sections, such as sections 5440 and 5442, on the exposed surface of the tray to a source of powdered substances "ADSP". In this way powdered substances, such as heat activated adhesives, can be provided into the manifold openings and by applying a vacuum source to the underside of the tray, the powdered substances can be deposited onto the exposed surfaces of the tray and/or in recesses such as recess 5432. After the powder 5416 has been deposited into the recesses 5432 the manifold and vacuum plate can be opened pneumatically allowing the EPS tray to be removed therefrom and subsequently passed into and through a suitable heat and/or suitable energy source, such as a microwave oven. The powder 5416 can be arranged to contain substances such as water or suitable metal elements, so that when the tray with powder 5416, 5444 is exposed to a microwave, magnetic field or other suitable source of heating energy, the powder will be heat activated and bond together and to the surface of the tray and in the recess 5432. The powder 5416, 5444 can thereby be securely bonded to the EPS tray at selected locations on the exposed surfaces of the EPS tray. This method of using a magnetic field, microwave or other suitable source of heating energy can selectively heat the powder 5416, 5444 without application of excessive heat to the EPS tray.
Powder application apparatus including the vacuum plate and the manifold material clamping AMENDED SHEET

devices with all required driving and controlling apparatus can be integrated into a typical thermoforming equipment, such as an Irwin Magnum or a Commodore 730-12 MM continuous thermoformer (as manufactured by Commodore Machine Company of Bloomfield, New York. The disclosed powder application with selective microwave heating of the powder 5416, 5444 can be located between a thermoforming station and a trim press of the thermoforming equipment. In this way, a heat activated adhesive can be applied to specific locations of any suitable material such as the flaps andlor tray walls of EPS trays such as a tray with flaps described above.
Apparatus for A~plying_Adhesives and Iron Powder to Outer Cover Referring now to FIGURE 143 an embodiment of apparatus constructed according to the present invention to apply adhesive materials and powdered iron to a web of material such as stretch or shrink wrapping materials is shown.
The description disclosed herein provides details of a method and apparatus for producing stretch or shrink wrapping material that can be used in the production of those packages disclosed above, having an outer cover web material. The stretch or shrink wrapping material with powdered iron attached thereto absorbs any residual oxygen that may be present within the master container and also the cell structure of EPS materials used in the production of the finished package.
The apparatus shown in FIGURE 143 includes a series of rollers, a hopper containing powdered iron, a tray containing solvent based adhesive, an oven and a continuous web of outer cover material 4300 that is arranged to follow a path over rollers, through oven and onto a web winder assembly as shown. The sketch includes a cross-section through the apparatus.
A suitable tension is applied to web outer cover materia14300 which is arranged to follow a path over idler roller 4302 and then to contact imprint roller 4304, over roller 4306, between oven segments 4308 and onto a roll 4310 at a web winder assembly 4312. Web 4300 is wound onto roll 4310 by web winder assembly 4312 at a suitable tension and speed. In this manner, imprint roller 4304 is arranged to apply a suitable adhesive, which may be solvent based, onto web 4300 in a registered print pattern and in rectangular areas 4314 as shown in FIGURE

where a section of finished web material 4316 is detailed in plan view, with a cross-sectional view shown in FIGURE 145, after processing through the apparatus shown in FIGURE 143. The method includes transferring the adhesive 4318 from the tray 4320 via contact with roller 4322 which in turn transfers the adhesive to transfer 78' AMENDED SHEET

_98_ roller 4324 which in turn transfers the adhesive onto the imprint roller 4304.
Transfer of the adhesive from the transfer roller 4324 to imprint roller 4304 occurs only at selected areas on the roller 4304 that correspond with the rectangular areas 4314 such that areas 4314 only are imprinted with the adhesive applied thereto and leaving other sections of the outer cover 4300 free of adhesive. The outer cover web material 4300 can be printed with information and graphics as required on the opposite side of the web to the applied solvent based adhesive in rectangular areas 4314 and in registered relationship to the rectangular areas 4314, such that when the web 4300 is cut by slitting along the length of the outer cover web, and wound conveniently onto rolls, the web 4300 can be applied, in an earlier described manner to cover the finished packages and with the rectangular area 4314 adjacent to and in direct contact with the base of trays.
Refernng again to FIGURE 143, powdered iron is dispensed from the hopper evenly across the web, so as to fall directly downward toward web 4300 above roller 4306. Roller 4306 includes a tube manufactured, most preferably, from a non metallic material such as fiberglass and is cylindrically ground on both internal and external surfaces to provide a finished tube of specified internal and external diameters. External diameter is arranged so as to have a circumference equal to two (x 3 across the web) consecutive imprints (6 imprints in total) of rectangular areas 4314 per single revolution of the roller 4306. Correspondingly, during a single, full revolution of the roller 4306, 2 times 3 imprints (6) are applied to the web 4300.
Corresponding to the imprint areas 4314, magnets 4305 are located and fixed to the internal surfaces of roller 4306 in a pattern that corresponds with the rectangular areas 4314 in positions such that when the powdered iron is dispensed from the hopper it is drawn by the magnets so as to be deposited substantially within the specified rectangulai~ areas 4314. When the powdered iron contacts the areas 4314, on the web 4300, the powdered iron bonds to the solvent based adhesive applied by imprint roller 4304. The powdered iron thereby becomes fixed to the web 4300 by adhering to the solvent based adhesive. The web 4300 then passes between the oven segments 4308 that are arranged to have sufficient capacity to cure and dry the solvent based adhesive prior to further processing and/or winding of web 4300 onto the roll 4310 by web winder assembly 4312.
Web 4310 may be further processed by applying solvent based adhesive onto rectangular areas 4314 after the powdered iron has been applied and cured together therewith by passing through the oven segments. This process may be repeated 79.' AMENDED SHEET

several times and as may be required to produce the most effective finished outer cover web 4316 materials.
In yet another preferred embodiment other web materials such as perforated polyethylene and polyester may be laminated to web 4300 and over the powdered iron. Most preferably the powdered iron will thereby be applied and retained between the outer cover 4300 and the polyethylene and for polyester webs in such a manner so as to allow oxygen to transmit through the outer webs and contact the powdered iron and after reacting therewith, inhibiting the escape of any odor that may be produced as a result of oxygen reacting with the powdered iron, and/or other substances contained therein. Solvent based adhesive can also allow transmission of oxygen therethrough while inhibiting transmission of odors therethrough.
Alternative oxygen absorbing materials that are suitable for the application may be applied with the iron powder or in place thereof.
The finished web material4316 can be slit and wound onto conveniently sized rolls for subsequent use as the outer cover of packages similar to the finished packages described above.
Tray Sealing Apparatus Webs suitable for use as trays and covers have thus far been disclosed. A
method for sealing a cover to a tray web now follows.
Referring now to FIGURE 146, a tray sealing apparatus is shown to produce packages, including a tray, a web and perishable goods contents shown as ground meat. The perishable good ~ may be portions of beef, pork, or any other suitable perishable goods. A horizontally disposed, continuous conveyor 2326 including a number of carrier plates 2302 suitably attached to chains is arranged adjacent and below a series of stations. The conveyor 2326 is driven by a driver that intermittently indexes in a forward direction indicated by arrow 2328, at a rate of one carrier plate per index. Trays 2300, as described in any of the previous embodiments, are dispensed into apertures in the carrier plates 2302 at a first station generally denoted by the number 2330. With each progressive forward indexing movement of the conveyor, stations will perform a function. Cutting devices at a second station generally denoted by 2304 severs flaps. Product such as portions of ground beef is leaded into the tray at a product loading station 2306, and a web of material 2308 is heat sealed to flanges at a heat sealer station 2312. Scrap material from web 2308 is wound onto scrap roll 2310. Preferably, tray apertures are provided by heated pin devices at station 2314. Flaps are turned over by rotating AMENDED SHEET

about hinge so as to then locate flanges adjacent to tray 2300, at flap turning station 2316. Preferably flanges of flaps are then sealed to flanges of tray at station 2318 and flange trimming is performed as may be required at station 2320.
Labeling is done with a tray labeler at station 2322. The finished tray with perishable goods packaged therein is ejected from the conveyor at an ejector station 2324.
Referring now to FIGURE 147, a preferred tray constructed according to the present invention is shown in an inverted position. The tray 2402 includes those apertures made by the apparatus of FIGURE 146.
Method and Apparatus for Evacuatin~~ Master Containers Trays constructed according to the present invention provided structures which allowed the evacuation of ambient atmosphere and flushing with inert gases.
Trays according to the present invention are also stackable atop one another to allow placement within a master container. Therefore, a method for evacuating a master container appropriately follows.
Referring now to FIGURE 148, details of a vacuum and modified atmosphere packaging and sealing apps~.atus is shown. The apparatus 3564 can be used to hermetically seal a web of material over the open end of a plastic bag or pouch. The web of material and pouch may include substantially gas barrier materials and the hermetically sealed pouch and web can be used for any useful purpose, such as vacuum packaging meat primal portions or to contain one or more retail packages, thereby providing a master package which can be subsequently packaged inside a suitably sized shipping carton.
The apparatus 3564 includes a lower vacuum chamber 3566, that is suitably mounted with a driver (not shown) attached to a shaft 3568, an upper vacuum chamber 3570 with a moveable heat bank 3572, attached to a driver (not shown) via shaft 3574 and suitably mounted between the upper and lower vacuum chambers, and a web unwinding assembly 3576 arranged to allow controlled unwinding of web material 3578 from roll 3584. A conduit 3582 is connected to upper vacuum chamber 3570 and a conduit 3584 is connected to lower member 3566. Both conduits 3582 and 3584 can be connected to a suitable source of vacuum and/or supply of suitable gas. The upper vacuum chamber 3570 is fitted with a suitable rubberized sealing member 3586 which is attached to the rim of the vacuum chamber 3570 and a corresponding and matching sealing member 3588 is mounted, in similar fashion, to a rim of member 3566, so that when the upper and lower vacuum chambers are closed and held together, members 3586 and 3588 are in $1.' AMENDED SHEET

intimate contact with each other, thereby providing an enclosed vacuum chamber that is sealed from ambient atmosphere with space 3590 contained therein. Web unwind assembly 3576 is arranged to unwind material 3578 from roll of material 3584, as required, and locate the web between the upper and lower vacuum chambers. In this way suitable portions of the material 3578 can be automatically unwound by web unwind assembly and clamped between sealing members 3586 and 3588. Referring now to FIGURE I50, it can be seen that rim at 3588 is extended beyond rim at such that when web 3578 is clamped between members 3566 and 3570 a space 3594 between the web 3578 and the rim at 3592 is provided. Sealing members 3588 and 3586 are parallel and follow adjacent paths at parallel perimeters of the respective members 3570 and 3566 along corresponding rims at 3586 and 3588, such that when the vacuum chambers 3570 and 3566 are closed together a completely sealed and defined space 3590 is provided therein. In this way space 3590 can be evacuated and substantially all air contained therein removed, as required, and then space 3590 can be filled with suitable gas such as nitrogen, C02 or any other suitable blend of gases, at a suitable pressure, via conduits 3582 and 3584.
Referring now to FIGURE 149, a three dimensional sketch is shown of the lower vacuum chamber with a portion of the lower vacuum chamber shown in FIGURE 150. The vacuum chamber can be manufactured from any suitable material such as stainless steel. It can be seen that vacuum chamber 3566 includes a rectangular profiled component with vertical walls and a rectangular depression 3596 provided therein; two parallel and continuous rims, an inner rim 3592 and an outer rim 3598 are provided with a recess 3600 between the parallel rims. A suitably sized pouch 3602 can be located into the depression 3596 and the "mouth" 3604 of the pouch can be cuffed over the rim 3592 such that the mouth of the pouch is tensioned around and over the external and upper surface of rim 3592. A vacuum source can be provided to recess 3596, via conduit 3584, such that the pouch can be drawn against the internal walls of the depression 3596, prior to closing the upper and lower vacuum chambers together. In this way the mouth portion of the suitable pouch can be tensioned across the rim 3592 in such a manner so as to ensure that no creases are present in the pouch mouth section that is located directly adjacent (and above) the rim 3592. Any suitable stretching devices may be provided that will stretch the mouth section of the pouch and ensure that no creases are present, thereby allowing subsequent and effective sealing of the web 3578 to the pouch when required.
Following loading of goods into the pouch 3602, heat bank member 3572 can be AMENDED SHEET

activated so as to provide heating and sealing of a section of web 3578 to the mouth of the pouch around the full continuous length of rim 3592. An automatic cutting device 3606, can be arranged so as to provide suitable cutting and severing of the web 3578 after sealing to the pouch. In this way web 3578 can be hermetically sealed to the mouth section of the pouch 3602 so as to completely seal and enclose any space and goods that may be located in the pouch prior to sealing of web 3578 thereto.
Any suitable method of manufacturing a suitable pouch with adequate gas barrier properties may be employed to manufacture the pouches. For example the pouch may include a suitably sized; multi-layer plastics tube, extruded from an annular die with specified layers of material that provide all gas barrier and sealing properties and features required. Such a tube may be extruded and cut into suitable lengths and then heat sealed to close one end of each length of tube, in any suitable fashion, to produce pouches and, if required, a valve may be fitted to the wall of the pouches. The valve can be arranged to allow excess gas such as carbon dioxide, that may be generated in the pouches after sealing with goods, such as carbonized retail packaged ground meat, therein.
Referring again to FIGURE 149, a grouping of several identical such members 3566 may be arr2nged by attaching to the upper surface of a suitable conveying device such as a horizontally disposed carousel style, circular table, of suitable size arranged with suitable driver to intermittently rotate the carousel. In this way, pouches could be automatically loaded into each lower vacuum chamber 3566, consecutively and immediately prior to loading goods into the pouch. After loading the goods, the carousel can rotate so as to locate the loaded member 3566 directly under upper vacuum chamber 3570 and web unwind assembly so as to allow sealing of a section of web-3578 thereto. In this way, an automatic and semi-continuous packaging process can be arranged to automatically open the pouches, load into member 3566, fill the pouch with goods, evacuate and gas fill the pouch with goods therein and then heat seal a web of material 3578 over and to the mouth of the pouch.
An automatic ejection device can be provided that may include a method of relaxing tension in the pouch mouth and lifting the sealed and finished pouch (with goods therein) from member 3566 and then locating the finished pouch into a carton prior to closing the carton closed aid sealing the finished pouch therein.
Referring to FIGURE 213, yet another preferred embodiment of an apparatus 8300 for producing a master container with finished packages is shown.
$3 AMENDED SHEET

Equipment 8300 includes an upper chamber $306 and a lower chamber 8310. A
master container 8316 with finished packages 8308 is contained within lower chamber 8310. The operation of this apparatus is in many respects similar to the previous embodiments. Master container 8316 is loaded with finished packages 8308, and located in the lower vacuum chamber. A web 8314 is passed through the chamber to cover the opening in the master container 8316. The upper 8306 and lower 8310 chambers close, providing a substantially air tight seal.
Air is evacuated through any number of ports 8304 and 8312. a suitable gas is flushed into the chambers. The cycle can be repeated any number of times to expel IO the air and/or oxygen from the master container 8316 and packages 8308. The master container is then sealed with web 8314. The vacuum chambers separate, and a new master container is evacuated, flushed and sealed.
In yet another preferred embodiment, the packages need not have apertures, but rather are sealed or wrapped with a web that expands to fill the voids in the master container to expel the air. This is possible because the web preferably has memory, to contract to its relaxed state. The packages need not be evacuated because packages can be wrapped in a low oxygen atmosphere according to the invention, thus eliminating the need for values.
Method and Apparatus for Packaging=Labeling and Wei ping Trays containing perishable goods are preferably weighed and labeling prior to sealing. Therefore, it is appropriate to describe a method and apparatus of the invention for such a task.
FIGURE 151 shows a packaging machine constructed according to the present invention to apply labels) to the second web and also an alternative printing device to print directly onto the second web. Reference is also made to patent application PCTIAU93/00484, which is herein incorporated by reference.
FIGURE 151 shows a side elevation of the packaging apparatus and FIGURE 152 shows a plan view of the upper side of the packaging machine of FIGURE 151.
Packaging machine 1800 is arranged in two sections to provide a space so as to allow a sufficiently clear area to install a scale 1802 with load cells 1828.
Packaging machine 1800 is mounted and attached to the floor (also shown) independently of scale 1802 such that they are not in contact with each other. Second web unwind roll 1806 is provided with braking devices attached thereto. Drive 1804 is arranged to unwind second web from rill 1806 of second web 1812. Printer 1808 is located between second web roll 180ti and third web roll. Printer 1808 is attached to driver to move in X, Y and Z axis in horizontal and vertical planes. Printer 1808 includes a mechanism to print onto labels and then apply labels to second web or alternatively print directly onto second web. Third web roll 1810 is located above second web 1812 and is fitted with braking devices as well to maintain tautness of the web as it is unrolled. Packaging apparatus 1800 includes a vacuum chamber assembly.
The assembly includes a number of components including a lower 1816 and upper 1824 vacuum chamber, a lower 1820 and upper 1822 plate and a sealing plate 1818.
FIGURE 154 shows a cross-section through the vacuum assembly - constructed according to the present invention. Sealing plates 1818 are arranged in a conveyor which is driven by a motor as required providing intermittent movements of the conveyor 1826. Lower vacuum chamber 1816 is independently moved by pneumatic driver (not shown) so as to apply pressure to underside of sealing plate 1818. Plate 1820 is located between sealing plate 1818 and plate 1822.
Plate 1822 has vacuum port 1830 provided therein. Upper vacuum chamber 1824 is located above plate 1822. All components are in vertical alignment and when lower chamber 1816 and upper chamber 1824 are retracted and moved in the vertical plane away from each other, plates 1818, 1820 and 1822 which can be spring loaded also "expand" away from each other so as to allow free movement of first 1836 and second 1832 webs between plate 1820 and plate 1822 or between plate 1818 and plate 1820 as may be selected according to requirements or preferred operation of apparatus. As is shown in FIGURE 154, third web 1834 enters the vacuum chamber assembly between plates 1822 and 1824 and exits the vacuum chamber assembly between plates 1820 and 1822. Also it can be seen that second web 1832 enters vacuum chamber assembly between plates 1820 and 1822. A space 1838 is shown between the second 1832 and third 1834 webs with port 1830 opening into space 1838. During the operation of the packaging apparatus, after closing of lower vacuum chamber 1816 and upper vacuum chamber toward each other thereby providing a closed and sealed vacuum chamber, a vacuum source can be applied to port 1830 and thereby evacuate substantially all air from the space 1838.
Evacuation of air from space 1838 can cause second 1832 and third 1834 webs to become laminated together after removing substantially all air from the space 1838.
Slots shown as 1840 are provided between the faces of plates 1816 and 1818, 1818 and 1820, 1820 and 1822, and 1822 and 1824. These slots provide spaces between each of the components also, "O" rings are fitted along the outer edges of each slot to AMENDED SHEET

provide a seal when the components are in contact with each adjacent component. A
vacuum source can be applied to each of these spaces, simultaneously, thereby providing a method to hold them together with a force equal to that provided by the ambient atmospheric air pressure prevailing at the time. The holding force that urges the components together is therefore approximately equal to the width of the slots between each component, times the length of the slot, multiplied the difference of the prevailing atmospheric air pressure minus the air pressure within the slots defined by the equation:
F = WL(Pa PS)wherein, F is the force, W is the width of the slot, L is the length of the slot, Pa is the atmospheric pressure, and PS is the pressure inside the slot.
The width of each slot can be arranged, by enlarging (or decreasing) so as to provide a level of force that exceeds the desired and opposing force of gas pressure within the closed chamber. A pair of "O" rings are also provided around all shafts that penetrate the chamber and spaces provided between each pair of "O" rings can also be evacuated.
Refernng again to FIGURE 151, printer 1808 is equipped so as to either apply a label or print desired information onto second web 1812. Load cells 1828 are located along a beam 1854 that extends across and under the full width of sealing plates 1818. Beam 1854 can be elevated and lowered. Scale 1802 and beam 1854 is arranged to elevate load cells 1828 upwardly so as to contact underside of trays in apertures of sealing plates 1818 and lift the trays from apertures in sealing plates 1818 in conveyor. Trays are lifted to an extent that prevents any contact with anything else apart from the load cells 1828. The weight of each separate tray can thereby be determined and this information is transferred to a printer 1808.
Printer 1808 prints information onto labels (prior to application of label onto second web) or directly onto the second web 1812. Second 1812 and third web 1856 are then laminated together before heat sealing to flanges of first web trays.
FIGURE 153 shows one embodiment of a single register detail of second web. The single register detail includes a frame 1842 of heat activated adhesive that can be printed directly onto web. The frame is arranged with dimensions that correspond to the flange of third web tray such that the frame 1842 covers flanges R$~= AMENDED SHEET

and located above third web tray. Other details of package contents are also shown and boxes 1846 provide areas onto which information can be printed at the time of packaging. Barcode 1847 contains product information, such as date of packaging and weight, which can later be used to determine price at the point of sale.
FIGURE 155 shows a cross-section view through a laminating assembly including a first 1848 and second 1850 driven rubber coated roller arranged in horizontal disposition and with devices (not shown) to be urged toward each other so as to press and laminate the second 1832 and third 1834 webs when the webs are passed between the rollers. Rollers are driven by a variable speed motor (not shown). Laminating assembly can be located between the third web roll 1810 and the vacuum chamber assembly and provide a method to laminate second 1832 and third 1834 webs together before entering the vacuum chamber assembly.
Method and Apparatus for Facka~i~ Trays Trays with flaps constructed according to the present invention can be sealed by a first and second web. Webs are sealed to the flap in the non-folded state in two or one heat sealing stations. Ilpon bending of the flaps, the webs are stretched, thus, providing a taut appearance and protection for the perishable goods inside:
The following description provides apparatus and methods for production of a package of the type shown in FIGURE 158, with a pre-stretched second web 1004.
The preferred use of this embodiment is for the packaging of shallow products such as boneless pork loin chops, butterfly steaks, thick-cut bone in pork chops and New York Strip, super trim beef and pork cuts that are generally not displayed in the package by shingling but are laid flat and adjacent to each other and spaced apart so that a consumer can inspect carefully.
FIGURE 168 shows a sketch of a side elevation of a preferred packaging machine constructed according to the present invention that can be used to produce packages of types described herein in this disclosure. The packaging machine includes a frame supporting a driven conveyor with two roller chains located one on each side the packaging machine and engaged with a first 1044 and second 1128 set of sprockets, each pair of the sprockets is located at opposite ends of the frame.
Sealing plates, 1012, as shov~m in FIGURES 159-162 are attached to the roller chains via attachment points. First and second stations, generally denoted by 1014 and 1016, respectively, are located on the upper side of the packaging machine with web unwind arrangements rolls 1130 and 1132 and scrap web wind-up arrangements at 1120 and 1138. Continuous conveyor 1010 carnes sealing plates 1012 in the $.' AMENDED SHEEI-direction indicated by arrow 1126. Details of a preferred sealing plate 1012 can be seen in FIGURES 159-162. Preferably, first and second stations 1014 and station 1016 are mounted onto the upper side of the packaging machine frame adjacent to the upper section of the conveyor 1010. A loading section 1018 is preferably located adjacent to and down stream of station 1014. Conveyor 1010 is supported within the frame and is attached to a powered indexing device for moving the conveyor 1010 and sealing plates 1012, intermittently and in a direction from loading section 1018 toward first station 1014. Preferably, each intermittent movement of conveyor 1010 travels one pitch which is equal to at least the distance required to move a sealing plate 1012 the full distance of the length ef the sealing plate. Preferably, with each movement of the conveyor, a sealing plate is located directly between the lower vacuum chamber 1020 and the lower clamp plate 1022 shown in FIGURE 167. Preferably, a sealing plate is also located directly beneath heat bank 1024, as shown in FIGURE 159. Preferably, this arrangement transfers a package that has been sealed in first station 1014, to a subsequent location at second station 1016. Preferably, the driving devices for the packaging machine, machine components and conveyor are a pneumatic cylinder and electrically powered driving motors of suitable size and capacity. The pneumatic cylinders are attached to shafts 1030 (attached to heat bank 1024), 1032 and 1028 (attached to water-coded clamp 1036) and, 1034 and 1026 (attached to cutting device 1038), and provide independent reciprocating movements to each shaft and attachments generally in the directions shown in the diagrams by arrows drawn adjacent to each attachment.
Similarly, pneumatic cylinders (not shown) are attached to upper 1056 and lower 1020 chambers to provide reciprocating movements parallel with shafts 1030, 1028, 1032, 1026, and 1034 to provide movement and apply pressure as required.
Preferably, an electrically powered drive motor 1042 is attached to conveyor sprocket 1044 so as to intermittently drive the conveyor 1010 as required such that the upper section 1046 of the conveyor travels in a direction from right to left.
First Heat Sealing and Vacuum Chamber FIGURE 167 shows a cross-sectional view through a first station vacuum chamber assembly 1014 constructed according to the present invention which details the first 1002, second 1004 and third 1006 webs prior to sealing the webs together.
This vacuum chamber has a plate, separating the second and third webs, unlike the chamber of FIGURE 154. Meat is loaded into tray (first web 1002) and then each loaded tray is placed into ape:-tures in sealing plate 1050. The conveyor indexes $8~~ AMENDED SHEET

forward such that a loaded tray is located at first station 1014. During indexing, third web 1006 and second web 1004 are also indexed forward and a longitudinally disposed tension can be applied to third and second webs and in a direction parallel with the conveyor. Preferably, lateral stretching can also be applied to second web 1004 such that it is stretched taut. Upper clamp member 1052 and lower clamp member 1022 then close against the middle clamping plate 1054 thereby clamping and firmly holding third and second webs 1006 and 1004, respectively.
Preferably, lower vacuum chamber 1020 and upper vacuum chamber 1056 are closed against the clamping plate assembly such that a substantially "airtight" seal is provided and the upward movement of lower vacuum chamber 1020 lifts sealing plate 1050 and holds it firmly against the underside of the lower clamp 1022 thereby providing substantially "airtight" seals around the perimeter of the upper and lower vacuum chambers 1056 and 1020. Closing the upper and lower chambers thereby defines a single enclosed chamber that is substantially isolated from atmospheric gasses.
During the procedure of closing the upper and lower chambers, the lower vacuum chamber 1020 lifts the sealing plate 1050 upwardly and tray (first web 1002) is carried upward. The upper rim portion of sealing plate 1050 and 1058 contacts the underside of second web 1004 stretching second web upwardly until sealing plate 1050 contacts the underside of lower clamp 1022 at surface thereby stopping the upward movement in a closed and substantially "airtight" condition.
Preferably, the second web 1004 is now stretched taut across the opening of the ring 1058 and distanced preferably about 1/64" to about 1/2, and most preferably about 1/8"
above flange 1072 (FIGURE 158) and preferably about 1/64" to about 1/2, and most preferably about 1/8" below third web 1006.
Preferably, atmospheric air contained within the enclosed chamber is then substantially evacuated through evacuation ports 1008, to a pressure of less than 5 ton. Preferably, immediately after evacuation, the chamber can be filled with carbon dioxide gas, or a blend of carbon dioxide and nitrogen gasses, to a pressure of up to 2 bar (28 psi) or more, by injection through ports 1064 and optionally 1008, and held at pressure for a period of 1 to 5 seconds or more and most preferably until water and goods in the tray have become substantially saturated with dissolved carbon dioxide.
The gas pressure within the chamber assembly can then be lowered to a pressure equal to that of the prevailing ambient atmospheric pressure prior to sealing.
Evacuation and gassing of the chamber assembly in accordance with the invention, provides a method of filling packages with a chosen gas such that the residual $9.' AMENDED SHEET

atmospheric oxygen that remains within the package does not exceed an amount about 0.05% by volume of the gas that remains within the package after sealing the first 1002, second 1004, and t?~ird 1006 webs together.
Referring now to FIGURE 167, a clamping member 1036, that is preferably water cooled, can now be moved and positioned so as to clamp third web 1006 against second web 1004 and in turn against the inner edge portion of flange 1072 on first web tray 1002. Preferably, heat bank 1024 can then clamp and heat seal second and third webs 1004 and 1006 to flange of first web 1002, under pressure.
Preferably, heat bank 1024 can now be retracted followed by cutting of second and third webs with cutting member 1040 attached to cutting device 1038. The cutting member is withdrawn from the cutting position followed by release of clamp 1036.
Preferably, enclosed vacuum chamber assembly can then be opened allowing conveyor to move forward a single pitch followed by closing the enclosed chamber assembly, followed by evacuation, gassing and heat sealing. Preferably, this cycle can be repeated in an automatic and continuous mode. Vacuum chamber assembly constructed according to the present invention and frame to which it is attached is built in a manner that will allow continued cycling of the packaging process and pressurization without sustaining excessive damage other than normal wear and tear.
An optional method of using the apparatus whereby a gas is not provided in the space between third web 1006, the upper barner web, and second web 1004 (so as to subsequently facilitate urging of the second 1004 and third 1006 webs together), before sealing the third web 1006, second web 1004 and first web 1002 (shown as tray) together at a path near what will be a perimeter of the package. The tray 1002 is elevated so as to urge second web 1004 toward the underside of third web thereby providing stretching means to second web 1004 to sealing webs together to form a package. Apparatus for evacuation of substantially all air from the space between the third 1004 and the second 1004 webs, through ports 1008 is optionally provided.
Preferably, packages are then transferred from the vacuum chamber at first station 1014 via the conveyor to the secondary sealing apparatus located at second station 1016.
Second Heat Sealin~LChamber Referring now to FIGURE 156, a cross-sectional view of second station 1016, constructed according to the pr~;sent invention is shown in a partially closed position.
AMENDED SHEET

Refernng to FIGURES 157-I58 a cross-sectional view through a finished and sealed package constructed by second station 1016 is shown. Package 1092 includes a flange with second web 1004 and third web 1006 attached thereto. Shown is first web, tray 1002, formed with two flange portions 1072 and 1074. Preferably, flange portions 1072 and 1074 are adjacent and concentric to each other, with flange located on the inner side of flange 1072.
Referring now to FIGURE I56, an assembled package is positioned in the sealing plate which is located beneath heat bank 1070. It can be seen that lip has a profile that corresponds and follows the path and plan profile of flange portion 1074. A section of flange 1074 can be clearly seen in the enlarged cross-section in FIGURE 157. Preferably, flange portion 1074 is parallel and concentric to flange portion 1072 but follows a path on the inner side of flange portion 1072 and at a plane shown to be at a distance 1076, about 1/8", below flange portion 1072.
Preferably, heat bank 1070 is pneumatically operated and can extend downwardly and be retracted upwardly as required to exert a force such as to provide pressure onto the lip 1080 and when engaged with flange portion 1074, simultaneously depressing third and second webs that' are then held, under pressure (sealing pressure), between the surface of flange portion 1074 and lip 1080 for a set period of time (set time). Preferably, the temperature of heat bank 1070, and correspondingly lip 1080, can be controlled and is set at a suitable temperature (set temperature).
Preferably, the temperature of heat bank 1070 is less than temperature of heat bank 1024 located in first station 1014. Preferably, pressure is applied at lip 1080 and can be set at sealing pressure. The suitable time of contact and clamping of third and second webs to flange portion 1074 can be varied. Time of contact is defined as the length of time during each cycle from the first instant of first contacting between lip 1080 and flange portion 1074 through the third and second webs, to the first instant of no contacting after retraction of heat bank 1070. Thereby, when the set temperature, sealing pressure and set time of heat bank 1070 are adjusted as required, the selective heat sealing of second web to flange portion 1074 can be achieved while third web does not heat seal to second web. This can preferably be achieved when first, second and third webs include materials as shown in FIGURES 43 and 44.
Referring now to FIGURE 43 a representation of an enlarged view of a section through a flange portion of an assembled package is shown. FIGURE 43 shows heat sealing bars and a section of a rubber seal mounted on sealing plates around the perimeter of the apertures in the sealing plates. Details of materials that ~.~'l' AMENDED SHEET

can be used in the first, second and third webs are also shown and described in detail below: Preferably, third web 1006 is a co-extruded web including at least two layers with a first layer 1082 of Eastman PET 9921 and a second layer 1084 of material on the underside of the third web including a blend of 2 grades of Eastman polyesters in amounts of about 50% Eastobond 6763 and about 50% Eastobond 9921 or alternatively the layer on thA underside may be about 100% Eastman PM 15086.
Preferably, third web can be about 0.006" thick, about equally divided between first and second layer. Preferably, second web 1004 is a web of pPVC with a thickness of about 0.0008". Preferably, first web 1002 includes a thermoformed tray produced from a multilayer co-extruded web with an outer layer 1088 of Eastman 9921 and an inner layer 1086 including a blend of about 50% Eastman PETG 6763 and about 50% Eastman 5116 (or Eastman PM14458 or equivalent). Preferably, first web has a thickness of about 0.012" where the inner layer 1086 is about 0.004"
thick and the outer layer 1088 is about 0.008" thick. Preferably, under such conditions the heat transferred through third web is insufficient to cause bonding between the third and second webs but sufficient to cause bonding between the second and first webs at flange portion 1074. Preferably, such arrangement provides stretching of second web, after sealing of third and second webs to first web at first station 1014.
Preferably, applying gas pressure to the upper surface of the third web, when located at second station 1016, so as to cause the second and third webs to depress downwardly and substantially conform to the contours of flange portion 1074 prior to providing heat seal 1090 provides an alternative step in the method.
Preferably, second web 1004, will have a feature known as a "memory". The term "memory", in this context, is known in the packaging industry and is characterized as a material that will substantially return to its original shape after distortion has occurred due to, for example, a consumer "feeling" the goods contained within the package while the package remains intact, with second web sealed to the tray flanges. This can cause finger marks and depressions in the second web as prospective purchasers of the package examine it prior to purchase during retail display of the package. After excessive handling by consumers the package can become unattractive to an intending purchaser and financial losses can result therefrom. Materials such as polyethylene substantially do not have "memory".
However, plasticized PVC (pPVC) web materials, such as are made by Borden do provide this important feature. Second web constructed from pPVC may be perforated by perforating apparatus to improve gas transmission therethrough.
$2.AMENDED SHEET

Preferably, perforations can be provided in second web 1004. The perforations can allow gas to permeate into a space between second web and third web. Preferably, when the gas pressure inside the sealed package is at a pressure slightly above ambient air pressure, third web will be stretched outwardly into a dome shaped condition thereby providing a gas buffer between third web and the surface of goods beneath the second web. Second web may be in contact with the surface of package goods, alternatively a space can be provided therebetween.
Preferably, the seal between second web and first web may be arranged such that it is not a continuous seal along the full path of flange portion 1074 and may be arranged - 4s an intermittent sealing, completely along one or more sides only or parts thereof.
In yet another embodiment heat bank 1070 may be mounted at first station 1014, concentrically with and on the inside of heat bank 1024 within the same chamber but with separate moving shafts. Such an embodiment would allow sealing at flange portion 1072 and flange portion 1074 without the need to transfer the package from first station 1014 to second station 1016 for sealing of flange portion 1074. Preferably, web cutting devices are located at second station 1016 to separate the sealed and finished package 1092 from webs.
After passing through stations 1014 and 1016 on packaging machine, the finished packages are ejected from the machine.
In yet a further embodiment, the tray evacuation arrangement can be set up to transfer trays containing goods to a vacuum chamber, evacuate any ambient atmosphere from the trays and then transfer the trays into an enclosure excluding air.
However, the trays have not been sealed with a lid at the vacuum chamber.
Sealin Pg fates Sealing plates constructed according to the present invention are members attached to conveyors to carry trays in the packaging system.
FIGURES 163-166 show the use of sealing plates with trays of the present invention. Package 1224 contains goods 1214 shown in FIGURE 163. In FIGURE 163, the first web 1200, second web 1202, and the third web 1204 are shown sealed together to form a complete package 1224. FIGURE 164 shows a cross-section through the tray (the first web). Dotted lines are shown in FIGURES 164-166. The dotted lines in FIGURES 164-166 show the position of the side walls before insertion of the tray into the aperture 1206 in the sealing plate member I20$. Dotted lines in FIGURE 166 show the relative position of the edge of the flange prior to the tray insertion into the aperture. The aperture is sized to suit .g3~. AMENDED SHEEI-and is slightly smaller than the tray. The aperture is located in member 1208 which includes a plate means with the aperture therein with the aperture having dimensions slightly smaller than the external dimensions of the side walls of the third web tray such that when the tray is inserted into the aperture, the side walls are distorted and urged inwardly. The solid lines show the side walls after the inward distortion and the dotted lines show the relative position of the tray prior to insertion into the aperture. FIGURE 164 shows a plan view of a section of a conveyor such as may be installed in a packaging machine. Sealing plate 1208 may have a plurality of apertures, all of a suitable size and arranged to hold a plurality of the trays in like distorted condition as herein described.
Refernng to FIGURES 159-162, a cross-section of a preferred sealing plate 1050 constructed according to the present invention is shown with a plan view shown in FIGURE 160. Sealing plate includes attachment points 1094.
Preferably, attachment points 1094 attach the sealing plates to a pair of continuous roller chains that engage with sprockets 1044 and 1128 and are located, one at each relative side of conveyor. Preferably, sealing plate 1050 has a depth dimension that is about equal to or deeper than the depth of depressions in first web. Preferably, a rubber seal 1100 is attached to the sealing plate 1050 by an adhesive and is profiled to provide flanges 1096 and 1098 that correspond to flange portion 1072 and flange portion 1074 of first web tray. Preferably, a space between the rubber seal 1100 and rim 1078 is provided to allow clearance for cutting member 1040 during the cutting of the third and second webs after sealing to flange portions 1072 and 1074.
Refernng now to FIGURE 162, a cross-sectional view of the details of sealing plate 1050 are provided. As an example, a preferred embodiment with three apertures 1150 and rubber seals 1100 located around the perimeter of each aperture is shown. However, sealing plates may have more or less apertures and corresponding rubber seals. Preferably, rubber seals are made optional. Preferably, sealing plates are machined from aluminum or other metals or any suitable plastic plate, for example, about 0.75" thick polypropylene with upper 1152 and lower 1154 faces.
Referring again to FIGURE 164, wherein the arrangement of first web 1200 (tray) with a flange 1210 extending continuously around the perimeter of tray 1200 to provide a flat ledge to which second web 1202 is sealed. Preferably, tray 1200 has been distorted such that side walls are urged inwardly and held in position by the limiting size of aperture 1206 located in sealing plate 1208 of FIGURE 165.
Preferably, second web 1202 is a gas permeable material such as pPVC of about ~g~s AMENDED SHEET

0.0008 inches thickness and first web 1200 is constructed of a substantially gas impermeable material such as a co-extruded multilayer sheet of Eastobond APET 9921 and a blend of about 16% Eastobond PETG 6763 and about 84%
Eastobond 9921. A third web 1204 is sealed to second web 1202 adjacent to seal 1212 of the second web to the first web.
Alternatively, the tray 1200 can be formed from a web of polystyrene foam that has been previously laminated to a web of gas barrier material. A second web of material can be sealed to the web of gas impermeable material laminated to the upper side (inside) of foam tray. Trays according to the present invention are substantially impermeable to gases.
Referring to FIGURE 163, webs are shown sealed together by a strip-like seal 1212 on flange 1210 that follows a path that continues around the flange near the perimeter of the package thereby providing a substantially hermetically seated package. Preferably, goods 1214 are contained within the sealed package and a suitable gas blend such as may include about 40% carbon dioxide and about 60%
nitrogen is provided within the package. Preferably, sealing of the package is effected while side walls c~f the tray are urged inwardly. Preferably, side walls thereby retain a tension and desire to return to their original relative position thereby exerting a substantially outwardly disposed urging around the perimeter of the depression in the tray but which is retained and held captive by the combined tensile strength of third and second webs sealed to the flange. Preferably, third web is sealed to the package in such a manner as to allow peeling from the package, without rupturing second web and thereby leaving second web attached to the flange.
Preferably, when third web is peeled from the package the tensile strength of the second web is insufficient to restrain outwardly urging of the side walls, thereby releasing urging and providing a means to stretch the second web into a substantially flat condition. The extent of the urging can be controlled such that it will maintain a tension in second web.
FIGURE 163 shows a finished package that has been produced by the method herein described and, after heat sealing of first 1200 and second 1202 webs together, has been removed from aperture 1206 in sealing plate 1208.
Method and Apparatus for Producing Laminated Webs Having discussed the advantage obtained by packaging trays having second and third webs, another embodiment of producing bilayer coverings is herein described. Referring to FIGURE 169, an apparatus for producing a pre-stretched 95. AMENDED SHEET

second web of flexible gas permeable material laminated to a substantially more rigid gas barrier material is schematically illustrated.
First 1400 and second 1402 roll of web material including a second web 1404 and a third web 1406 are preferably unwound simultaneously and laminated by passing the webs through a pair of "nip" rollers 1408 that apply pressure against each other and to the webs as they pass through nip rollers 1408. Preferably, nip rollers 1408 are driven by any suitably powered driver to rotate at a suitable speed.
Preferably, the laminated web 1412 is rewound onto a single roll 1410 together to produce a laminated web 1412. Third web 1406 may include a semi rigid polyester material, of about 0.005" to about .007" thick. The construction of this material is such that it can be used in a packaging machine to produce packages as described herein whereby laminated webs are sealed to a first web of gas barrier material (tray).
First web may have a depression formed therein into which goods such as red meat can be placed before heat sealing the third and second webs to the first web.
Goods will typically not completely fill the depression and space will remain in the depression in addition to the goods. A blend of gases or a single gas such as C02 can be provided in the space with goods and. thereby can contact the goods. The gas substantially eliminates the presence of oxygen and any red color present in the red meat may be transformed to a purple color. This is caused in part by the reduction of oxymyoglobin to deoxymyoglobin. After storage of perhaps a period of 14 - 28 days from packaging but prior to retail display at an intended point of sale to consumers, the third web can be peeled from the package allowing atmospheric oxygen to permeate the second web of gas permeable material and to contact the goods.
Atmospheric oxygen can then generate a bright red colored substance such as oxymyoglobin. Such use involves the sealing of the laminated webs to the first web of gas barner material such as a two-layer co-extrusion where the outer layer includes Eastman APET 9921 of about 0.0035" thickness, and the inner layer may is a blend of Eastman polyester materials including about 16% of 6763 and about 84%
of 9921. The thickness of blended layer 1412 can be about 0.0015". Second web 1404 includes a roll of monolayer pPVC with a thickness of about 0.0008"
to about 0.0012". Preferably, as second web 1404 is unwound it can be passed through a perforator 1414 that perforates the second web by creating small apertures therethrough. Preferably, second web 1404 can be tensioned in a controlled manner by retarding the rate of unwinding of second web 1404 from roll 1400 relative to the unwinding rate of third web 1406 from roll 1402. Tension is thereby applied to gg< AMENDED SHEET

second web 1404 of material prior to passing through the nip rollers 1408 at which point substantially all of the air between the two layers of material is forced out by the nip rollers 1408. The consistency and texture of elasticized PVC material including second web 1404 is such that it adheres lightly to third web 1406 unwound from roll 1402 forming a very light seal that excludes all air from between the webs.
Second web 1404 is applied to the inner, blended layer of third web 1406, preferably a substantially more rigid material unwound from roll 1402. Preferably, an anti-blocking agent, such as very fine sand, can be added to the third web upper (outer) layer of the co-extrusion so as to preferentially inhibit sticking of second web to what will be upper layer such that second web will remain in close contact with what will be the underside of third web during storage in a roll 1410 condition and during un-winding from roll 1410 in normal operation on a packaging machine.
Second 1404 and third 1406 webs, having been laminated to produce a lamination and subsequently wound onto the finished roll 1410 can be stored and when required for use in packaging can be loaded onto packaging machine as shown in FIGURE 170.
Referring now to FIGURE 170, a process to laminate two webs of material together is shown. The two webs include the third and second webs. The apparatus is suited to produce any packages herein described. First web 1416, preferably of a substantially gas barrier material is located into an aperture (not shown) in sealing plate 1418 mounted on the conveyor 1420. Preferably, sealing plate 1418 being similar to sealing plate member 1208 shown in FIGURE 159. Preferably, first web has a cup-shaped depression formed therein and similar to that shown in FIGURE 171. Red meat or other perishable goods is loaded into first web tray 1416 and a plurality of trays are located into the apertures in each sealing plate 1418 mounted- to conveyor 1420. The conveyor indexes forward such that a loaded tray is located between upper vacuum chamber 1422 and lower vacuum chamber 1424. During indexing of the conveyor the third web tray is also indexed in a direction parallel with the conveyor and placed into position between upper and lower vacuum chambers. Upper 1422 and lower 1424 vacuum chambers are closed together such that sealing platy is clamped therebetween to provide a substantially sealed and enclosed chamber assembly. Air is evacuated from the chamber assembly to a pressure level of approximately 5 torn and a selected gas is injected into the chamber assembly. The gas being chosen for its properties of enhancing the keeping qualities of goods, in first web tray 1416, such as carbon dioxide or a blend of carbon dioxide and nitrogen is suitable. First, second and third webs are then sealed together to produce a package. Upper 1422 and lower 1424 vacuum chambers are then opened so that conveyor 1420 can carry sealed package to an ejection point.
The package may be trimmed by a cutting devices located within the chamber assembly such that a skeletal scrap web can then be wound onto a single wind-up spool, or alternatively, could be separated by de-laminating the third web scrap from second web scrap onto scrap wind-up 1426 and 1428 as shown in FIGURE 170. The package may be trimmed within vacuum chamber in one machine cycle or alternatively the package may be trimmed from the web in a secondary operation immediately after the vacuum chamber.
Preferably tray construction may be thermoformed from co-extruded polyester plastic materials as shown in FIGURE 171. Co-extruded material may include two layers of a total thickness of about 0.015". The outer layer 1430 is about 0.0135" thick and the inner layer 1432 is about 0.0015" thick. The outer layer includes Eastman APET 9921 and the inner layer 1432 is about a 50% / 50% blend of Eastman 13162 and Eastman 6763.
Method and Apparatus for Packa~inQ Perishable Goods Having described laminated webs, it is now appropriate to describe a method to package perishable goods using a laminated web. Although the description preferably applies to laminated webs, one or more non-laminated webs can also be used with the method with apparent modification.
FIGURE 172 shows a schematic representation of a side elevation of a preferred packaging apparatLS including a conveyor with a plurality of sealing plates generally denoted 1436 attached thereto. Preferably, a drive motor 1438 is connected to conveyor sprockets 1440a, and b and arranged so as to provide intermittent driving of the conveyor as required. 'frays with goods therein are loaded into apertures in sealing plates at the loading section and the conveyor is driven forward in the conveyor direction shown in intermittent increments of one pitch which is equal to the distance of a single sealing plate. The conveyor is otherwise stationary except during each movement of one pitch. A scale 1442 can be positioned under the upper section of the conveyor and is attached to a driver such that when the conveyor is stationery the scale can be elevated and lift the tray from sealing plate 1436, and weigh the tray and goods. Preferably, scale can be interfaced with a label printing device. Preferably label will include information such as price, weight and time of packaging and then label printing device will apply the label to the upper surface of gg,:, AMENDED SHEET

the second (or third web) in a label position. Label position can be predetermined such that when first, second and third webs are sealed together the self adhesive label is in a desired location which can be easily seen by any prospective purchaser of the finished package after removal of the third web. Alternatively, if the label is located on the third web and if the third web is not removed before retail display then the label can be viewed. A roll of material 1444 is mounted above the conveyor adjacent to a first station 1446 to facilitate unwinding of the material 1443. The material may include a single web of material or alternatively the material may include a roll of two laminated webs such as described above. Packages produced with material according to the present invention would he similar to packages shown in FIGURE 173, whereas packages produced with web conventional material would be similar to the conventional package in FIGURE 174. First station 1446 includes an upper vacuum chamber 1448 and lower vacuum chamber 1450 and both are mounted to the packaging machine and pneumatic drivers. Pneumatic drivers are arranged to move the upper 1448 and lower 1450 vacuum chamber in a reciprocating upward and downward motion.
Preferably, vacuum chambers operate such that they move simultaneously but in opposing directions such that when they are moved toward each other a sealing plate 1436 is clamped therebetween to provide a completely enclosed chamber that is isolated from ambient atmosphere. Preferably, each vacuum chamber has ports and is attached to a vacuuri pump (not shown) and sources of gases via ports 1452.
Preferably, the gas sources can be several in number but typically can include: 100%
carbon dioxide and a blend of carbon dioxide and nitrogen in any concentration.
Sources of gas can be switched from one to the other such that a selected gas can be injected into the chamber as required and at will. For example after evacuation of the vacuum chambers, a gas, such as 100% carbon dioxide, can be provided in the vacuum chamber at a gas pressure above ambient atmospheric pressure, for example about 25 psi. Gas pressure may then be reduced to any pressure between about 0 and about 25 psi before then providing a gas, such as 100% nitrogen, in the vacuum chambers. A heat bank sealer 1454 is located within the upper vacuum chamber 1448. Sealing device is also attached to a pneumatic cylinder that provides motion in an upward and downward fashion. Sealing device is profiled to provide a flat strip like surface, horizontally disposed, that corresponds to the flange of the tray and can apply pressure downwardly onto the flange. Preferably, second station includes lower clamp 1458 and upper clamp 1460. Preferably, clamps 1485 and -~9 AMENDED SHEET

1460 are attached to pneumatic cylinder and can be operated such that when moved toward each other a single sealing plate 1436 is clamped therebetween.
Preferably, a sealing device is located within the upper clamp 1460 with pneumatic cylinders attached thereto and a cutting device 1462 is located on the outer perimeter of heat bank 1464 and on the inside of 1460. Preferably, members 1462, 1460, 1464, and 1458 can be moved independently and in vertical directions. A winding arrangement 1466 is mounted above the conveyor and is powered by an electric driver to wind skeletal scrap. The preferred sequence of operation of the packaging machine is as follows. Sealing plate 1436, attached to the conveyor with a loaded tray contained therein is indexed into position in first station 1446. Lid material 1443 is unwound from 1444 and located above tray 1436. Chambers 1450 and 1448 are clamped together with 1436 clamped therebetween. Air is substantially evacuated from the vacuum chambers which are then filled with carbon dioxide gas or a blend of carbon dioxide and nitrogen. The gases are pressurized to a pressure above atmospheric pressure to about 25 psi and held for a period exceeding about one second. Pressure of the gas in the chambers is reduced to about atmospheric pressure and sealer 1454 is lowered so as to clamp the lid material against the flange portion of the tray. The lid material is then sealed thereto along the complete path of tray flange. Vacuum chambers 1448 and 1450 open and the conveyor indexes forward until sealing plate 1436 is located at second station 1468, between upper clamp 1464 and lower clamp 1458. Clamps 1464 and 1458 close together thereby clamping sealing plate 1436 between the clamps. Sealing device 1464 is lowered to seal the lid material to tray at flange and cutting device 1462 is also lowered and retracted thereby severing the tray and package from web while the tray still located in the sealing plate 1436. Skeletal scrap is wound onto scrap winding spool 1466.
Conveyor indexes forward and packages are ejected therefrom.
Cross-sections through the package shown in FIGURE 173 and a conventional pack of FIGURE 174 are shown alongside for comparison. The conventional package shows the absence of second web. The tray constructed according to the present invention include a second and third web sealed to a tray flange around the upper periphery of the tray. A tray constructed according to the present invention provides a peelable lib to introduce oxygen at a predetermined time, thus extending the shelf life of the perishable good stored therein.
~t~~' AMENDED SHEET

Method and Apparatus for Packaging Finished Packages Now that trays, webs, and methods have been described, it is appropriate to consider master packs and their methods for making.
Referring now to FIGURE 175, details of a packaging apparatus constructed according to the present invention for producing substantially gas barrier master containers and heat sealing; a substantially gas barner lid material to the master containers to produce hermetically sealed containers is shown. The following description discloses a method and apparatus for producing the hermetically sealed containers for providing a vzcuum andlor selected gases in the containers at selected and variable pressures, so as to accelerate the dissolving of selected gasses into perishable goods such as red meat that may be contained therein and then exchanging the selected free gases with other suitable gases for the purpose of enhancing the keeping qualities of the perishable goods. Furthermore, the method provides methods of removing residual oxygen gas that may be retained within the cell structure of packaging materials such as EPS, that may be contained in the hermetically sealed master.
FIGURE 176 shows a cross-section through an apparatus intended to produce master packs thermoformed from a continuous web of plastics material. The dimensions of the master containers are arranged so that they can be filled with preferably an exact number of finished packages containing perishable goods such as any of the finished packages herein described. The apparatus preferably includes a horizontal thermofornung, reel fed packing machine, sinular to Model 8530 packing machine manufactured by Multivac Sepp Haggenmuller GmbH & Co. of Germany.
Preferably, the apparatus includes a frame (not shown) that is arranged with two horizontally disposed and parallel continuous gripper chains generally denoted as 4400 in FIGURES 176, 177 and 178 that run almost the full length of the frame and are retained in tracks that are located on each side of the frame. tripper chains 4400 are arranged to grip the two opposing edges of the lower web 4402 and apply suitable lateral and longitudinal tension thereto. The machine direction is shown by arrow 4470 and the chain is preferably powered by an electrical motor (not shown) that is controlled electronically to carry the lower web 4402 in the machine direction in intermittent movements. The distance traveled by the gripper chains, carrying the lower web, is controlled so as to carry the formed master packs forward and simultaneously locate a suitable area of the lower web material between the upper and lower sections of the thermoforming section. Each ~~01 v' AMENDED SHEET

intermittent movement, during each machine cycle, of the gripper chains is equal in distance traveled and the apparatus can be arranged to automatically operate at a machine speed of a set number of cycles per minute which may be, preferably about 4 cycles per minute.
During a single machine cycle the following functions preferably occur.
After the gripper chains cycle forward carrying a section of lower web material 4402 into position between the upper and lower sections of the thermoforming section 4406 the upper and lower sections close together and thermoform master packs including , in the present case, three containers. A hole punch 4466 is arranged to provide apertures 4452 in the lower web located between the containers as shown in FIGURE 176 and in an enlarged cross-sectional view in FIGURE 178.
Finished packages are then loaded into the master packs (containers) in the loading section 4446 and with each machine cycle the lower web travels forward an equal distance. The gripper chain carries the lower web 4402 in the machine direction a distance of a single pitch for each machine cycle until the loaded master packs are located between upper chambers, generally denoted by 4410 and lower chambers, generally denoted by 4412. Preferably, a total of five upper chambers and five corresponding lower chambers are arranged such that the upper chambers 4414, 4416, 4418, 4420 and 4422 can be elevated and lowered as required. Lower chambers 4424, 4426, 4428, 4430 and 4432, are located directly below the upper chambers and arranged with powered drivers (not shown) to elevate and lower the lower chambers as required. A cross-section is shown in FIGURE 176 and is typical for upper chambers 4414, 4416, 4418, and 4420 with corresponding lower chambers 4424, 4426, 4428, and 4430. Upper chamber assembly 4410 and the lower chamber assembly 4412 operate simultaneously so as to close toward each other and open away from each other, as required. During a single machine cycle upper chambers and lower chambers close and open once. After upper chambers and lower chambers open, gripper chains 4400 carrying the lower web 4402 move and carry the master packs forward for one single pitch. A ro114434 of upper web material is located as shown and upper web material 4444 is unwound, as required, during each machine cycle, providing a length of upper web material equal to the distance of the lower web forward movement. A side web sealer 4436 is located one on either side of the machine in a position that allows sealing of the upper web to the lower web, forming a single and continuous heat seal between the upper web and the lower web, along the outer edges of t'ae upper web, along path 4438 and 4440 shown in lfQ2. AMENDED SHEET

FIGURE 176. A gassing member 4442 is located between the upper web and the lower web such that the upper web and the lower web can be heat sealed together at paths 4438 and 4440, thereby encapsulating the gassing member 4442 with the upper web 4444 and the lower web 4402, in close and touching proximity to the gassing member 4442. The gassing member 4442 is attached and fixed to the machine at the entry end to the upper and lower chambers assembly and otherwise floats along its entire length. Gas ports 4446 and vacuum recesses 4448 are machined in the gassing member, such that the gas ports 4446 provide direct communication from a suitable gas source separately to each lower chamber location 4424, 4426, 4428, and 4430, thereby introducing into the. master. containers chosen gases separately and during each cycle of the machine. Vacuum recesses 4448 provide communication between the master containers and a vacuum source via apertures 4452 in lower web and vacuum ports 4450.
Preferably, during each machine cycle, upper chamber assembly 4410 and lower chamber assembly 4412 close toward each other with a clamping force, and clamping the upper web and lower web with gassing member therebetween, such that master packs in lower web are enclosed in the cavities in the lower chamber.
As can be seen in FIGURE 178, the upper chamber 4414 is clamped against the upper web 4444 and the lower chamber 4424 is clamped against the lower web 4402 with the gassing member 4442 between the upper web 4444 and the lower web 4402, which are sealed along path 4440. Seals 4468 are provided as required and as can be seen in this closed position, ahe upper chamber 4414 and the lower chamber provide a substantially airtight assembly. Preferably, after closing of the upper and lower chambers together, a vacuum source is connected to vacuum ports 4450, which substantially evacuates all air from within the master packs. Preferably after evacuation of the master packs, a suitable gas which may be selected from those gases listed herein, is provided through gas port 4446 and into the master packs 4404.
The suitable gas is provided at a pressure that exceeds ambient atmospheric pressure and may be provided at a pressure preferably between about 0 psi and about 200 psi or more. The gas can be retained at the desired pressure for a set period of time preferably equal to about one or more seconds. Preferably, after the set period, suitable gas pressure is reduced to slightly above ambient atmospheric pressure so as to maintain a positive pressure within the master containers but not at such a high pressure that may cause rupturing of the seal between the upper and lower webs at seal paths 4438 and 4440, after opening of the upper and lower chambers.
AMENDED SHEET
x The upper and lower chambers assembly is then opened and the master packs move forward one pitch so as to be located directly between upper chamber 4416 and lower chamber 4426. The upper and lower chambers assembly is then closed and the evacuation and gassing sequence as described for upper chamber 4414 and lower chamber 4424 is repeated, however, the gas provided through the gas port into the closed upper and lower chambers may be a different gas. This sequence of evacuation and pressurized gassing is repeated during each machine cycle in upper chambers 4418 and 4420 with corresponding lower chambers 4428 and 4430.
FIGURE 177 shows a cross-sectional view through upper chamber 4422 and lower chamber 4432 with heat bank. Upper chamber 4422 and lower chamber 4432 close against each other and heat bank 4458 heat seals the upper web 4444 to the lower web 4402, at a path that follows the perimeter fully around each master container, so as to hermeticall~r heat seal the upper web 44.44 to the lower web 4402 with suitable gas contained therein. Upper chamber 4422 and lower chamber 4432 open to allow the hermetically sealed master packs 4456 to be earned forward toward the exit end of the machine. The master packs 4456 are slit longitudinally with a slitter 4462 and cut laterally with a knife 4464 as shown in FIGURE 175, prior to the ejection of finished master packs from the machine.
In this way residual oxygen that is retained in the cell structure of the EPS
foam trays, contained in the mater packs, can be exchanged with other suitable gasses. Preferably, gasses such as carbon dioxide can be provided under pressure so as to dissolve in any free liquids such as water and oils contained in the perishable goods such as red meat.
Modified and Controlled Atmosphere Packaging Before disclosure of the preferred methods for conditioning meats prior to packaging, the inventor, without intending to be bound to the particular theory, now wishes to advance the theory for the formation of metmyoglobin in packaged red meats and solutions to the problems of metmyoglobin formation, with reference to FIGURE 179.
Fresh meats that have been chilled during an adequate storage period will contain large quantities of purple colored, de-oxymyoglobin which is unattractive to typical consumers. When the chilled meat is sliced in ambient atmosphere the de-oxymyoglobin that consequently comes into contact with atmospheric oxygen, will then, by oxidation, convert into oxymyoglobin (referred to as "bloom") displaying a bright red color that is attractive to consumers. However, if the sliced meat (or ~((1~~ AMENDED SHEET =, -~2kQ

ground meat) is intended to be stored in a low oxygen gas atmosphere, case ready condition, as a way of extending storage life prior to retail display, the oxymyoglobin that has formed after slicing and/or grinding (but before subsequent packaging in the low oxygen atmosphere), may provide for undesirable transfer of oxygen gas into the sealed environment of the master container. Even though the quantity of oxygen transferred by the de-oxymyoglobin, is relatively small it can lead to the formation of undesirable metmyoglobin on the visible surface of the retail packaged red meat.
Metmyoglobin is brown in color and is unattractive to consumers. It is therefore desirable to prevent andlor minimize the extent of such deleterious formation of the metmyoglobin. The apparatus disclosed in the following subject matter details preventative methods. In order to provide a more detailed description of the conditions under which the undesirable metmyoglobin may form, the following known laws of physics and natural processes are referenced:
Normal Conditions for Oxym~ro~lobin Formation After storage under commercially normal refrigerated conditions in carcass or vacuum packed conditions, freshly sliced beef will predictably turn bright red (by oxidation of purple colored deoxymyoglobin to bright red colored oxymyoglobin) with a virtually 100% probability, when exposed to ambient air.
Optimum conditions for metmyoglabin formation It is known that optimum conditions for formation of metmyoglobin, at the surface of sliced, fresh beef muscle exposed to a gas occurs when the free oxygen content of the gas is approximately 5000 to 30,000 ppm.
Graham's Law of Gas Diffusion The rate of gas diffusion is inversely proportional to the density of the subject gas.
Relationship between Density of Gas and Temperature The density of a gas (and most matter) is inversely proportional to temperature (i.e.: the gas densit;~ increases as its temperature is decreased).
Henrys Law At a given temperature, the solubility of a gas in a liquid is directly proportional to the pressure of the gas above the liquid.
~la~ AMENDED SHEET

The "Mud Puddle Rin 'g' Effect According to the present inventors observations and independently performed empirical trials, the "Effect" can typically occur, immediately following packaging, when the following prevailing conditions are generally approximated:
1). The subject sliced beef has been allowed to "bloom" as a result of exposure to ambient atmospheric oxygen immediately prior to packaging.
2). The temperature of the sliced beef is lower than the gas and packaging materials surrounding it, immediately after packaging.
3). The sliced beef is placed in an "enclosed space" defined by the "retail package" including an EPS foam tray (or other) and a high OTR over wrapping web (the "web"). The "enclosed space" is not completely filled with the subject sliced beef and a remaining space ("the space") is also contained. "The space" is subsequently filled with a "suitable gas" during evacuation of master container.
4). The ratio of beef to gas is low, i.e. the volume of "suitable gas" is relatively low and the volume beef is relatively high, in the "enclosed space".
5). The "retail package" is placed into a substantially gas barrier "master container" which is evacuated (including the "retail package") of ambient air and then filled with the "suitable gas". The composition of the "suitable gas" can be carbon dioxide, nitrogen and residual oxygen at approximately 100 to <500 ppm.
Thereby, substantially filling "the space" and "other space". The "other space" is defined by the internal space of the master container but excluding space occupied by "retail packages".
6). The temperature of "suitable gas" is lowest at the lowest point in "the space".
FIGURE 179 is intended to be representational and not a depiction of the actual "Effect" which is described as follows. Immediately after packaging, the highly oxygenated condition of myoglobin (oxymyoglobin), which is present at the surface of the beef slices starts to reduce, releasing oxygen gas inside the enclosed space 1242. At those sliced beef surface locations shown as 1228, that are in direct and intimate contact with the web 1232 (such that there is no gas between the beef surface and the web), the released oxygen gas passes through the gas permeable web, directly and diffuses into the other space 1240 inside master container but outside retail package 1230. This newly released oxygen gas is therefore immediately separated and essentially excluded from within the retail package. Any further gas contact with this area in direct and intimate web contact is limited to any gas outside =~~0~, AMENDED SHEET

the retail package, where the oxygen concentration remains relatively low.
However, oxygen gas that is released from the beef surface that is not in contact with the web enters the space 1242 inside the retail package which immediately causes a significant elevation of oxygen concentration in the small free space under the web.
Even though the web is oxygen permeable the rate of oxygen gas diffusion therethrough is such that it can take an extended period of time for the oxygen content in the gas under the 'web to equilibrate with the oxygen content of gas outside the retail package. Furthermore, the temperature of the oxygen atomslmolecules as they are emitted from the surface of the beef is the same as the beef which is significantly lower than the temperature of the gas in the space and therefore the density of the released oxygen is relatively high. This condition results in two additional effects. The diffusion rate is lower (Grahams Law) and because the density is higher, these newly emitted oxygen atoms tend to sink toward the lowest point in the package and/or remain in contact with the sliced beef surface for a longer period than may otherwise be required. Consequently, the partial pressure of oxygen at the surface of the meat increases and, in accordance with Henry's Law the level soluble oxygen gas in the meat surface liquid elevates. The temperature of gas in space 1242 is higher at the highest point and lowest at the lowest point. It can be concluded that oxygen gas emitted from the beef surface will remain in contact with the surface of the beef for a more extended period at lower locations and therefore higher concentrations will be present at these lower locations. Conversely, lower concentrations will be present at higher locations. Correspondingly, concentrations of metmyoglobin will form in direct proportion to the concentrations of oxygen. The composition of the gas in direct contact with the surface of the beef, a layer of gas that is probably less than about 0.01" in depth, is the active gas that has effect at the surface of the beef. Under the conditions described above, the oxygen concentration in this layer can become signifi;,antly elevated.
The tendency of the relatively heavier oxygen atoms to move toward the lower levels in the space 1242 can cause it to tend to follow the downwardly disposed surface of the sliced beef, carried with other gasses and liquids that are close to the surface. This condition can therefore result in an increased level of oxygen concentration at the surface of the beef which exponentially increases toward the lowest point in the space 1242 and is consequently highest at the lowest point in the space 1242. This results in correspondingly higher (and darker) concentrations of ~.~p= AMENDED SHEET
_.:k,:.;,:.,:::a:~' metmyoglobin at the lowest point in the package and, conversely, visible but lower concentrations at the highest point.
A mud pool drying in the sun can appear to be surrounded by parallel rings that are typically gray/brown in color. These rings are lightest at the furthermost point from the center of the puddle and typically darkest at the center of the puddle, with a gradual color density change between the two points. The color density of metmyoglobin that is formed under the conditions described above gradually increases between the highest point in the package where the color is the lightest to the lowest point in the package where the color is darkest. Hence the comparison with a mud pool drying under the sun.
Eventually, any free oxygen gas released by the reduction of oxymyoglobin, will become either reabsorbed in the form of metmyoglobin or will be diffused and equilibrated with the modified atmosphere contained throughout the master package.
However, the effective, irreversible, deleterious event of formation of metmyoglobin at the visible surface of the meat will have already occurred and under the prevailing conditions prior to intended retail sale of the meat, will permanently remain visible.
Subjectively, the above occurs in what can appear to be a confusing manner.
The best most highly oxygenated and therefore red looking beef (as in that having an attractive red "bloom") prior to packaging in the low oxygen atmosphere will, with an almost certain predictability, emerge as the worst looking beef after removal from the master container. Conversely, the worst looking (as in that beef colored by purple deoxymyoglobin) prior to packaging in the low oxygen atmosphere will, with an almost certain predictability, emerge as the best looking beef after removal from the master container.
Other issues of multiple species mass transfer with chemical reaction (i.e. a potential cause for the mnd puddle ring problem in packaged fresh meat) are described as follows.
1. Equilibrium beoween a gas and a liquid is governed by Henry's law which states that the partial pressure of a gas at equilibrium is equal to the Henry's Law constant multiplied by the concentration of the gas in the liquid phase at equilibrium. The gas is oxygen (02) and the liquid is water (H20).
2. Based on the functional relationship expressed in Henry's law, several conditions can influence the state of equilibrium between free 02 in the package and 02 absorbed in water.
A. Partial pressure of free 02 in the in-package atmosphere.
'~f~$' AMENDED SHEET

B. Temperature as Henry's constant is temperature dependent.
Conversion of absorbed 02 in water due to chemical reaction. (The work reported by Zhao and Wells indicates that in-package absolute gas pressure can vary in fresh packaged meat, either increasing or decreasing due to a combination of factors including composition, storage time, temperature, pre and postmortem factors, and others. Since total in-package gas pressure can vary, partial pressure conditions of 02 can vary causing a migration of 02 in and out of water solely based on consideration of factor A. With respect to factor B, it is likely that there are thermal gradients that develop across products, from the center to the surface, for even slight temperature variations that are experienced within the package.
This would have two results. The temperature gradients across a product would help to cause moisture migration within a product; and the temperature fluctuation would promote a change in 02 equilibrium concentration within water. In effect, 02 could be absorbed into water, the water migrate, and subsequently be deposited somewhere else in the product.
As a result of factors A znd B, and the role of chemical conversion, it is likely that some aqueous participation is needed. Given this, the question becomes what relative O2 concentration and reaction time is needed to produce brown metmyoglobin color. If the time is sufficiently long, factors A and B would operate to move 02, seemingly through the product, to a point to produce the mud puddle ring.
Because the in-package gas atmosphere in a closely wrapped product package is minimal, there is very limited opportunity for bulk convective gas movement by mass transfer within the package. The enclosed space near the permeable web, product and tray are particularly prone to development of a boundary layer away from free mixing of gas molecules within a larger, relatively unconfined headspace.
Boundary layer phenomena may include the establishment of a proportionate localized gas concentration compared with the free gas concentration. This situation would aggravate the 02 conditions outlined above in point 2A and 2B compared with a package with a larger headspace volume.
Once formed on a slice of fresh red meat, metmyoglobin is essentially a fixed stain, with unappealing appearance and is generally unacceptable to consumers.
On the other hand, oxymyoglobin, which imparts an acceptable red bloom color is attractive to consumers and is therefore desirable.
AMENDED SHEET

a The present invention provides methods and apparatus for grinding meats such as beef by processing boneless beef through a grinding machine (such as may be supplied by Weiler & Company of Whitewater, Wisconsin, USA) and substantially preventing exposure of the ground meat from contacting ambient air until the ground meat is delivered in any suitable retail package to a point of sale, such as a supermarket. In this way formation of excessive quantities of metmyoglobin and/or any cause of excessive discoloration can be minimized. In a preferred embodiment, the meat can be vacuum packaged after treatment with C02 in any one of the methods described herein.
Meat Grinding, Blending and Methods for Controlling Fat Typically meat packing companies slaughter cattle and then process the dressed carcass by chilling and then disassembling the carcass into portions of meat which can then be, in part, delivered to the point of sale to consumers, in vacuum packs. However, approximately 40% of the disassembled meat is processed at the point of animal slaughter by grinding and then blending to provide ground meat with a selected fat and lean content as required by the retailer. The fat and muscle content of the ground meat may be, for example, 20 % fat and 80% lean. Current processing methods require that the boneless meat be firstly coarse ground then blended, vacuum packaged, delivered to a supermarket or packaging facility close to the consumer where the coarse ground meat is fine ground and then retail packaged immediately prior to retail display. This process inherently results in excessive exposure of the ground meat to ambient atmosphere during the grinding and blending process at the point of slaughter. Furthermore, this process requires that relatively large quantities of ground beef' are blended together in a single batch.
Because it is not possible to disassemble a carcass and provide boneless meat therefrom with a precise and selected ratio of fat to muscle tissue, the typical batch blending process often requires several attempts to produce the desired ratio of fat to lean content. The general industry practice is to deposit selected boneless beef with a fat to lean ratio as close to a desired tolerance as possible. The selected boneless beef may have a fat to lean ratio of 15% fat to 85% lean +/- 5%. The selected boneless beef is then coarse ground and blended in a batch blender such as can be acquired from Weiler and Company. Typically, a sample of the blended boneless beef is then removed from the blender and then can be tested to determine fat and lean content using, for example, a device known as an Analray testing procedure. After determining the fat and muscle content of the coarse ground meat additional fat or lean meat is added to ~~1.0 AMENDED SHEET

the batch blender and the full batch is again blended for a period of time and then a second sample is extracted and tested to determine fat and lean content. If the fat and lean content is as required at this point, the batch of coarse ground meat can be vacuum packaged and stored in refrigerated facilities prior to delivery to the point of retail sale. However if the fat and lean content is not as required then additional fat or lean meat can be added to the batch and further mixing is then required.
This process is often repeated as many as 5 times or more. Each time the coarse ground meat is blended again it is damaged by the blending process. This damage may include "fat smear" or over heating. Heat is generated during this blending process and "fat smear" occurs when the meat has been exposed to excessive blending.
This procedure is expensive in terms of energy, labor and equipment time.
Furthermore, damage to the ground meat is undesirable and yet damage typically occurs as a matter of normal process with the currently predominant industry procedures.
During the process described above the meat is exposed to ambient air and bacteria such as E. Coli and other dangerous bacteria can be present in the blended ground meats. Excessive blending can cause the bacteria to spread throughout the batch of meat in the blender.
Ground foods such as ground beef have been produced by processing in meat grinding and blending equipment and associated equipment, such as blending and processing equipment manufactured by Weiler Beehive. The equipment can be viewed at the following web site: www.meatingplace.comJcomlbeehive Ground meat such as ground beef is produced by processing selected portions of boneless meat, including fat and muscle tissues, through a grinding machine. The relative quantities of fat and muscle contained in any batch of the portions of boneless meat is typically arranged to correspond with set industry standards.
The batch of boneless meat may include about 93% muscle tissue and therefore the balance of about 7% would be fat. The following list of items 1 to 5, shows the fat and muscle tissue content of some typical industry specifications for boneless meat:
Item Muscle Fat Tissue Tissue 1 93% 7%

2 90% 10%

AMENDED SHEE-f ,,9s ..

Item Muscle Fat Tissue Tissue 3 75% 25%

4 6S% 35%

50% 50%

Although the industry standards are established, it is difficult to produce large quantity of boneless beef to any specification or ratio of fat and muscle.
This difficulty can arise as a result of genetic variation in the animals from which the 5 boneless meat is harvested, Consequently, there is often variations that could be as much as +/- 2% to 3%, which corresponds to a possible variation of up to 6%
and perhaps even more, in the actual fat or muscle content of the boneless meat.
Typically, consumers can purchase fine ground beef with a fat content that is specified and clearly marked on any retail package. The fat content may be specified to 10%, 25%, or 30% and it is illegal to sell such retail products to consumers if the fat content is higher than the amount shown on the retail package. Therefore, producing retail packages of ground beef with a fat content of, for example, 25%, may be achieved by grinding a known quantity of Item 2 (listed above) and blending this with a known, measured and corresponding quantity of Item 4 (listed above).
The fat content of the resulting ground beef can be measured but it is common for the fat content variation in the initial quantity of the boneless beef items to vary to such an extent that a compensating procedure must be accommodated during production of the product for retail packaging. This compensating procedure can often result in production of ground beef that has a muscle content that is higher than is specified on the retail package. The consumer, however, only pays for the ground beef according to the fat content shown on the retail package. Thus a loss of profit for the ground beef producer can be incurred.
A quantity of boneless beef, with a specified muscle and fat content, say Item 5, is loaded into a hopper which is connected directly to a primary meat grinder.
The portions of meat are progressively carried, by augers and compressed into a tubular conduit with a perforated grinding plate fitted across. The grinding plate is typically manufactured from suitably hardened steal and the perforations may include AMENDED SHEET
mtAe!~°.....e..v.,:..,.

drilled and reamed holes of a chosen diameter, which may be about 0.5"
diameter, and which extend completely through the grinding plate. The primary grinder typically produces coarse grinds with the diameter of the meat pieces corresponding with the diameter of the drilled and reamed holes in the grinding plate.
After primary grinding a quantity of Item 5 may be blended with a selected quantity of coarse ground Item 4. After the blending of Item 5 with Item 4 the resultant mix is processed through a secondary fine grinding machine prior to portioning and retail packaging. The secondary fine grinding machine may be similar to the primary coarse grinding machine except that the grinding plate can be drilled and reamed with holes of less than about 0.25" diameter.
Typical fine ground meat for retail packaging and sale to consumers may be produced with fat and muscle content as shown in the following table:
Item Muscle Fat Tissue Tissue 1F 90% 10%

2F 75% 25%

3F 65% 35%

The existing grinding, blending and processing equipment, such as WeilerlBeehive equipment, has been demonstrated as effective for grinding meats of various types. However, little has been proposed to improve the quality of the ground meats by, for example, arranging equipment in such a manner so as to substantially prevent contact of the ground meats with air and/or atmospheric oxygen during the grinding and blending process. Meats are ground and blended in such a manner so as to produce ground meats including a product with a desired ratio of muscle and fat content. The conventional equipment does not allow for continuously and automatically grinding and blending the ground meats in such a manner so as to continuously produce quantities of ground meats to an exact and predetermined muscle and fat content.
The present invention provides methods, systems and apparatus to automatically and continuously grind, condition and blend the ground meat products AMENDED SHEET

with improved accuracy of muscle tissue to fat tissue ratio, so as to minimize losses to the processor. The ground meat can then be packaged in suitable packaging that will enhance the keeping qualities of the products and provide a safer method of delivering the goods to consumers.
Meat Grinding and Conditioning Apparatus Having described tray construction, web covers, master container and associated methods for making and packaging, it is now appropriate to discuss apparatus and methods for treating the perishable food items that are to be packaged by those methods herein described. A logical starting point is a method and apparatus for grinding and conditioning meat.
Referring to FTGURE 180, a cross-sectional view of a preferred grinding head 1300 constructed according to the present invention is shown. Preferably, grinding head 1300 is attached to a source for the carbonation of liquids and water contained in ground meats. Meat 1310 is processed through grinding head 1300 of a meat grinder 1302 and deposited into vessel 1304. Vessel 1304 is substantially sealed from the external atmosphere. Preferably, entry point 1306 and exit point 1308 are such that wizen compacted meat 1310 fills the grinding head adjacent to the cutter 1312 and similarly compacted ground meat 1316 fills the exit point 1308 of vessel 1304 adjacent to the end of screw-auger 1314, the vessel can be filled with a gas such as carbon dioxide under pressure. Preferably, pressure is kept above ambient atmospheric pressure therefore assisting the dissolving process of carbon dioxide into water in meat. Preferably, screw-auger 1314 is attached to a driver (not shown) and rotate,l so that the ground meat is carried forward and as it travels down the length of the screw auger 1314, the space between the tapered flights 1320 of the screw auger 1314 gradually is reduced, thereby compressing the ground meat just prior to ejection at exit point 1308, thus providing a seal of the vessel 1304 from ambient atmosphere.
This embodiment provides a cost effective method of increasing the pressure of carbon dioxide and elevating the quantity of dissolved carbon dioxide in water and ground meat to a desirable level. Gas provided under pressure into the vessel may include, preferably, a suitable blend of carbon dioxide and other gasses such as nitrogen, stabilized chlorine dioxide (stabilized chlorine dioxide brand name Oxine), helium, and other inert gases, but substantially excluding oxygen, and including an amount of carbon dioxide of about 5% to about 100% by volume or weight.
s~,~:4°a AMENDED SHEET

One embodiment of screw-auger 1314 is shown but alternates may be arranged in other configurations such as when connected directly to and parallel with screw auger 1318 and housed in a tube that has an internal diameter slightly larger than the outside diameter of screw auger 1314, that is also in line and parallel with screw auger 1318. Such an arrangement passes ground beef through a pressure box or vessel and exposes the ground beef to carbon dioxide or other suitable gasses at a gas pressure above ambient atmospheric pressure.
Preferably, suitable blends of gasses can be produced and/or blended at the point of use and injected into vessel 1304 and grinding head 1300 at ports 1322.
Preferably, a stainless steel or plastic extension tube is fitted to the flanges of the "downstream" egress/exit point of the pressure box (so as to allow all ground meat to pass through the tube) and the blend of gases is injected into the tube so as to substantially expel atmospheric gasses and oxygen from the tube such that the blend of gasses remains in contact with the meat within the tube. The tube may house an auger type screw arrangement to transfer ground meat inside the tube. The auger has apertures and holes drilled that connect to a pressurized supply of gas.
When the gas is injected through the drilled holes and apertures, exposure of the ground meat to the gasses will be maximized. The ground meat can be shaped or profiled and cut into portions of specified size and directly loaded into packaging while enclosed in a space containing the gas.
Temperature of the gas or blend of gases can be preferably controlled, and may include individual gases in varying relative proportions so as to optimize the cooling of the meat simultaneously while providing sufficient carbon dioxide to allow maximized dissolving of carbon dioxide into the water contained in the freshly ground meat content liquids.
Gasses will most preferably be injected into the grinding head at a pressure that will purge or cause to be expelled, substantially all atmospheric gases from the grinding head and both upstream and downstream of the grinding head.
Preferably, covers (not shown) will enclos;, the portions of the grinding process, package filling and packaging equipment to limit and control escape of dangerous levels or quantities of carbon dioxide or other gasses that may cause damage to health of any machine operators and/or personnel. Preferably gas extraction fans can be located adjacent to the equipment to ensure that safety to operators of the equipment is maintained.
115' AMENDED SHEET

Covers will also preferably restrict egress of atmospheric gasses, such as oxygen, from contacting the freshly ground beef and/or meat prior to packaging and hermetic heat sealing of each package. Such apparatus will substantially inhibit the oxidation of deoxymyoglobin contained in those freshly ground meat portions that were previously not exposed to atmospheric oxygen.
Alternatively, a suitably concentrated solution of carbonic acid (carbon dioxide dissolved in distilled water) can be injected into the grinding head 1300 at port 1322, or mixed with the meat portions immediately prior to grinding such that it becomes mixed with the meat in the grinding process. Preferably, subsequent to grinding, the ground meat can be carried through a tube or "tunnel" that is filled with carbon dioxide.
Alternatively, prior to grinding the meat, the portions of meat are passed through a carbon dioxide tunnel to evaporate a quantity of free water equal to the amount of carbonic acid injected into the grinding head. Carbonic acid solution may be sprayed onto the portions of meat while passing through the carbon dioxide tunnel. Preferably, solid carbon dioxide ("snow") may be dissolved into water to produce carbon dioxide solution (carbonic acid and water). A measured quantity of snow may be injected into the grinding head at a point immediately adjacent but located on the up stream side of the grinding head such that, during the grinding process, the solid carbon dioxide is blended with the meat so as to substantially cover the surface of the meat particles after grinding. Preferably, a controlled and continuous weighing and feeder device may be used to accurately dispense the solid carbon dioxide.
The process of the present invention advantageously inhibits the growth of bacteria on the surface of the meat portions and particles and maximizes shelf life of the meat for a longer period than the shelf life period that would otherwise be possible without an increase of dissolved carbon dioxide in surface water and also minimizes exposure of ground meat to atmospheric oxygen while in processing from grinder to retail pack. This reduces the normal event of the oxidation of deoxymyoglobin, contained in the meat prior to cutting, to oxymyoglobin and then the reduction back to deoxym~roglobin after packaging in the packages that do not contain oxygen. Alternatively, freshly ground or cut meat may be passed through apparatus for removing and collecting some of the free surface liquid in a continuous or batch process such as with a centrifuge. The liquid is then processed by way of pasteurization at a temperature that does not cause any undesired effects on the AMENDED SHEET

ultimate oxidation of the deoxymyoglobin to oxymyoglobin to produce a desirable fresh red color at the point of sale. The liquid can also be exposed to carbon dioxide by mixing with solid or gaseous carbon dioxide. After sufficient carbon dioxide has dissolved into the liquid, the liquid can be sprayed onto meat or other types of goods in a continuous production process.
Alternatively, in another embodiment of the present invention, the carbonation of the free surface liquid may be achieved by including a further step in the process/method of producing modified atmosphere retail packages. Fresh meat can be packaged in a substantially gas impermeable plastic package including a thermoformed tray and flexible plastic lid, hermetically sealed to the tray.
The process involves locating the tray (with fresh meat) into an enclosed chamber and then substantially removing atmospheric air from within the chamber before then filling the chamber with a blend of desired gases followed by hermetically sealing the lid to the tray. The present invention provides an apparatus and method for, after IS substantially evacuating the chamber and filling the chamber with the desired gas, compressing the gas (blend of N2 and C02 or 100% C02 ) within the chamber to an optimized pressure of between slightly above ambient atmospheric pressure and up to 6 bar (6 times the atmospheric pressure). The gas pressure within the chamber is then lowered to ambient pressure (1 atmosphere) and the package is then hermetically sealed. This process of carbonation increases the quantity of carbon dioxide that is dissolved intc the liquid in the meat and goods. After hermetic sealing of the package, the liquid is substantially saturated with dissolved C02. This inhibits further dissolving of COZ into the liquid, that may otherwise cause the package to collapse, and can also extend the shelflstorage life of the meat when held under refrigeration (at preferably between about -2 to about 4 degrees C).
Meat Carbonation Ec~ui-pment Referring now to FIGURE 181, another preferred pressure vessel assembly constructed according to the present invention is shown. The pressure vessel preferably saturates any given quantity of ground meat, with absorbed or dissolved gasses and particularly carbon dioxide gas while also controlling the temperature of the ground meat and minimizing or eliminating freezing of the ground meat during the process.
An adapter tube 1602 is shown connecting a meat grinder 1604 to the pressure vessel assembly 1600 and is most preferably provided with an airtight connection. Compacted meat 1606 is shown within the meat grinder 1604.
AMENDED SHEE-f Preferably, the compacted meat 1606 is forced through holes in a plate and cut by a rotating blade in a manner as is typically incozporated in most meat grinders and is well known to manufacturers and users of meat grinding equipment. Preferably, compacted meat provides a seal to substantially prevent escape of pressurized gasses that may be provided to the pressure vessel. Preferably, a port 1608 is provided in a section of the meat grinder 1b04 to allow injection of gasses such as carbon dioxide or blends of carbon dioxide nitrogen or any other suitable gas. Preferably, injection of the gasses into port 1608 substantially purges air that is in contact with the meat just prior to grinding and displaces the air with the desired gas. Preferably, the gasses may include a gas blend of carbon dioxide and nitrogen where the percentage of carbon dioxide is about 95% and the balance of about 5% includes nitrogen.
Preferably, the interior of pressure vessel 1600 is substantially isolated from atmospheric air and is fitted with a removable dome 1610. Removable dome 1610 can facilitate easy access for general cleaning and sanitizing purposes.
Preferably, the main portion of pressure vessel 1600 is enclosed by a jacket 1612 providing a space between the jacket 1612 and walls of pressure vessel 1600. Preferably, temperature is controlled by circulating fluid through jacket through port 1614 and extracted through port 1616. A cross-section of the vessel 1600 taken along line P-P, through the jacket and pressure vessel walls is shown in FIGURE 182 for clarity.
Preferably, a port 1622 is provided at the apex of removable dome 1610 providing a port to inject gasses and other substances such as 03, F2, H202, KMn04, HC10, C102, 02, Br2, I2, or any combination thereof and flavors into or alternatively extract from within the pressure vessel through port 1622.
Alternatively, a gas blend is injected into the pressure vessel through port 1622 and maintained at a pressure of about 25 psi. Most preferably, a gas blend including nitrogen andlor carbon dioxide and/or ozone (03) will be provided into pressure vessel via port 1622. Water and oils contained in the ground meat can then absorb carbon dioxide until it becomes substantially saturated and cannot absorb any additional carbon dioxide. Preferably, a controller to maintain and/or adjust and vary pressure of the gasses within the pressure vessel, as desired, is also provided but not shown. Preferably, a side port 1624 is provided in the wall of the pressure vessel through which ground beef may be provided into the pressure vessel 1608 fvr further processing in the pressure vessel assembly. Preferably, the size of the pressure vessel can be adjusted to suit requirements. The dimensions of length and height may be increased or decreased to accommodate the required processing capacity of the first 'f 1~'- AMENDED SHEET

pressure vessel assembly. The lower end of the pressure vessel 1600 is attached to a horizontally displaced tube section 1626 within which an auger 1628 is mounted.
Preferably, auger 1628 includes passageways and holes 1646 provided so as to allow injection of gasses therethrough by connection to a source of gasses through port 1648, thus substantially maximizing exposure of the ground meats to direct contact with the gas blend. Tube section 1626 has a length dimension L which can be increased or decreased according to requirements. Preferably, auger 1628 is attached to a driver {not shown) that can provide a force to rotate auger 1628 in a direction such that ground meat will be transferred through horizontally displaced tube section 1626 and toward a.tapered tube section 1632. Preferably, driver has the capacity of rotating auger 1628 at a desirable speed which can be adjusted as may be required to optimize throughput of ground meat by first pressure vessel assembly.
Fine ground meat passes into the pressure vessel 1600 and accumulates until the upper level of accumulated ground meat is adjacent to proximity switch 1650.
Switch 1650 sends a signal to the variable speed drive motor which motor starts to slowly rotate auger 1628. Ground meat continues to accumulate and when level reaches a point adjacent to proximity switch 1654 variable drive motor is accelerated to a higher speed. The level of ground meat may continue to elevate and when the level reaches proximity switch 1652 drive motor speed is increased to maximum speed causing the level of ground meat to drop below a level adjacent to 1654 at which point the drive motor slows down to a lower speed. When the level of ground meat drops to a level below 1650 the drive motor is signaled to stop.
Therefore, in this fashion, the level of ground meat within the pressure vessel 1600 can be maintained at a point between the lowest proximity switch 1650 and the highest proximity switch 1652.
Preferably, tapered tube section 1632 has ports 1634 and 1636 to allow injection of gasses into section 1632 or allow gasses to be extracted from within the tapered section by passage. Preferably, additional ports may be provided through any part of apparatus walls as may be required to optimize efficiency and operation of pressure vessel assembly. A transfer section 1630 is located at the egress end of tapered tube section 1632. Preferably, section 1630 is provided with a port through which gasses may be injected mto or extracted from within section 1630.
Preferably, a desired profile can be varied by interchanging an extruded profile section 1640.
Preferably, the continuous length of extruded food product can be severed by a cutting device such that pieces of extruded food can be provided with specified and M'a<a.
'~il'!'v AMENDED SHEET
s ~ ~:..._ desired lengths. The pieces of extruded food can then be packaged into packages of suitable size. Such an extruded profile section 1640 is attached to the egress end of the transfer section 1630. A cross-section through section 1640 is shown in FIGURE 183 where a rectangular profile can be seen. Ground meat can be compressed by auger 1628 and thereby forced through section 1640. Preferably, compression of the ground meat through the profiled section provides a similar rectangular profile to the ground beef as it passes through the egress end of section 1640.
A side view and end view of an alternative extruded profile section 1640 in the form of a manifold is shown in FIGURES 18S and 184. Preferablyy manifold 1642 includes a series of three tube profiles through which ground meat can be extruded. Such a process can provide three separate streams of profiled ground meat. The manifold 1642 may include one or several streams of profiled ground meat. A tube of similar internal cross-section to the stream of ground meat may be connected to each stream of ground meat and thereby contain each stream of ground meat separately within a corresponding number of tubes so as to allow transfer of the profiled ground meat to other processing equipment such as automatic ground meat patty production equipment or a second pressure vessel. The tubes) will thereby provide protection to the. ground meat and substantially isolate it from contact with external contaminants or atmosphere.
Preferably, a 3 way valve (not shown) can be inserted between transfer section 1630 and profile sectifln 1640. The 3 way valve can be attached to section 1630 and section 1640 in a substantially airtight fashion so as to provide direct connection to each other or a connection to an alternative tube connected to other equipment or to port 1624. Preferably, this provides diverting the ground meat to other equipment for further processing or, as may be required at the start of a period of production, diversion of the ground meat into a first pressure vessel through port 1624 for additional processing to ensure that the ground meat is substantially saturated with dissolved carbon dioxide or other gasses. After the ground meat has been re-processed, which may require return to pressure vessel 1600 via port repeatedly, the three way valve can be switched to direct passage of the ground meat through the extruded profile section 1640 or other equipment for further processing or retail packaging. Preferably, valves (not shown), most preferably automated valves to close all ports shown in FIGURE 181 and any others that may be provided, in a substantially airtight man;~er, are provided to each port but not shown.
al~U= AMENDED SHEET

As can be learned and understood with the foregoing description an adequately effective gas tight seal can be provided by compacted meat 1606 within meat grinder 1604. Furthermore, auger 1628 can be arranged so as to fit closely within transfer sections 1632 and 1630 such that when 1628 is rotating, during normal operation of the apparatus, ground meat will become compacted within and 1634 and around auger 1628 and thereby provide an adequately effective gas tight seal. Therefore, gas pressure within the pressure vessel 1600 can be increased to above ambient atmospheric air pressure as required and maintained at a selected pressure by a controller to maintain and/or adjust and vary pressure of gasses within the pressure vessel 1600, as desired. The.gasses within the pressure vessel 1600 will therefore be substantially contained between the compacted meat at 1606 in the meat grinder and compacted meat 1656, within transfer sections 1632 and 1630 at a desired pressure. Pressure can therefore be maintained at a pressure most suited for rapid absorption by water and oils in the ground meat contained within the apparatus during operation and transfer of the ground meat through the apparatus.
Preferably, second and additional pressure vessel assembly of similar construction to the first pressure vessel assembly, can be provided and attached to the first pressure vessel assembly via an adapter tube so as to provide direct passage of the ground meat from the egress point at the extruded profile section 1640 by way of a tube connected directly to the adapter tube 1602 into the second pressure vessel assembly thereby providing direct communication to the second pressure vessel.
After passage of the ground meat through the first pressure vessel it can therefore be passed directly into a second pressure vessel. Preferably, the second pressure vessel is attached to a vacuum pump via a similar port to that as shown as port 1622 in FIGURE 181. Preferably, the port shown as port 1624 is not provided in the second pressure vessel. A suitable gas such as nitrogen is injected into ports provided in the second pressure vessel assembly which are shown as ports 1608, 1634 and 1636 and the nitrogen gas is also injected through ports and passageways in auger, also provided in the second pressure vessel assembly and shown as 1628 in the first pressure vessel assembly. The gas pressure within the second pressure vessel assembly is maintained at approximately a pressure equal to or higher to the prevailing atmospheric pressure. The ground meat is passed through the second pressure vessel assembly and through extruded profile section and into other equipment as required for packaging and or further processing. Passage of the ground beef through the second pressure vessel assembly removes free carbon y~,~~y... AMENDED SHEET

dioxide that may remain within the voids contained within the ground meat and replaces it with a gas such as nitrogen.
A preferred embodiment is to provide a method of substantially restricting the escape of any gasses, such as carbon dioxide or ozone, from an apparatus, that may be hazardous to the wellbeing of operators of the apparatus. This can be achieved by locating the apparatus, such as shown in FIGURE 181, within a confined space such as an enclosed room or other enclosure that is substantially filled with an inert gas such as nitrogen. The enclosure may include several parts and be arranged to cover only certain parts of the apparatus. The apparatus can be arranged such that certain i0 parts are exposed to allow access or loading. Preferably, the gas contained in the room or enclosure will be substantially nitrogen with a residual oxygen content of less than 20,000 parts per million. The enclosures or room can be extended to enclose or house other equipment such as conveyors and packaging apparatus that may be used to process and package the ground meat. Such an arrangement would most preferably isolate the ground beef from contact with gasses containing oxygen in concentrations greater that 20,000 parts per million, or greater than 300 parts per million, and allowing the ground meat, which may be ground beef, to be packaged in a vacuum pack or a modified atmosphere package containing a _ gas that includes a blend of desired gasses but containing residual oxygen of not more than 500 parts per million. The gas contained within the enclosures or the room may be pressurized and vented to a convenient and safe point into the atmosphere.
Meat Carbonation System In another preferred embodiment a series of enclosed vessels which may be pressure vessels, can be connected together, in series, via suitable conduit means with a positive displacement pump located between each pressure vessel and connected to the conduit means such that a pump can transfer product such as ground meat, by pumping means, from a first pressure vessel to a second pressure vessel. Goods such as ground meat can be transferred directly from a grinder into a first pressure vessel and a first pump can transfer the ground meat from the first pressure vessel to a second pressure vessel. A second pump can be provided to transfer the ground meat from the second pressure vessel to a third vessel and a third pump can be provided to transfer the ground meat from the third vessel to a fourth vessel. Any desired number of vessels and pumps rnay be assembled in series so as to provide a method of transferring the ground meat progressively from the first vessel to subsequent vessels as may be required. Gases andlor other goods and materials may be AMENDED SHEET

transferred by any suitable means into any of the vessels at any suitable temperature and pressure. Blending and mixing devices may be installed in the vessels, as may be required, and any suitable means of controlling and adjusting temperature of goods transferred into and from the vessels can be provided. In this way each vessel can be separately and independently controlled and arranged with a holding capacity to accommodate any desire3 quantity of ground meat, with selected gases and other materials provided therein, and held at any chosen temperature and pressure.
Each pump can be arranged to separate each vessel such that temperature and pressure can be independently adjusted in each of the vessels.
In a preferred embodiment, for example, fat and muscle tissue containedin .a .
quantity of boneless beef can be separated into a first quantity and a second quantity where the first quantity includes only muscle tissue which is then ground or cut into suitably sized pieces and then transferred directly into a vessel containing a suitable oxygen free gas and held at a temperature of 140 degrees F for a period of time sufficient to substantially kill any bacteria contained therein. The second quantity including only fat can be transferred into a second vessel and subjected to ultra high pressure (UHP), exceeding $0,000 psi, so as to substantially kill all bacteria contained therein while maintaining the second quantity of fat at a temperature of not more than I04 degrees F. The first quantity of muscle tissue can be chilled to a temperature below 100 degrees F and processed by extrusion to provide a first continuous stream of muscle tissue with a desired cross-sectional profile that can be arranged to be similar to the profile of the muscle component of a typical New York strip. The second quantity of fat can be chilled to a temperature below 100 degrees F
and extruded to provide a second stream of fat with a profile similar to the fat component of a New York strip. The first stream of profiled muscle tissue and the second stream of profiled fat can be then be combined into a single stream of muscle tissue and fat and the temperature of the single stream be reduced to about 29.5 degrees F. In this way, a substantially bacteria free, continuous stream of extruded muscle and fat having a cross-sectional profile similar to a New York strip can be produced which can then be sliced into suitable portions prior to retail packaging.
In this way, ground meat (and other meats) can be processed so as to substantially prevent the formation of oxymyoglobin immediately after grinding.
The ground meat can then be retail packaged in a low oxygen package such as a master package system as described herein and delivered to the point of sale in a de-oxymyoglobin condition. The package can be removed from the de-oxymyoglobin '~23 AMENDED SHEE-f condition immediately prior to retail display so as to allow generation of the consumer appealing red color or "bloom" for the first time after grinding.
Meat Grinding and Conditioning Apparatus Referring now to FIGURE 186, a meat grinding assembly constructed according to the present invention includes a first and second meat grinders that are in direct communication via a pressure vesse11700. Preferably, first meat grinder 1702 is fitted with an auger 1704 and meat grinder 1702 is attached to pressure vessel 1700 via adapter tube 1706 thereby providing direct communication to transfer ground meat that has been ground by grinder 1702 directly into the pressure vessel 1700. Preferably, adapter tube 1706 is provided with a substantially gas tight seal at the point of connection to pressure vessel 1700 such that pressurized gas that can be provided into 1700 will not escape. Preferably, the adapter tube 1706 is fitted with a valve (not shown), such that when grinder 1702 has completed grinding and no compacted meat remains in the grinder, the valve can be closed thereby closing communication between the pressure vessel 1700 and grinder 1702.
Closing the valve can thereby allow continued processing of any coarse ground meat that may remain in pressure vessel 1700 with gas provided therein under pressure and above ambient atmospheric pressure as required and until all coarse ground meat contained in the pressure vessel 1700 has been processed through second fine meat grinder 1738 and into downstream pressure vessel 1730. Furthermore, if so desired an additional valve, similar to the valve at grinder 1702, can be provided in the adapter tube 1718 so as to allow further processing of the fine grinds in the pressure vessel 1730.
Preferably, pressure vessel 1700 is fitted with a removable dome 1708 in which is provided a port 1710. Preferably, the lower portion of pressure vessel 1700 is attached to a housing containing auger 1712 which is directly attached to a variable speed drive (not shown) that can rotate auger 1712 in a direction that causes coarse ground meat to be urged into and through blade 1714 and plate 1716.
Preferably, an adapter tube 1718 is fitted so as to provide direct communication to pressure vessel 1730 Preferably, proximity switches 1720, 1722 and 1724 are conveniently located in walls of the pressure vessel 1724. Preferably, proximity switch 1720 is located at a point higher than the location of switch 1724, and switch 1722 is located between switches 1720 and 1724.
Pieces of meat are placed into a hopper (not shown) attached to first meat grinder 1702 and auger 1704 is rotated to cause pieces of meat to be urged through a ~;~~r~AMENDED SHEET

rotating blade and a perforated plate 1734. Compacted meat 1732 accumulates in a compressed condition just prior to passing through blade 1736 and plate 1734, providing a gas tight seal between the grinder 1702 and the pressure vessel 1700.
Coarse ground meat passes into pressure vessel 1700 and accumulates until the upper level of accumulated ground meat is adjacent to proximity switch 1724.
Preferably, switch 1724 sends a signal to a variable speed drive motor (not shown) connected to shaft 1728 which starts motor to slowly rotate auger 1712. Coarse ground meat continues to accumulate and when level reaches a point adjacent to proximity switch 1722, the variable drive motor is preferably accelerated to a higher speed.
The level of ground meat may continue to elevate and when the level reaches proximity switch 1720, preferably the drive motor speed is increased to maximum speed causing the level of ground meat to drop below a level adjacent to switch 1722 at which point, preferably, the drive motor slows down to a lower speed. When the level of ground meat drops to a level adjacent to switch 1724, preferably, the drive motor is signaled to stop. Therefore, in this fashion, the level of ground meat within the pressure vessel 1700 can be maintained at a point between the lowest proximity switch 1724 and the highest proximity switch 1720. Preferably, meat is compacted at just prior to passing through rotating blade 1714 and perforated plate 1716, thereby providing a gas tight seal between pressure vessel 1700 and pressure vessel 1730.
In this fashion compacted meat remains in a compacted condition at location 1732 and 1726 providing gas tight seals. Preferably, a desired gas or blend of gasses can be injected into pressure vessel 1700 at a desired pressure.
Preferably, gas pressure is slightly above ambient atmospheric pressure or up to 150 psi and is maintained at desired pressure by metering and gas pressure regulating equipment (not shown). In this fashion gas can be continuously injected into the pressure vessel 1700 and maintained at a desired pressure at a rate equal to the rate of absorption of gasses by the ground meat. The meat and ground meat may be compacted to provide substantially gas tight seals other than as described herein while providing for a continuous production process of meat treatment during the meat grinding procedure. Production speed can be adjusted to optimize the gas absorption (and contact with surface of the ground meat) at a desired rate while maximizing output of the apparatus and equipment.
In yet another preferred embodiment, pressure vessel 1700 and/or other pressure vessels attached thereto, preferably are provided with valves, that can be opened and closed, and that are provided at all ports, adapter tubes, entry and egress 1~5' AMENDED SHEET

apertures in the pressure vessel(s), so as to enable isolation of the pressure vessels) from external ambient atmosphere. Preferably, when isolated, gas pressure within the pressure vessels) may be adjusted to a suitable and adjustable pressure below and/or above ambient atmospheric pressure. Preferably, the gas pressure, in the pressure vessel, may be increased and decreased in a pulsating andlor oscillating frequency and pattern that can provide for the efficient removal of undesirable gasses and the replacement with desirable gasses at a desired pressure.
Meat Processin,grSvstem A processing system is disclosed including a meat grinder and a processing and blending tube with three augers to transfer the meat through the sysiem.
The tube includes a heat exchanger to maintain temperature and ports for the introduction of conditioning gases.
FIGURES 187-189 discloses a preferred apparatus constructed according to the present invention arranged to process perishable foods such as ground beef.
Preferably, the apparatus can be assembled in a gas tight manner with components manufactured from any suitable materials such as approved stainless steel or plastics.
Preferably, the assembled apparatus may be arranged in a horizontal disposition or with devices to adjust the horizontal disposition to any desirable angle of repose.
Apparatus 5600 includes an enclosed vessel 5624 of circular cross-section profile, with end enclosures 5602 and 5604. Preferably, vessel 5624 can be arranged to contain any suitable gas at any suitable internal gas pressure and at any suitable temperature. Preferably, the temperature of the gas is controlled. Preferably, vessel 5624 can be fitted witl-~ drivers 5614, 5616, 5618 and 5620 attached thereto at suitable convenient locations and as required to provide driving forces to a round blending tube, shown as 5622, located inside vessel 5624. Preferably, the drivers can be controlled to drive the tube 5622 at a suitable constant and variable speed. The tube 5622 engages with four drive wheels, all shown as 5626 for clarity, and tube 5622 is supported thereon, but otherwise is free from contact with other components except for suitable contact with seals as may be required at each end of the tube 5622. Preferably, drive wheels 5626, are engaged to the corresponding drivers 5614, 5616, 5618 and 5620. In this way, the tube 5622 is retained by the drive wheels, 5626, in a horizontally disposed position or as may be otherwise required. Preferably, press~.~re vessel 5624 is fitted with vent 5628 which can be provided with a valve (not shown) to allow any excess liquids or gases to be drained therefrom. A vent with valve and venturi, 5632, can be fitted to vessel 5624.
AMENDED SHEET

Preferably, any desired number of vents with valves and venturis can be fitted to the vessel 5624. Preferably, venturis can be arranged to provide gas injection into space 5636 in such a manner that will cause the injected gas to flow along space 5636 and then through tube 5622, in a desired direction at a suitable velocity.
The tube 5622 is arranged inside the vessel 5624 and passageway 5636 is thereby provided between the outer surface of the tube 5622 and the inner surface of vessel 5624. Gas can therefore be provided inside the pressure vessel and in the passageway 5636. Preferably, any suitable gas temperature controller may be arranged such as by arranging a heat exchanger 5638 connected to the vessel 5624 as shown. Preferably, a first and second suitably sized tubes, 5640 and 5642 are attached in direct communication with vessel 5624 such that gas can pass between the tubes and the vessel 5624. Preferably, tube 5640 is connected to the heat exchanger 5638 and another connecting tube 5644 is attached to a gas blower which in turn is connected to the connecting tube 5642. In this way gas can pass through tube 5640, into and through the heat exchanger 5638, through tube 5644, into and through the gas blower 5646, and through connecting tube 5642.
Preferably, a barrier 5648 is located in space 5636 which can follow the outer circumference of tube 5622 so as to substantially inhibit gas passing therethrough. In this way, when gas blower 5646 is activated, gas can be drawn in from space 5636 on one side of barner 5648, through tube 5640 and passed through tube 5642 and back into space 5636 on the opposite side of the barrier 5648. Preferably, this provides recirculation of any suitable gas along the space 5636, through tube 5622, back into space 5636 and again through the heat exchanger 5638. The gas can be re-circulated and repeatedly passed through heat exchanger, 5638, to maintain the gas at a desired temperature. A tube shown as 5650 is provided to allow suitable gas to be injected into the heat exchanger 5638. Preferably, the suitable gas can be provided in a liquid or high pressure condition and allowed to expand in the heat exchanger 5638, and thereby cause a lowering of temperature. Suitable gas can then pass from heat exchanger 5638 and into tube shown as 5652 which is connected to tube 5644.
Alternatively, suitable gas can be allowed to escape through tube 5654 and valve 5656. In this way, by controlling the flow of gas, the internal temperature of vessel 5624 and all other items therein can be controlled. During the re-circulation of gas through tube 5622 and heat exclanger 5638, a quantity of water, contained in the grinds, may evaporate and condense in heat exchanger 5638. The quantity of condensed water in the heat exchanger may be processed, sterilized and carbonized, j~j~AMENDED SHEET

by dissolving carbon dioxide therein and then injected into the grinds through vent tube 5658. Preferably, tubes 5652 may be provided with pressure regulators and valves to allow excess gas to escape therethrough, from vessel 5624 at a suitable rate and in such a manner as to maintain the temperature of the gas within a temperature range of plus or minus about 0.5 degrees F, or at any other suitable temperature range. Preferably, the suitable gas andlor any other suitable substances can be provided in vessel 5624 at any suitable gas pressure to facilitate dissolving of the gas and/or substances into the ground meats contained in the tube 5622. In this way, the suitable gas can be controlled to either chill or heat the ground meats being processed in tube 5622, and by the apparatus.
Referring now to end enclosure 5602 with a plurality of apertures.
Cover 5660 is located over an inspection access hole so as to provide a convenient access into the apparatus for any purpose such as for cleaning. Preferably, a vent 5662 is provided to allow excess gas to escape. Preferably, vent 5662 can be attached to suitable valves with gas pressure regulators as may be required to control gas pressure. A tube 5664 is located through a tube in the wall of end enclosure 5602. Preferably, tube 5664 connects to a nozzle 5666, that can be arranged to provide temperature controlled water or other liquids, at any suitable pressure into the inner space contained within tube 5622. Preferably, the water or other liquids can be used to clean the internal surfaces of the apparatus after use of the apparatus. Bearings such as bearing shown as 5668 are also located in the end enclosure 5602.
Referring now to er~d enclosure 5604, several openings are shown therein with other apparatus attached thereto. Preferably, three variable speed drive motors, 5614, 5616 and 5618 are fixed to the end enclosure 5604 and each motor is attached to corresponding shafts shown as 5670, 5672 and 5674. A subassembly 5601 is mounted to end enclosure 5604 in a desired position and can pass ground beef into the tube 5622 directly from a grinding apparatus without contacting atmospheric air.
Preferably, all shafts, tubes, components and assemblies attached to end enclosures are sealed in a suitable and desired gas tight manner, thereby retaining any gas that may be contained within vessel 5624, at any suitable pressure.
Refernng again to FIGURE 187, three separate augers (two shown), depicted as 5676, 5678 and 5680 we preferably mounted in close proximity to each other and with a member 5682 arranged above auger shown as 5676 separating it from augers 5678 and 5680. Preferably, augers 5676, 56?8 and 5680 can be arranged in a '~(~g~ AMENDED SHEET

horizontally disposed and parallel position. Auger 5676 is attached to drive motor 5614, auger 5678 is attached to drive motor 5616 and auger 5680 is attached to drive motor 5618. The end sections of each auger 5676, 5678 and 5674 are arranged with shafts and each shaft end mates with bearings located in end enclosures 5602 and 5604. Drive motors 5614, 5616 and 5618 are arranged to drive the corresponding augers at variable rotating speeds in any chosen direction, either clockwise or counterclockwise, as may be selected according to any desired direction and at any suitable speed that will enable optimized mixing of the ground meats processed in tube 5622. Alternatively one or any number of augers may be located in tube 5622 to provide the most optimized mixing therein.
Refernng again to FIGURE 187, sub-assembly 5601 is attached to end enclosure 5604 and can be operated to grind beef and inject the ground beef directly into tube 5622. In this way, ground meat can be continuously provided into tube 5622, at any suitable rate mthin the capacity of the apparatus. Referring now to FIGURE 190, the ground beef that flows into tube 5622 can be arranged to fall directly onto but centrally and between the center lines of augers 5678 and 5680.
Preferably, augers 5678 and 5680 can be arranged to rotate in opposite directions.
Direction of rotation of auger 5680 can be in a clock-wise direction and auger can be rotated in a counter clockwise direction. In this way, the ground beef can be carried by augers 5678 and 5680 toward end enclosure 5604 and away from end enclosure 5602. Member 5682 is arranged to allow containment of the ground beef between its upper faces and augers 5678 and 5680 for a brief period such that as augers rotate the ground beef is earned toward the end enclosure 5604. As augers 5678 and 5680 rotate the ground beef will then drop and contact tube 5622.
Preferably, tube 5622 can be arranged to rotate at a suitable speed, of between about 100 rpm or less and about 500 rpm or more, such that centrifugal force will hold the ground beef against the internal surface of tube 5622. When tube 5622 has rotated by approximately one half of one revolution and the ground beef is carried to an upper location and above augers 5678 and 5680, a scraper 5625 can be provided to remove the ground beef from contact with tube 5622. The scraper 5625 can be arranged to cause the ground beef to be directed back onto augers 5678 and 5680.
Auger 5676 can be driven in a direction that will carry any ground beef, that it contacts, toward the end enclosure 5602. Preferably, the rotating speed of each auger can be adjusted as required. Preferably, auger 5676 can be arranged to have an extended length, that is longer than 5678 and 5680 such that 5676 extension extends AMENDED SHEE-f beyond 5678 and 5680 and into a tubular section, shown as 5722, with an internal diameter slightly larger than the external diameter of auger 5676. As shown in FIGURE 187, auger 5676 can then be arranged to carry ground beef from within tube 5622 and through tubular section 7522 at a desired rate. In this way the ground beef will be carried toward end 5604 by augers 5678 and 5680 and toward end by 5676. The rotation of tube 5622 and its interaction with the scraper 5625 will then provide further mixing fat and muscle content of the ground beef. By independently adjusting the rotating speed of augers 5676, 5678 and 5680 and also tube 5622, the period of time that the ground beef is retained within the tube 5622 can be controlled to an optimized period of time and thereby allow an efficient method of blending.
Preferably, after a suitable period of retention, the ground beef will be transferred through tube 5642 and will then fall downwardly into tube 5724. Tube 5724 can be located directly above and connected to a suitable vane pump shown as 5726, which may include any suitable vane pump manufactured by Weiler & Company, Inc.
Preferably, the ground beef can be pumped at a known and controlled velocity by vane pump 5726 into tube 5728 which is connected directly thereto. Tube 5728 can be connected to another measuring device 5730. In this way, ground beef can be ground and injected into tube 5622, by sub-assembly 5601, and after passing through a first measuring device 5730, blended by augers before pumping through a second measuring device 5730 located between tubes shown as 5728 and 5732. Ground beef can be conditioned and blended at a production rate limited only by the chosen size and capacity of the ground beef conditioning and blending apparatus, which may be varied in size and capacity as required.
The conditioned and blended ground beef can thus be pumped through tube 5732 at a desired and controlled temperature with a quantity of suitable gas such as carbon dioxide, dissolved in the ground beef to any desired level of saturation.
Vane pump 5726 can be provided with a variable speed drive motor and arranged to pump ground beef at a controlled velocity into other apparatus for subsequent blending with other ground beef or chosen material and/or further processing.
In a preferred embodiment the conditioned ground beef may be exposed to a suitable beam of electrons by locating an electron beam generator and accelerator such as may be manufactured by Titan-Scan Systems of 3033 Science Park Road, San Diego, CA 92121. Preferably, the electron beam generator may be located in such a manner that the suitable beam of electrons produced there with, is directed directly at and through a stream of grinds while the grinds are passing through a tube AMENDED SHEET

such as tube 5754 shown in FIGURE 191. The cross-sectional profile of the tube may be arranged to provide maximum exposure to the electron beam. In this way the conditioned ground beef can be sterilized at any temperature while maintaining a fresh and uncooked condition. Preferably, electron beam sterilization is used on fresh ground beef which is in a low oxygen environment to prevent over-oxidation.
In an alternative embodiment the stream of conditioned ground beef can be exposed to irradiation from a source of gamma rays.
Referring again to FIGURE 191, a section of assembled tubes is detailed.
The section of tubes includes a first tube 5744, a second tube 5746 and a third tube 5748 which are all joined at a confluence, 5750, to a fourth tube 5754.
The . . . . _ tubes and particularly the confluence may be manufactured from any suitable plastics or stainless steel materials and machined so as to ensure that any processed materials passing therethrough, will not be subject to significant turbulence until after passing through the confluence 5?50. Preferably, any number of two or more tubes joined, at a confluence, to a single tube 5754, may be arranged to produce processed materials as may be desired. In a preferred configuration, a first processing machine (not shown), is arranged to deliver the processed material via tube 5744, a second processing machine (not shown), is arranged to deliver the processed material via tube 5746 and a third processing machine (not shown) is arranged to deliver the processed material via tube 5?48. Preferably, the fat content of each stream of ground beef can be measured, by any suitable measuring device such as that shown as 5730 in FIGURE 195, and the fat content will therefore be known.
Preferably, the velocity of each stream of material can be adjusted by adjusting the speed of separate vane pumps arranged in such a manner so as to provide for velocity adjustment.
By adjusting the velocity of each stream of processed material corresponding to the measured fat content contained therein, delivered quantities of the processed material, can be adjusted such that when any two or more streams are combined together, the resultant fat content of the combined stream will be substantially constant and as required. I.1 this way, the known fat content of the combined stream of processed material can be maintained to within a narrow range of variation.
The variation may be within a range of not more than +/- 1% of the fat content of any item such as Item 1F.
Referring now to FIGilRE 192, a preferred embodiment including a group of three blending tubes 5756, 5758 and 5760 is shown, each tube being similar in operation to tube 5622 shown in FIGURE 187. Preferably, the group of three AMENDED SHEET

blending tubes are each assembled with an auger similar to as described above in association with the tube 5622 and auger 5676, 5678 and 5680. Rollers 5762, and 5766 are arranged to engage and retain the blending tubes as shown. A
pressure vessel 5768, is arranged to accommodate the group of three blending tube assemblies such that drive wheels 5770 are engaged there with and as shown and can be activated as required so as to rotate the blending tubes. Ground beef can be provided into each blending tube by similar apparatus to that disclosed above with sub assemblies 5601 of FIGURE 187. In this way, three grades of ground beef can be processed simultaneously in three continuous streams. Each of the continuous streams of conditioned ground beef can be further processed if desired.
In a preferred embodiment, a plurality of processing machines are arranged to process material such as fine ground (or coarse ground) meat, such as beef grinds.
Each of the processing machines may be similar to the apparatus shown in FIGURE 187. A total of three processing machines can include a first machine, a second machine, and a third machine, and can be arranged so that each processing machine can process a separate quantity of boneless beef. The first machine, may process a quantity of Item 1, the second machine, may process a quantity of Item 2 and the third machine, may process a quantity of Item 3. The first, second and third machines will therefore produce first, second and third streams of ground beef (processed material) that, after processing, will be pumped, by separate vane pumps (for delivery as required), along tubes shown as 5732 in FIGURE 188.
Preferably, any number of one or more processing machines may be arranged so to provide any number of streams of processed material. Preferably, the streams of processed material may be combined and joined together in any chosen configuration, to produce one or more subsequent streams of processed material.
Preferably, the velocity of each stream of material may be adjusted, so as to deliver a known and corresponding quantity of processed materials with any desired fat content as required. Preferably, the fat content and muscle content, of each stream of processed material can be continuously measured, as described herein, or in any other suitable manner. One or more streams of processed materials may be combined to produce a single stream of processed material. By adjusting the velocity and consequent delivered quantity of each stream of material (before combining together into a resultant single stream) any quantity of any processed material, such as Item 1F can be produced to a substantially constant and precise specification.
The combined stream of processed materials may be further processed through a grinder AMENDED SHEET

and/or through processing machines such as that shown in FIGURE 187.
Additionally, the streams of processed materials may be directed through a tube that is exposed to sterilization such as by exposure to gamma irradiation, or any other suitable sterilizer while contained within the tube.
Subsequent to processing, the beef grinds or processed material can be retail or bulk packaged in any suitable manner, such as a substantially oxygen free modified atmosphere master package.
The packaging may be arranged to accommodate a variation in total volume of the package such as an expansion or contraction in volume. The package volume variation may occur as the temperature variation of the packaged processed material.
The volume variation may correspond to the temperature variation as a result of any gases dissolved in the processed materials "boiling off' or again dissolving in direct relationship to the temperature variation. Accommodation of the variation in package volume may be achieved by provision of a suitably sized, flexible, substantially gas barner package.
Referring again to end enclosures 5602 and 5604 shown in FIGURE 187, suitably located apertures shown as 5736, are provided therein so as to allow free movement of gas therethrough. The velocity of the gas can then be controlled by blower 5646 and along a path through tube 5622, into the spaces shown as 5738 and back through space 5636. Preferably, the velocity and temperature and pressure of the gas can then arranged at the most effective settings to control the temperature of the ground beef and the rate of gas dissolving therein.
Refernng now to FIGURE 194 and particularly, end enclosure 5604, a member shown as 5738 is arranged to mate with member 5604 at a close contacting face shown as 5740. Members 5604 and 5738 are in contact at interface 5740, and fixed relative to each other but not locked together. Member 5738 can move relative to 5604 but is retained by interface 5740 and shafts shown as 5670 and 5674 (and 5672, which is not shown). Suitable bearing surfaces are provided between 5738 and 5604 and also between 5738 and 5670, 5672 and 5674. Sub assembly 5601 is arranged so as to be removable for cleaning purposes and plugs may be inserted into the connecting apertures created by removing sub-assembly 5601. When 5601 is removed and replaced with the plugs, member 5738 can be moved away from tube 5622 by sliding along shafts 5670, 5672 and 5674 so as to provide a space between member 5738 and the end rim of tube 5622. Preferably, such an arrangement may be installed at either or both end enclosures of the apparatus in '13~~~! AMENDED SHEET

such a manner so as to facilitate effective cleaning of apparatus after use.
Other cleaning features may be incorporated into the apparatus. Preferably, pressurized and heated water may be provided inside the apparatus with suitable sanitizing detergents in such a manner so as to facilitate an automatic cleaning when augers 5676, and 5680 and tube 5622 are all rotated in common or opposing directions and at suitable speeds. Alternatively or additionally high pressure steam may be provided inside the apparatus to facilitate sterilization and thorough cleaning of the internal surfaces of the apparatus. Draining/venting tubes such as 5742 can be provided with valves, at any suitable and convenient location on the apparatus.
Lean Muscle and Fat Measuring Apparatus A lean tissue and fat analyzer is an optional feature of the meat processing system. Refernng now to FIGURE 189, a cross sectional view of the conduit of FIGURE 188 is shown as a square or rectangular tube 5730. Preferably, tube and tube 5702 are similar. Tube 5730 can be manufactured from any suitable material which includes plastics as well. Preferably, two electrodes, shown as and 5712 are located on opposing internal sides of tube 5730 and attached to terminals. Electrode 5710 is attached to terminal 5714 and electrode 5712 is attached to terminal5716. An electrical current can be arranged to flow through terminals 5714 and 5716 and into electrodes 5710 and 5712. Ground beef (ground meat) is shown as 5715 and in this way, will directly contact the electrodes as it passes through tube 5730. The electrical current can therefore pass through ground beef from electrode 5712 and to electrode 5710. Electrical current will be affected by the resistance of the ground beef and this resistance will vary according to the ratio of fat and muscle content of the ground beef and therefore the electrical resistance can be measured. The variation in electrical resistance can be measured and such measurements can be converted and used to determine the ratio of fat and muscle contained in the ground beef in a continuous process. Tube 5730 with terminals and electrodes together include a measuring device shown as 5718.
Preferably, the measuring device may be installed, and used to measure the ground beef fat and muscle content ratio, at any convenient location as may be required.
Meat Grinder Sub-Assembly A meat grinder sub-assembly is an optional feature of the meat processing system. Several embodiment of a meat grinder have been previously described.
However, a meat grinder preferably for use with the processing machine follows.
AMENDED SHEET

Referring now to FIGURE 193, a meat grinder sub-assembly according to the present invention is shown. The sub-assembly includes a pressure vessel 5684, with an entry port 5686 at an upper location and an exit port 5688 at a lower location. A
horizontally disposed and tapered auger 5690 is located in a lower portion of vessel 5684 and arranged with a shaft 5692 that can be attached directly to a suitable variable speed driver. Preferably, the tapered auger is suitably profiled and is fitted with passageways therein to allow any suitable gas to be injected therethrough. A
meat grinding apparatus is attached directly to the entry port 5686 and can be disconnected therefrom to provide access for cleaning as required. Boneless meat portions can be . processed by grinder 5694 to produce grinds which are then transferred directly into vessel 5684 in a continuous stream. Preferably, the cross-sectional profile of vessel 5584 is circular and a valve member 5696 is arranged to mate with a valve seat 5698, which is located between the entry port 5686 and the auger 5690, to provide a gas tight seal when required. Valve member 5696 can be opened and closed by valve stem 5697 as required and an:anged to automatically close as required for any reason. Ground beef that is transferred into vessel 5684 can contact auger 5690. Preferably, any suitable gas at any suitable pressure can be injected into vessel 5684 through ports 5700 and/or 5702. Each port such as and 5700 is fitted with suaable valve and pressure regulator: As desired, gas can be injected into a port such as port 5702 and allowed to exit through a port such as 5700.
Pressure regulators maintain a desired gas at any suitable pressure in the vessel 5684.
In this way, the continuous stream of ground beef can be transferred through the vessel 5684 by auger 5690 at a desired rate and pressure. As the ground beef is transferred through vessel 5684 by tapered auger 5690, the ground beef is compressed and extruded through a restriction as shown, so as to exclude gas and produce a substantially continuous flow of ground beef without gas bubbles contained therein. In this way the compressed ground beef can provide an effective gas tight sealing between vessel 5684 and vessel 5624 of FIGURE 187. The continuous flow of ground beef is passed through a tube section 5702 at a desired and controlled rate. After passing through tube 5702 the ground beef passes through the exit port 5688 and can be directed into any suitable container such as tube shown in FIGURE 187. If desired, a secondary grinder may be interposed between the vessel 5684 and a valve 5706. Valve 5706 is provided at the exit port 5688 and can be arranged with an automatic actuator to open and close at a remote distance as may be required for any reason. When in a closed position valve 5706 can seal the :1,35: AMENDED SHEET

exit port 5688 in a gas tight manner. As the ground beef passes through tube section 5702, the fat and muscle content of the ground beef can be measured.
The measuring device may include the passing of an electric current through the ground meat as it passes through the section 5702. Preferably, the electrical resistance is measured and a muscle and fat concentration can be obtained.
Meat Pre-Conditioning. System Referring now to FIGURES 196-197, a plan view and a side elevation view of an apparatus designed to slice meat while conditioning in an oxygen free environment is shown. The apparatus is shown in diagrammatic form and includes a continuous conveyor 5100, with a driver mounted to a rigid frame (not shown) and horizontally disposed to allow horizontal motion in a machine direction in intermittent or continuous movement. The conveyor is fitted with two corresponding and vertically opposed pairs of pressure chambers includes an upper chamber with a corresponding lower chamber 5104 and another upper chamber 5106 with a corresponding lower chamber 5108. An enclosed gassing tunnel 5118 is arranged to enclose the upper section of the conveyor 5100 with a gassing port 5112 affixed thereto to provide any suitable gas, such as nitrogen gas or carbon dioxide, into the tunnel S 118.
Referring now to upper chamber 5102 and corresponding lower chamber 5104 the opposing chambers are arranged so as to open and close. Upper chamber S 102 is mounted to a driver (not shown) to provide elevating, lowering and clamping apparatus. Lower chamber 5104 is also mounted to a separate driver (not shown) to provide elevating, lowering and clamping. Chambers 5102 and S 104 can be closed together by moving in opposing directions so as to contact each other along a path around the perimeter of openings. In this way a single chamber is so arranged in a manner that is airtight and sealed from external atmosphere. An evacuation port 5114 and a gas port 5116 are provided so as to allow evacuation and gas flushing of the closed chamber. As shown in FIGURE 196 two separate pressure chamber assemblies are arranged such that conveyor 5100 passes through both chamber assemblies. Trays with sliced beef or other meat primal, placed therein, are located into carrier plates in conveyor 5100. The primals are sliced in a suitable manner and can then be opened so as to expose the multiple surfaces of the slices immediately prior to entry into enclosed tunnel5118. Enclosed tunnel5118 is arranged so as to substantially exclude atmospheric oxygen gas by flushing other 3S suitable gases therein. The trays with sliced primal S 122 are located in carrier plates ~~13~~ AMENDED SHEET

and progressively move through enclosed tunnel 5118 until each tray with primal is located directly between an upper chamber 5102 and lower chamber 5104. The upper and lower chambers close together and around the sliced primal 5122 in an airtight and sealed manner. Substantially all air is evacuated from the chambers and a suitable gas, including carbon dioxide, is injected through port 5116. The suitable gas pressure can be increased to any suitable pressure as desired. The primal can be retained in the pressure chambers for a desirable period of time so as to cause sufficient carbon dioxide gas to dissolve in the oils and water contained in the primal 5122. After the primal 5122 has been exposed to the high pressure carbon dioxide gas for a suitable period of time, the pressure chambers open and allow conveyor 5100 to carry sliced primal 5122 in tray, forward in machine direction and through the enclosed tunnel 5118. A second pressure chamber assembly may also be closed around the sliced primal 5122 in tray. Any suitable gas at any suitable pressure can be provided in the second enclosed chamber. Second chamber includes an evacuation port 5115 and a gassing port 5117. The sliced primal 5122 in tray is intermittently carned through the tunnel 5118 until it emerges at the exit end of the tunnel.
In this way, rapid formation of oxymyoglobin is inhibited when the primal 5122 is exposed to ambient atmosphere.
Plant Layout Having described meat grinding systems and ancillary equipment, it is appropriate to describe the integration of equipment to form a whole production facility for processing and packaging meats.
Refernng now to FIGURE 198, a plan view of a preferred production plant layout is shown, including ground meat processing, blending equipment and retail packaging plant. The equipment shown in FIGURE 198 is represented by diagrammatic sketches and is integrated such that ground beef processed by the equipment shown can be transferred directly from grinders 6400, 6402 and 6404 into oxygen free vessels shown as 6408, 6410 and 6412, respectively.
The chart set out below provides a list of equipment shown in FIGURE 198.
ID Item 6400 Grinder '13~ AMENDED SHEET

m Item 6402 Grinder 6404 Grinder 6406 Grinder (Fine) 6408 Vessel + Mix 6410 Vessel + Mix 6412 Vessel + Mix 6414 VesseIJHo er 6416 VessellHo er 6418 Vessel/Ho er 6420 Positive dis 1. um 6422 Positive dis 1. um 6424 Positive dis 1. um 6426 Positive dis 1. um 6428 Measure fatllean 6430 Measure fatllean 6432 Measure fatllean 6434 Continuous blendin 6436 Control Panel 6438 Valve (diversion) ''.'138-AMENDED SHEET

m Item 6440 Elevator 6442 Elevator 6444 Dischar a Ports 6446 Dischar a Ports 6448 Dischar a Port 6450 Ma azine 6452 Gas Exchan a 6454 Tra Welding 6456 Grinds Portionin machine 6458 RT 1800 Packa in Machine 6460 Horizontal Vacuum Boneless beef with a suitable fat/lean composition is loaded into grinders 6400, 6402 and 6404. Ground beef is produced by grinders 6400, 6402 and 6404 and transferred directly into enclosed vessels 6408, 6410 and 6412 that are otherwise filled with a suitable gas at a suitable pressure.
Vessels 6408, 6410 and 6412 can be fitted with blending apparatus so as to blend grinds therein. Positive displacement pumps 6420, 6422 and 6424 pump quantities of grinds, in three respectively separate streams from vessels 6408, 6410 and 6412 directly into continuous blender 6434. The quantity of grinds pumped by the positive displacement pumps in the separate streams is controlled and dictated by the measured fat and lean content of each stream of grinds. Fat and lean content of each stream of grinds is measured by measuring devices shown as 6428, 6430 and 6432. Continuous blender 6434 terminates at positive displacement pump 6426 and blended grinds are transferred directly from 6434 into 6426. Pump 6426 can transfer AMENDED SHEET

the blended grinds in a single continuous stream into either vessel 6418 or vessel 6416.
Grinds can be stored in vessels 6416 and 6418 as may be required. The grinding, pumping, measuring and blendsng apparatus can be arranged so as to produce a single stream of grinds by combining three separate streams into a single stream in continuous blender 6434. The single continuous stream of blended grinds can be produced according to a specification such as 85% lean and 15% fat.
Alternatively, single stream of blended grinds can be produced according to any other desired specification such as 90% lean and 10% fat. In this way two separate quantities of specified grinds can be stored with one in each of vessels 6416 and 6418. For example, a quantity of 85% lean and 15% fat grinds can be stored in vessel 6416 and a quantity of 90% lean and 10% fat grinds can be stored in vesse16418. Suitable positi»e displacement pumps can be arranged to transfer specified quantities of grinds from either or both vessels 6416 and 6418 for separate or combined grinding in a grinder such as is shown as 6406 in FIGURE 198. Any suitable number of pumps can be arranged to transfer grinds from either of the vessels 6416 and 6418 for further blending and/or grinding and subsequent retail packaging in packaging machine shown as 6458. If required suitable blending equipment can be provided for blending of any suitable number of additional pairs of streams of grinds, in selected quantities, after pumping from vessels 6416 and to produce specified quantities of blended grinds that can then be fine ground prior to retail packaging.
In this way, ground meat can be processed and packaged while being contained within a series of vessels and tubes that are filled with ground meat and suitable gas that substantiall~r excludes oxygen and any other undesirable gas and/or material. Therefore, formation of oxymyoglobin on substantially all freshly cut meat surfaces can be inhibited until after packaging and immediately prior to retail display or other desired use.
Referring now to FIGURE 199, a plan view of another preferred production plant layout is detailed including production and packaging equipment.
A preferred layout includes items of equipment in the table below and identified by a reference numeral.
Production Ec AMENDED SHEET

Item Production ui ment Packa 'n a ui ment #

5900 Grindin machine 5960 Chub/vacuum acka in machine 5902 Grinding machine 5930, Ground beef portioning 5932, machines 5904 Grinding machine 5940, Over wrapping packaging 5938, machines 5906 Ground beef processing 5954, Foam tray erecting machines machine 5956, 5908 Ground beef processing 5924, Conveyor belts machine 5926, 5910 Ground beef rocessin machine 5922 Ground beef rocessin machine 5942 Gas blower with heat exchan er.

5912 Ground beef In'ector 5914 Ground beef In'ector 5916 Ground beef In'ector 5944 Ground beef In'ector 5946 Vane um 5948 Vane um 5950 Vane um AMENDED SHEET

Item Production ui ment Packa in a ui ment #

5952 Vane um 5918 Multi-tube combinin die 5920 Electron beam sterilizer and/or 'nder Preferably, the equipment shown in FIGURE 199, and listed above, is arranged to continuously produce and retail package, case ready ground meats.
Quantities of specified boneless beef raw materials are processed by grinding machines 5900, 5902 and 5904 to produce grinds that are transferred directly into ground beef processing machines 5906, 5908 and 5910 via corresponding injector machines 5912, 5914 and 5916. Each grinder processes a quantity of specified boneless beef raw materials each of which may be selected from the following table of raw materials Item 1 through Item 5.
Item Muscle Fat Tissue Tissue 1 93% 7%

2 90% 10%

3 75% 25%

4 65% 35%

5 50% 50%

Equipment shown as vessels 5906, 5908 and 5910 is arranged to process grinds as above described apparatus shown in FIGURE 187. Grinds are injected into vessels from the grinders 5900, 5902 and 5904 by injectors 5912, 5914 and 5916 which are arranged to operate as the above described apparatus shown in FIGURE 193. Conditioned grinds are transferred in a single continuous stream from ~q.~'~ AMENDED SHEET

each vessel, by a pump from vessels into transfer tubes which are then combined at confluence 5918 into a single tube. Confluence 5918 includes a manifold generally as the above described apparatus shown in FIGURE 191.
Preferably, the fat content of the continuous streams of grinds is continuously measured by measuring devices as the above described apparatus shown in FIGURE 194. Preferably, the fat content of the grinds can be continuously measured before injection into the vessels and immediately after transfer from the vessels and into the transfer tubes. Preferably by measuring the fat content and automatically adjusting the flow rate of each stream of grinds, directly and according to the measured fat content, prior to combining the streams of grinds; a combined stream of grinds with consistent fat content can be produced. The combined stream is then transferred via a tube into a single grinder shown as 5920. An electron beam generator of suitable capacity may be integrated such that the combined stream of grinds passes therethrough prior to injection directly into vessel 5922.
Vessel 5922 may be arranged to process grinds as the above described apparatus shown in FIGURE 187. A single stream of conditioned grinds is then transferred into a single tube that is divided into four separate streams of grinds.
Still refernng to FIGURE 199, the preferred plant layout includes four packaging systems and a single supply stream of grinds is transferred to each of the packaging systems. Preferably, one stream to "chub/vacuum" packaging machine.
Preferably, apparatus constructed according to the present invention includes three packaging machines 5924, 5926, and 5928, and a single stream of grinds to each of three portioning machines, shown as 5930, 5932, and 5934, respectively.
Portions of grinds are then retail packaged by automatic loading into trays which are then over wrapped by packaging machines shown as 5936, 5938, and 5940. While, an embodiment has been described and shown to include three processing trains, any suitable number of processing trains may be used in accordance with the present invention, which may include more or less than the three trains herein described.
The equipment as dzscribed herein may be arranged to automatically produce any quantities of coarse or fine ;rinds according to any specifications. The following table shows the specified muscle and fat tissue content of three types of fine beef grinds.
Item Muscle Fat Tissue Tissue '143 AMENDED SHEET

Item Muscle Fat Tissue Tissue 1F 90% 10%

2F 75%a 25%

3F 65% 35%

Equipment as described herein maybe arranged to grind, measure, condition, blend, process and package specified portions of grinds according to any suitable size by automatically computer controller. The computer controller may continuously provide production information including such data as the total fat and muscle tissue content of each and alI streams of grinds during the processing. In this way, a method to improve efficiency and reduce total losses is provided by producing grinds to meet precise specifications according to, for example, the list of fine beef grinds shown above.
Plant Layout Refernng now to FIGURES 200 and 201, another preferred production plant layout including ground meat processing and blending equipment and a preferred CAP retail packaging plant layout including packaging equipment is shown. The equipment shown in FIGURE 200-201 is integrated such that ground beef processed by equipment shown in FIGUF;E 200 is packaged in packaging that is processed by equipment shown in FIGURE 201. The present invention provides for a method of grinding meats directly into an oxygen free vessel or hopper and then blend and process the ground meat as described herein. The present invention also provides a method of saturating the liquids, water and oils in the ground meats with a suitable gas or substance such as carbon dioxide, provided at a suitable pressure, to such a level that when removed from the processing equipment the ground meat will emit a suitable gas such as carbon dioxide.
Items of equipment shown in FIGURE 200-201 that are identified by letters and/or numbers are listed in the following table set out below:
FIGURE 200 ~ ~ FIGURE 201 'i44 AMENDED SHEET

Item Production E ui ment Packa in a ui ment #

6006 Conveyor (with variable 6122 Magazine speed control ) 6008 Conveyor (with variable 6124 Magazine speed control) 6010 Conveyor (with variable 6126 Magazine speed control) 6018 Conveyor (with variable 6128 Tray material evacuation speed &
control) assin 6020 Conveyor (with variable 6130 Tray material evacuation speed &
control) assin 6022 Conveyor (with variable 6132 Tray material evacuation speed &
control assin 6034 Conveyor (with variable 6134 Tray flap erection & welding speed control) 6036 Conveyor (with variable 6136 Tray flap erection & welding speed control) 6030 Ultra violet sterilization6138 Tra fla erection & weldin a ui ment 6032 Ultra violet sterilization6140 Conve or a ui ment 6038 Grindin machine 6142 Conve or 6040 Grindin machine 6144 Conve or 6100 Grindin machine 6116 Ground beef ortionin machine 6104 Grindin machine 6118 Ground beef ortionin machine 6108 Grindin machine 6120 Ground beef ortionin machine 145' AMENDED SHEET

Item Production E ui ment Packaging equipment #

6046 Tube connection 6146 Conve or 6050 Tube connection 6148 Conve or 6048 Ground beef ho er 6150 Conve or 6052 Ground beef hopper 6000 Over wrapping packaging machines 6058 Ground beef hopper 6002 Over wrapping packaging machines 6064 Ground beef hopper 6004 Over wrapping packaging machines 6056 Statiflo blender 6062 Statiflo blender 6090 Statiflo blender r..

6092 Statiflo blender 6094 Statiflo blender 6096 Gas in'ection orts.

6054 Positive dis lacement um 6060 Positive dis lacement um 6066 Positive dis lacenie.nt um 6068 Positive dis lacement um 6070 ~ Positive displacement I I
pump AMENDED SHEET

Item Production ui ment Packa in a ui ment #

6072 Positive dis lacement um 6074 Positive dis lacement um 6076 Positive dis lacement um 6078 E silon GMS-40 6084 E silon GMS-40 6080 E silon GMS-4U

6086 E silon GMS-40 6082 E silon GMS-40 6088 E silon GMS-40 Electron beam sterilizer and/or rinder The equipment shown in FIGURE 200-201 is listed above and is arranged to automatically and continuously produce selected grades of retail packaged, case ready ground meats. The ground meats may include quantities of muscle and fat tissue such as shown in the following chart, where item 1F includes ground meat with about 90% muscle tissue and about 10% fat tissue, with a muscle to fat tissue variation within about ~-/- 0.2%. The packaging equipment shown in FIGURE 201 can be arranged so that the packaging machine 6000 will produce CAP case ready packages containing ground meats according to a specification equivalent to item 1F.
Similarly, packaging machine 6002 can produce CAP case ready packages containing ground meats according to a specification equivalent to item 2F and packaging machine 6004 can produce CAP case ready packages containing ground meats according to a specification equivalent to item 3F in TABLE 7.
AMENDED SHEET

Item Muscle Fat TissueMusclelFat Tissue Variation Tissue 1F 90% IO% +/-0.2% muscle content 2F 85% 15% +/-0.2% muscle content 3F 80% 20% +/-0.2% muscle content Referring again to FIGURE 200, variable speed conveyors 6006, 6008 and 6010 are preferably arranged in close and parallel proximity such that each conveyor can carry specified quantities of selected boneless beef. In this way conveyor can be arranged to carry specified quantities of raw material, which may be boneless beef selected from the chart shown below, in a direction indicated by arrow 6012, conveyor 6008 can be arranged to carry specified quantities of selected boneless beef in a direction indicated by arrow 6014 and conveyor 6010 can be arranged to carry specified quantities of selected boneless beef in a direction indicated by arrow 6016.
I0 The specified quantities of selected boneless beef can be varied between the conveyors marked 6006, 6008 and 6010 such that 6006 carries selected boneless beef shown as 2X, in TABLE 8, conveyor 6008 carnes selected boneless beef shown as 3X and conveyor 6010 also carries the selected boneless beef shown as 3X.
Preferably, variable speed conveyors 6018, 6020 and 6022 are arranged in close and parallel proximity such that each conveyor can carry specified quantities of selected boneless beef. In this way conveyor 6018 can be arranged to carry specified quantities of raw material, which may be boneless beef selected from TABLE 8, in a direction indicated by arrow 6024, conveyor 6020 can be arranged to carry specified quantities of selected boneless beef in a direction indicated by arrow 6026 and conveyor 6022 can be arranged to carry specified quantities of selected boneless beef in a direction indicated by arrow 6028. The specified quantities of selected boneless beef can be varied between the conveyors marked 6018, 6020 and 6022 such that conveyor 6018 carnes boneless beef shown as 1X in TABLE 8, conveyor 6020 carries boneless beef also shown as 1X and conveyor 6022 carries boneless beef shown as 2X.
AMENDED SHEET

Item Muscle Tissue Fat Tissue MuscleJFat Tissue Variation 1X 99% 1% +1% l - 3% muscle content 2X 93% 7% +/-3% muscle content 3X 75% 25% +l-3% muscle content Preferably, the variable speed conveyors 6006, 6008 and 6010 can be arranged in close and parallel proximity and located inside an ultra violet light (UV) tunnel shown as 6030 in FIGURE 200. Tunnel 6030 can be arranged so as to expose any of the selected boneless beef to sufficient UV light so as to substantially sterilize the surfaces of the boneless beef. A suitable device of turning and/or rotating the boneless beef can be provided in the tunnel, so as to ensure that substantially all external surfaces of the boneless beef are exposed to the UV light to ensure the sterilization of the surfaces. Similarly, the variable speed conveyors 6018, 6020 and 6022 can be arranged in close and parallel proximity and located inside an ultra violet light (UV) tunnel shown as 6032 in FIGURE 200. Tunnel 6032 can be arranged so as to expose any of the selected boneless beef to sufficient UV
light so as to substantially sterilize the surfaces of the boneless beef. A suitable method of turning and/or rotating the boneless beef can be provided in the tunnel, so as to ensure that substantially all external surfaces of the boneless beef are exposed to UV
light to ensure sterilization of surfaces.
Preferably, the variable speed conveyors 6006, 6008, 6010, 6018, 6020, and 6022 can be provided with independent drivers and arranged to pass through a tunnel with a device to independently measure the fat and muscle content of the boneless beef earned on each individual and separate conveyor. Any suitable method of measuring the fat and muscle content of the boneless beef may be integrated with the conveyors 6006, 6008, 6010, 6018, 6020, and 6022 so as to provide a method of separate and continuous meas~irement of the fat and muscle content of the boneless beef separately carried on each conveyor. Preferably, the variable speed conveyors 6006, 6008, and 5010 can be arranged to converge and deposit the boneless beef, carried by each independent conveyor onto a conveniently located secondary conveyor shown as 6034 in FIGURE 200. Similarly, the variable speed conveyors 6018, 6020, and 6022 can be arranged to converge and deposit the ~.g, AMENDED SHEET

boneless beef, carried by each independent conveyor onto a conveniently located secondary conveyor shown as 6036 in FIGURE 200. Preferably, the speed of each conveyor can be varied in direct relationship to the variation of measured fat and muscle content of the boneless beef corned by each conveyor.
S Preferably, the length of the variable speed conveyors 6006, 6008, 6010, 6018, 6020, and 6022 can be extended so as to allow operators, such as carcass disassembly workers, to deposit the boneless beef raw material thereon immediately after disassembly and separation from an animal carcass source of the boneless beef.
Furthermore, the carcass disassembly workers can, for example adjust the fat content of boneless beef that is deposited onto each of the conveyors 6006, 6008, 6010, 6018, 6020, and 6022 according to requirements. More specifically, if it is determined by the fat measuring device that a reduced quantity of fat and an increased relative quantity of muscle (lean) tissue is required on any particular conveyor, this can be accommodated. Conversely, if it is required to deposit an increased relative quantity 1S of muscle tissue onto any particular conveyor, this also, can be accommodated. In this way, the fat and lean content of the boneless beef that is deposited onto each of the individual conveyors can be adjusted to suit requirements which can be determined by the fat content measuring method through which each of the conveyors can be arranged to pass. Preferably, boneless beef can be deposited onto variable speed conveyors 6006, 6008, and 6010 according to requirements and by varying the speed of each conveyor and therefore the quantity of boneless beef carried and deposited onto conveyor 6034, a combined stream of boneless beef including fat and muscle tiss~.e with a desired and constant relative ratio can be produced and corned on the conveyor 6034. Similarly, with variable speed 2S conveyors 6018, 6020, 6022, boneless beef can be deposited onto each conveyor according to requirements and by varying the speed of each conveyor and therefore the quantity of boneless beef carried and deposited onto conveyor 6036, a combined stream of boneless beef, carried on conveyor 6036 and including fat and muscle tissue with a desired and constant relative ratio, can be produced and corned on the conveyor 6036.
Referring again to FIGURE 200 and in particular to conveyor 6034, it can be seen that boneless beef carried on 6034 will be corned and deposited into meat grinder 6038. Similarly, it can be seen that boneless beef carried on conveyor will be corned and deposited into meat grinder 6040. By adjusting the ratio of fat 3S and muscle content of boneless beef carried on each conveyor 6006, 6008, and 6010 ~j~p AMENDED SHEET

and adjusting the speed and therefore the volume of boneless beef carned on each conveyor, a single stream, indicated as stream 6042 in FIGURE 200, of boneless beef including fat and muscle tissue of a desired ratio can be provided and carried forward on conveyor 6034. Similarly, by adjusting the ratio of fat and muscle content of boneless beef carried on each conveyor 6018, 6020, 6022 and adjusting the speed and therefore the volume of boneless beef carried on each conveyor 6018, 6020, and 6022, a single stream, indicated as stream 6044 in FIGURE 200, of boneless beef including fat and muscle tissue of a desired ratio can be provided and carned forward on conveyor 6036.
Preferably, in this way, boneless beef stream 6042 may include boneless beef with a fat and muscle content of about 95% lean muscle and about 5% fat with a fat content variation of about +/-0.3%. Preferably, boneless beef stream 6044 may include boneless beef with a fat and muscle content of about 80% lean muscle and about 20% fat with a fat content variation of about +/-0.3%.
Boneless beef stream 6042 is carried forward by conveyor 6034 and deposited into grinder 6038. ~~onveyor 6034 and grinder 6038 may be enclosed inside a substantially sealed outer covering with a suitable gas such as nitrogen contained therein in such a manner so as to substantially exclude ambient air from presence therein. The boneless beef carried in stream 6042 is ground in the grinder 6038 and transferred through tube 6046 and into hopper 6048. It can also be seen that the boneless beef stream 6044 is carried forward by conveyor 6036 and deposited into grinder 6040. The conveyor 6036 and grinder 6040 may also be enclosed inside a substantially sealed outer covering with a suitable gas such as nitrogen contained therein in such a manner so as to substantially exclude ambient air from presence therein. The boneless beef carried in 6044 is ground in grinder and transferred through tube 6050 and into hopper 6052.
Stream 6042 of ground beef is then transferred by a pump, such as a positive displacement pump 6054, from hopper 6048 into and through static blending tube 6056 and into hopper 6058. Stream 6044 of ground beef is then transferred by a pump, such as a positive displacement pump 6060, from hopper 6052 into and through static blending tube 6062 and into hopper 6064. Preferably, positive displacement pumps 6054 and 6060 can be fitted with variable speed drivers Hoppers 6058 and 6064 can be substantially filled with a suitable gas such as carbon dioxide or any other suitable substance, and both hoppers 6054 and 6060 are lb~:.' AMENDED SHEET

arranged to have an adequate capacity to accommodate any quantity variations in normal production of boneless beef that may result from any variable requirement.
Hopper 6058 is connected with three positive displacement pumps shown as 6066, 6068 and 6070. Preferably, any number of pumps may be provided and connected to hopper 6058. Similarly, hopper 6064 is connected with three positive displacement pumps shown as 6072, 6074 and 6076. Preferably, any number of pumps may be provided and connected to hopper 6064. Preferably, each of the positive displacement pumps shown as 6066, 6068 and 6070 can be fitted with suitable, independently controlled, variable speed drivers such that any required quantity of ground boneless beef contained in hopper.6058 can be pumped therefrom at a desired velocity, and through a measuring device, such as the Epsilon GMS-shown as 6078, 6080 and 6082. Similarly, each of the positive displacement pumps shown as 6072, 6074 and 607h can preferably be fitted with suitable independently controlled, variable speed drivers such that any required quantity of ground boneless beef contained in hopper 6064 can be pumped therefrom and through a measuring device, such as the Epsilon GMS-40 shown as 6084, 6086 and 6088.
The Epsilon GMS-40-40 Meat Analyzer is a fat measuring device and is commercially available from Epsilon Industrial, 2215 Grand Avenue Parkway, Austin, Texas 78728. Specifications for the GMS-40 are available from this supplier and information is also available from their web site at www.epsilon-gms.com.
While this component is specified herein, other suitable fat measuring devices can be used as an alternate for fat and/or muscle content measurement.
As can be seen in FIGURE 200, Epsilon GMS-40 measuring devices shown as 6078 and 6084 are preferably attached directly to junction box X, Epsilon GMS-40 measuring devices shown as 6080 and 6086 are preferably attached directly to junction box Y and Epsilon.GMS-40 measuring devices shown as 6082 and 6088 are attached directly to junction box Z. Suitably sized tubes connect pumps directly to corresponding Epsilon measuring devices as shown. The fat content of ground beef that is pumped by pump 6066 through the connecting tube and directly through Epsilon GMS-40 measuring device 6078, is measured by device 6078. The fat content of ground beef that is pumped by pump 6072 through the connecting tube and directly through Epsil~u GMS-40 measuring device 6084, is measured by device 6084. The ratio and percentage quantity of fat in each separate stream of ground beef pumped by pumps 6066 and 6072 can therefore be measured and compared and the pumping rate of pumps 6066 and 6072 can be automatically ~b~=' AMENDED SHEET

adjusted according to the respective fat content of each stream of ground beef so as to provide a single stream of ground beef, after combining in junction box X, with a desired fat content. In this way selected quantities of boneless ground beef can be pumped directly from hopper 6058, containing ground beef from stream 6042 and hopper 6064, containing ground beef from stream 6044, by pumps 6066 and 6072 respectively and through Epsilon GMS-40 measuring devices shown as 6078 and 6084 into junction box X. Similarly, selected quantities of boneless ground beef can be pumped directly from hopper 6058, containing ground beef from stream 6042 and hopper 6064, containing ground beef from stream 6044, by pumps 6068 and 6074 respectively and through Epsilon. GMS-40 measuring devices shown as 6080 and .
..
6086 into junction box Y. Preferably, selected quantities of boneless ground beef can be pumped directly from hopper 6058, containing ground beef from stream 6042 and hopper 6064, containing ground beef from stream 6044, by pumps 6070 and 6076 respectively and through Epsilon GMS-40 measuring devices shown as 6082 and 6088 into junction box Z.
Preferably, selected quantities of ground meat from stream 6042 and stream 6044 can be combined in junction boxes X, Y and Z. By varying the pumping rate of variable speed positive displacement pumps 6066 and 6068, a selected blend of ground beef, with a pre-determined and known ratio of fat to lean muscle tissue, can be pumped into junction box X. The fat content of the selected blend of ground beef pumped into junction box X may be, for example, about 10% +/- about 0.3%. Alternatively, the fat content of the selected blend pumped into junction box Y may be, for example, about 15% +I- 0.3% and the fat content of the selected blend pumped into junction box Z may be, for example, about 17% +/- about 0.3%. By processing ground meats in this way, the fat content of any given production quantity of selected ground beef can be controlled within a narrow margin of variation, such as about +/- about 0.3% and the muscle and fat content selected as desired by adjusting the fat content of raw materials that are deposited onto conveyors 6006, 6008, 6010, 6018, and 6020 accordingly.
Furthermore, the energy required to blend the ground beef in the methods described herein is much less than is t~rpically required to produce ground meats using currently common industry practice.
The selected ground beef blend that is pumped into junction box X by way of two streams from pumps 606b and 6072 is then transferred through blender 6090.
The selected ground beef blend that is pumped into junction box Y by way of two ~5~AMENDED SHEEI-streams from pumps 6068 and 6074 is then transferred through blender 6092. The selected ground beef blend that is pumped into junction box Z by way of two streams from pumps 6070 and 6076 is then transferred through blender shown as 6094.
Blender 6056, 6062, 6092, and 6094 are all conveniently arranged with gas injection ports shown as 6096. Preferably, gas injection ports 6096 are arranged to provide suitable gas, such as carbon dioxide, into blenders in such a way as to ensure that all ground meat that is pumped through the blenders is exposed to gas as desired and to an extent that will, for example, ensure that ground meat is saturated with dissolved suitable gas as required. Blenders 6056, 6062, 6090, 6092, and 6094 may include suitably sized continuous static mixing equipment such .as may be supplied by Statiflo International, Macclesfield, Cheshire, UK. Preferably, any continuous blender may be integrated and located where indicated in FIGURE 200 by blender reference numerals 6056, 6062, 6090, 6092 and 6094 or in any desired configuration that will ensure blending of ground meats as required.
The process described in association with FIGURE 200-201 shows a combination of equipment that is configured to preferably produce a first 6042 and a second 6044 stream of ground meat. Stream 6042 and stream 6044 are provided by measuring the fat content of two pair of three streams of boneless meat where streams 6012, 6014 and 6016 converge into a first stream 6042 and where streams 6024, 6026, and 6028 converge into a second stream 6044.
Preferably, the fat and muscle (lean) meat content of stream 6042 is determined by the following factors: The total quantity of boneless meat deposited onto the conveyors that include the streams 6012, 6014, and 6016 and the fat and muscle content of the boneless meat. The velocity of the streams 6012, 6014, and 6016.
Correspondingly, the fat and muscle (lean) meat content of stream 6044 is determined by the following factors: The total quantity of boneless meat deposited onto the conveyors that include the streams 6024, 6026 and 6028 and the fat and muscle content of the boneless meat. The velocity of the streams 6024, 6026 and 6028.
The fat and lean content of streams 6042 and 6044 can be determined by adjusting the velocity of streams 6012, 6014, 6016, 6024 and 6028 and the fat content of the boneless meat provided into streams 6012, 6014, 6016, 6026 and 6028.
Referring now to FIGURE 200, streams 6098, 6102 and 6106 are shown to be connected directly to meat grinders 6100, 6104 and 6108. Grinders 6100, 6104 and AMENDED SHEET

6108 are arranged to fine grind the corresponding stream of ground meat and transfer directly into a corresponding portioning apparatus. Grinder 6100 is arranged to fine grind ground meat in stream 6098 and transfer the stream of fine ground meat directly into portioning apparatus. Grinder 6104 is arranged to fine grind ground meat in stream 6102 and transfer the stream of fine ground meat directly into portioning apparatus 6118. Grinder 6108 is arranged to fine grind ground meat in stream 6106 and transfer the stream of fine ground meat directly into portioning apparatus 6120. Preferably, any suitable variable speed driver may be integrated into equipment shown in FIGURE 200 and may be controlled by a central processing computer.
The fat and muscle (lean) content of the stream of ground meat that is shown as stream 6098 and which is delivered to grinder 6100, is determined by the fat and lean content of a quantity of ground meat from both stream 6042 via pump 6070 and an additional quantity of ground meat from stream 6044 via pump 6076. The fat and muscle (lean) content of the stream of ground meat that is shown as stream 6102 is also determined by the velocity (and quantity of ground meat pumped therethrough) of the ground meat stream pumped into junction box Z by pump 6070 and the ground meat stream pumped into junction box Z by pump 6076. By adjusting the speed of pumps 6070 and 6076 the fat content of the ground meat in stream 6098 can be selected. The fat content of the ground beef in the stream pumped by pump 6070 is measured by the Epsilon (or other suitable fat measuring devices) fat measuring devices 6082. The fat content of the ground beef in the stream pumped by pump 6076 is measured by the Epsilon (or other suitable devices) fat measuring device 6086. The velocity of pumps 6070 and 6076 can therefore be controlled and set by the fat measurements provided by 6082 and 6086. In this way, a selected fat content can be produced by an automatic controller such as a computer that is preferably connected to all associated pumps and fat measuring devices.
The fat and muscle (lean) content of the stream of ground meat that is shown as stream 6102 and which is delivered to grinder 6104, is determined by the fat and lean content of a quantity of ground meat from both stream 6042 via pump 6068 and an additional quantity of ground meat from stream 6044 via pump 6074. The fat and muscle (lean) content of the stream of ground meat that is shown as stream 6104 is also determined by the velocity (and quantity of ground meat pumped there along) of the ground meat stream pumped into junction box Y by pump 6068 and the ground meat stream pumped into junction box Y by pump 6074. Preferably, adjusting the -~~' AMENDED SHEET

speed of pumps 6068 and 6074 the fat content of the ground meat in stream 6102 can be selected. The fat content of the ground beef in the stream pumped by pump 6068 is measured by the Epsilon (or other suitable fat measuring devices) fat measuring device 6080. The fat content of the ground beef in the stream pumped by pump 6074 is measured by the Epsilon (or other suitable devices) fat measuring device 6080. The velocity of pumps 6068 and 6074 can therefore be controlled and set by the fat measurements provide by 6080 and 6074. In this way, a selected fat content can be produced by an automatic controller such as a computer that is connected to preferably all associated pumps and fat measuring devices.
The fat and muscle (lean) content of the stream of ground meat that is shown as stream 6106 and which is delivered to grinder 6108, is determined by the fat and lean content of a quantity of ground meat from both stream 6042 via pump 6066 and an additional quantity of ground meat from stream 6044 via pump 6072. The fat and muscle (lean) content of the stream of ground meat that is shown as stxeam 6106 is also determined by the velocity (and quantity pumped there along) of the ground meat stream pumped into junction box X by pump 6066 and the ground meat stream pumped into junction box X by pump 6072. Preferably, by adjusting the speed of pumps 6066 and 6072 the fat content of the ground meat in stream 6106 can be selected. The fat content of the ground beef in the stream pumped by pump 6066 is measured by the Epsilon (or other suitable fat measuring devices) fat measuring device 6078. The fat content of the ground beef in the stream pumped by pump is measured by the Epsilon (or other suitable devices) fat measuring device The velocity of pumps 6066 and 6072 can therefore be controlled and set by the fat measurements provided by devices 6078 and 6084. Preferably, any quantity of ground meat with any selected fat content can be produced by an automatic controller such as a computer that is connected to preferably all associated pumps and fat measuring devices.
The configuration shown in FIGURE 200 preferably provides for automatic production of three streams of ground meat 6110, 6112 and 6I 14, each with a selected fat and lean content. A configuration of the required equipment, with any chosen capacity and size to suit any rates of production, can be arranged to produce any suitable number of one or more streams of ground meat, each with a selected fat and lean content, as may he d,;sired.
Overwranpi~ and Web Stretching-Apparatus and Method 156= AMENDED SHEET

Controlled Atmosphere Packages (CAP) are packages prepared or treated in an oxygen deficient atmosphere to remove or prevent the accumulation of oxygen within the package materials. Packages are overwrapped with apparatus having web stretching capabilities in one aspect of the invention.
Referring to FIGURES 202-204, details of a controlled atmosphere packaging system according to the present invention is shown. FIGURE 202 shows a section of PVC web materia16200 is about 0.0008" in thickness. Preferably, any suitable thickness or gauge can be used. Preferably, web 6200 can be coated, fully or in part and with any desired pattern such that parts of the web remain clear and other coated parts may be opaque. Web 6200 is shown with a suitable heat sealing coating that has been applied in two continuous strips along the edges of the web such that a continuous, central strip remains clear. The width of the clear section 6202 central strip may be about 50% of the total width of the web 6200 and the outer two printed sections 6204 of about equal width being about 25% of the full width each, of web 6200 such that when formed into a tube 6214 , a fin seal, 6208, can be provided by heat sealing there together. Preferably, a sealed tube including an upper clear section through which the tray 6210 can be seen and a lower, opaque section through which tray 6210 cannot be seen.
Web 6200 can be processed by a modified Hayssen RT1800, for example, in such a manner so as to form a continuous tube 6214, and shown as PVC web material "fin" sealed tube. Suitable packaging trays such as Mono-PakT"" trays 6210 that have been filled with perishable goods such as ground beef can be inserted into the tube 6214, by automatic devices (not shown) or any other suitable devices, and lateral stretching can be induced into the tube 6214. The lateral stretching can cause the tube 6214 material to firmly contact the tray 6210 and hold the perishable goods contained therein firmly. After the trays 6210 are located inside the fin sealed tube 6214 the tube can also be stretched longitudinally. After the longitudinal stretching of the tube 6214, lateral fin seals, followed by severing of the tube 6214 adjacent to the lateral fin seals, can be provided so as to provide a fully and hermetically sealed package as shown in FIGURE 204. The lateral and longitudinal stretching can be provided pri or to sealing and severing of the lateral fin seals.
Longitudinal stretching can be effected by the modified Hayssen RT1800 after modification and as generally descr'bed below.
Referring now to FIGURE 201, items 6000, 6002 and 6004 shown thereon include three modified versions of the Hayssen RT 1800 (modified RT1800), flow ,F~~7AMENDED SHEET

wrapping packaging machine. The modifications to each item 6000, 6002 and 6004 refers to the inclusion of a sub-assembly to each machine which is detailed in a cross-sectional sketch shown as FIGURES 205-206 so as to enable processing and use of pPVC web material on the RT1800 packaging machines. The following disclosure details the modification that can be incorporated in the RT1800 so as to facilitate the use of pPVC web material as the over wrapping packaging material used thereon to over wrap such packages as the Mono-Pak EPS foam tray.
The Hayssen RT 1800 is manufactured by Hayssen, a division of the Barry Wehmiller Company, which is located at 225 Spartangreen Boulevard, Duncan, SC 29334. Other information describing the RT1800 can be obtained from the following web site: www.hayssen.com . The RT 1800 incorporates a "rotary die wheel" in such a manner so as to provide a continuous movement of the web during machine operation and package sealing. This arrangement provides a method to process and seal packages more rapidly than other types of over wrapping machines but hitherto the RT 1800 has not been used to over wrap packages with pPVC
(plasticized polyvinylchloride) web material.
It is desirable to use pPVC web material, in this particular application, because of its most suitable physical characteristics for the packaging of fresh meats such as ground meats and poultry pieces. However, the standard RT1800 is not ideally suited to process pPVC web material and in order to ensure efficient stretching and sealing of the pPVC web the modifications to the RT1800 are necessary.
The HAYSSEN RT1800 rotary die wheel concept operates on the principal of maximizing dwell time. Individual MAGNUM sealing dies are released on demand as packaging material and product move through the machine. The RT1800 packaging equipment is well known to those skilled in the arts and all details of the RT1800 machine construction are readily available from the manufacturer to potential end users of this popular packaging equipment.
Packaging materials nay include the Mono-Pak~ EPS tray, over wrapped with plasticized PVC web material, (supplied by AEPBorden or Huntsman).
It should be noted that the readily available, low cost, pPVC web material as intended for use in this application, has the following properties:
1. Glass clarity 2. Stretch and high extensibility (SO - 100% before exceeding elastic limit) ~~$:, AMENDED SHEET

3. Memory, providing a "return to its original condition" after stretching (within elastic limit).
4. Standard, enhanced oxygen permeability.
5. Rapid heat sealing to itself.
6. Rapid hot "knife" cutting, providing clean cut edges.
7. Generally, the basic RT1800 machine, as manufactured by Hayssen, would remain similar to existing standard equipment, except for the modification described herein. The existing longitudinal fin or lap sealing (as shown as 6208, in FIGURE 203) may require adjustment to facilitate an enhanced lateral web 1C "stretching" capability for a pPVC web. The longitudinal web stretching apparatus, as disclosed herein, should be capable of installation without major structural and basic frame modifications to the existing equipment.
FIGURES 205-206 include an assembly intended for optional and interchangeable use on standard Hayssen RT1800 or similar packaging machines, shows detail of the following items.
Referring now to FIGURES 205-206, the apparatus constructed according to the present invention includes a die wheel 6216 shown in part with the axis of the wheel marked as axis 6218. A number of die carriers 6220 are also shown. The complete die wheel 6216 and drive is not shown, however, since a person skilled in the art will readily recognize the proposed modification when viewing the representation of the die wh.;el with die carriers as shown. The wheel die assembly fixture may include a standard Hayssen component modified to suit convenient attachment of the "Stretch Web Clamp Assembly".
The packaged product may include any of the number of trays disclosed herein, for example, the tray shown in FIGURE 55, over wrapped with standard (with enhanced 02 permeability) plasticized PVC web material, (supplied by AEPBorden or Huntsman). The EPS material can be produced with a surface finish that will not "cling" to the pPVC web material.
Plasticized web of stretch over wrap material is preferably printed or plain material can be used. Preferably, partial coating of the inside web surface, with a low melt heat activated coating ~HAC), can provide for improved performance.
A full width, lateral, impulse, heat sealing, element (e.g. cut from Inconnell SS sheet or other "marine" grade, SS sheet material) is installed by attachment to a horizontally disposed rigid and suitably heat tolerant, non metallic base.
Preferably, compensation for normal expansion and contraction of the element, during heating leg; AMENDED SHEEP

i and cooling, can be provided. The element is covered with suitable material (PTFE) so as to provide a "non-stick" surface that will not "cling" to pPVC web. The heat sealing assembly is arranged with the heating sealing element in close, adjacent and parallel disposition to a full length strip of a portion of the outer surface of roller 6224, as shown in the sketch. When held together under suitable pressure with two webs of pPVC material located between member 6228 and roller 6224, a full length and hermetic seal between the two webs can be produced.
An alternative heat sealing device includes a heat bank. Use of either impulse or heat bank devices may be determined by manufacturer preference. In the case of a heat bank device, the clamping bars 6230 and 6232 would be separated and insulated from the adjacent heat bank members 6230, 6232 and 6234, 6228 would require independent, return spring mounting. A suitable distance or gap (for insulation and sealinglcutting control devices), between the elevation of the clamping surface of the clamping bar and the elevation of the contact surface of the heat bank, would be required. This would allow clamping of the webs) by the clamping bar with subsequent web clamping, sealing and cutting by the heat bank.
Web clamping bar 6232 includes a strip like component that is arranged in parallel and close proximity to assembly 6228 so as to provide a clamp to web at the same time and with similar clamping effect as member 6232 when roller 6224, 6232 and member 6228 are arranged so to do.
Rubber coated roller with camlclutch bearing 6224 includes a heat resistant, rubber coated and suitably ground, solid steel, hardened, rigid roller. Roller 6224 is located between two end plates 6240 and 6242 (not shown) and mounted thereto by bearing (one located at each end of the roller 6224. The bearings are of identical dimensions with "camlclutch" feature provided in one only bearing. Such arrangement allows the roller ti224 to rotate in a clockwise direction only.
Impulse heat sealing element assembly is arranged to mirror image assembly 6228.
Web clamping bar 6230 is arranged to minor image web clamping bar 6232.
Rubber coated roller with camlclutch bearing 6244 includes a heat resistant rubber coated, solid steel, hardened, rigid roller identical to roller 6224 but with a "cam/clutch" feature provided in one only bearing so as to allow roller 6244 to rotate in a counter clockwise direction only, as shown by an arrow in the sketch. The surface finish on both rollers 6244 and 6224 can be arranged so as to cling to web 6236 when contact occurs between suitably tensioned web 6236.
1:~ AMENDED SHEET

Two end plates 6240 and 6242 are arranged to rigidly retain rollers 6244 and 6224 in relative, respective, parallel and separated proximity, allowing the rollers to rotate as described above. Both end plates may be fitted with suitable coil or flat return springs to hold the rollers 6244 and 6224 in a normal position at a desired distance from bars 6230 and 6232 and heating elements 6234 and 6228.
A cam follower is mounted to each end plate 6240 and 6242 so as to engage with cam tracks (not shown but mounted to main frame of FFS machine) arranged to provide a web sealing pressure to web 6236 by causing depression of end plate return springs.
The web.stretching bar 6226 includes a strip of suitable material profiled as shown and provided with an outer surface treatment that can cling to pPVC web material. Web stretching bar 6226 is attached to two pneumatic cylinders [6246 (shown) and 6248 (not shown)] with slotted fixture apertures so as to eliminate locking that may otherwise occur during operation. The web-stretching bar is shown in a normally withdrawn (closed) position and also in a fully extended position, by dotted lines. When in the normally closed position, the upper and highest edge of the bar extends along its full length and is in permanent contact with webs) 6236.
This contact is arranged so as to ensure a suitable tension is induced in the web(s). This can provide a condition allowing the free movement (by stretching) of the web material over roller's 6244 and 6224 only inwardly and toward the web-stretching bar. The cam/clutches installed in the rollers will not allow the web to be pulled away from the web-stretching bar. Preferably, web 6236 can be freely stretched but is essentially clamped by its tensioned and intimate contact with the surface of the rollers and the upper edge of the web-stretching bar.
The Rollers Assembly, includes two off each rollers, 6244 and 6224, endplates 6240 and 6242, carp followers 6250 and 6252, fasteners and return springs as required. When assembled with the complete web stretching assembly and in a normally closed position, a suitable gap is maintained between the rollers and the adjacent contact surfaces o~ items 6230, 6234, 6232 and 6228, thereby allowing free stretching of the web 6236, by activation of web-stretching bar 6226.
A pneumatic cylinder is shown, attached to the web-stretching bar 6226 to extend bar 6226 to the position shown by dotted lines and thereby stretch the web 6236. Preferably, two cylinders would be provided. Compressed air flow and pressure controls can be arranged to activate cylinders 6246 and 6248 so as to ='~l~'1=AMENDED SHEET

~ f optimize induced tension in web 6236. Any suitable alternative method of web-stretching bar activation and control may be used.
A vacuum tube may be conveniently located so as to provide a method of removing scrap web material (excess material for accumulation in a canister.
In this configuration independent pivoted mounting of each roller and clamping assembly 6256 and 6258 is provided. Each assembly 6256 and 6258 is held in the normal central position (close together), by controlled return springs.
Activation of the web-stretching bar 6226 will cause the two assemblies to move away from the central position until contact with the packages 6254. Such an arrangement will provide consistent web stretching with a final web heat sealing at a constant distance from the package. In this configuration end plates 6240 and would require slotting to accommodate outward rotation of each assembly.
Products, pre-filled with ground beef portions/blocks, are automatically loaded onto the entry end of the Hayssen FFS equipment. Orientation of the products may be in normal or inverted disposition. A normal disposition (with package "open top" side facing upward) would require a side fin or lap web seal, whereas an -inverted disposition would require a bottom web seal. Normal operation would include longitudinal sealing after induction of maximum stretch in web 6236.
Lateral sealing would occur after longitudinal stretching by web stretching bar 6226.
Activation of the web-stretching bar would not commence until closure of the subsequent closing of the closest clamp to its rear, on the wheel. In this way gradual stretching of the pPVC over wrap, during the wheel rotation, can occur until the desired level of stretch and/or tension is achieved when web heat sealing and simultaneous cutting could be provided immediately prior to ejection of the finished package(s). The finished packages could be ejected in a normal and upright disposition, assuming that the packages were loaded in an inverted disposition, alternatively, the packages could be inverted after ejection if the packaging had been loaded onto the RT1800 packaging machine in a normally upright position.
By incorporating the move described modification in the Hayssen RT 1800 packaging machine a web stretching arrangement is provided to stretch the over wrap material 6236 during the norm ~1 rotation of the die wheel. It is anticipated that, in view of the rapid heat sealing and cooling characteristics of thin gauge (0.0008") pPVC, the operational speed of the Hayssen RT 1800 could be increased to more than 1800 feet per minute.
Blending Apparatus ~~2' AMENDED SHEET ~'a ~~j Referring now to FIGURES 207-208, details of an apparatus that can be used to blend one or more individually controlled streams of ground meats that can also be combined with selected conditioning gases or suitable materials and blended together to produced a single stream of blended and conditioned ground meat, is shown.
FIGURE 208 shows a diagrammatic representation of three streams of ground meats, 6300, 6302 and 6304 that are each pumped through conduits shown as 6306, 6308 and 6310 at independently controlled velocities. Preferably, the apparatus can be arranged to provide one or more streams of ground meat but most preferably three streams will be provided where, for purposes of example, one stream may have an approximate fat content of about 20%r a second stream has an approximate fat content of about 30% and a third stream has a fat content of about 7%.
Preferably, the content of each stream can be varied as may be required. Conduits 6306, and 6310 can be arranged to house independent measuring devices such as the Epsilon GMS-40 in-line measuring equipment. The streams of ground meat can be pumped, by positive displacement pumps that are independently driven by variable speed drivers, at velocities that are continuously adjusted directly corresponding with - the respective fat and muscle content of each stream such that when the three streams are subsequently combined together into a single stream of ground meat, the fat and muscle content of the combined stream is substantially consistent and constant at a chosen composition with percentage quantities of fat and muscle held within a range of less than about +l- 1 % fat content. Furthermore, even though the velocity of each separate stream of ground meat is independently varied according to the fat and muscle content of the respective stream, the resultant single, combined stream can be arranged, by adjusting the velocity of each of the streams 6300, 6302 and 6304, to be at a constant velocity, volume and production rate and as desired within the capacity of the apparatus.
Referring now to FIGLfRE 207, a housing 6318 is arranged with six suitably profiled blades 6312 that are attached together at a central axis 6314 which in turn are attached to a driver 631 ~. Blades 6312 are attached at axis 6314 and to a driver 6316 in such a manner that blades 6312 can be rotated within the confinement of housing 6318, which is sealed and separate from external atmosphere.
Blades 6312 are arranged so as to not contact but be in close proximity to the internal surfaces of the housing 6318. A total of six spaces or segments shown as 6320, are therefore arranged between the blades 6312 that include equal volumes and a recess 6322 is provided at the axis of the blades 6312 so as to allow direct 3.~~~' AMENDED SHEET

communication between the spaces. The direct communication between the spaces 6320 may be provided or otherwise, if so desired, not provided. A
conduit 6324 is attached to the housing 6318 with a spiral auger 6326 contained therein. Auger 6326 may be directly connected to suitable driving devices (not S shown) that can provide a variable speed rotating of the auger as required to further blend the single stream of combined ground meats. Preferably, the streams of ground meat can be transferred directly through housing 6318 and into conduit 6324.
Blades 6312 can be rotated about the axis by driver 6316 at a suitable speed.
Preferably, a series of conduits 6330 can be arranged to have direct communication with the spaces between the blades 6312, as they rotate adjacent thereto, so as to allow injection of any suitable substances such as carbon dioxide into the spaces at any suitable pressure ana from a suitable source and in controlled quantities.
Preferably, a known quantity of ground meats can be transferred from conduits 6310, 6308 and 6306 into spaces 6320 with a known and controlled quantity of gas or other suitable substance provided therein via conduits 6330, as spaces 6320 rotate about its axis 6322, and pass through conduits. Blades 6312 are arranged with edges that are parallel and in close proximity to the internal surfaces of housing 6318. As ground meat is transferred from the conduits into the spaces 6320 at controlled rates and quantities, controlled quantities of carbon dioxide can also be transferred into the spaces. Preferably, selected quantities of ground meat and carbon dioxide can be transferred, consecutively, into spaces 6320 and transferred as a single volume of materials into conduit 6324 and blended therein, in a continuous process of measured amounts of ground meat and carbon dioxide. Preferably relatively small quantities of measured amounts of ground meat with a selected quantity of carbon dioxide can be blended most efficiently in a continuous process. Such a method of blending can provide a method of thorough and accurate blending with a minimum energy requirement. It can now be seen that the apparatus herein described can be used to efficiently produce a blend of ground meats that has been pre-conditioned with such substances as carbon dioxide and at a chosen rate of production within the capacity of the apparatus. The apparatus shown in FIGURES 207-208 can be enclosed in any suitable jacket or containr_lent so as to allow any suitable heat exchanging medium to contact the housing and thereby, by a heat exchanger means provide precise temperature control of the apparatus and any goods processed therethrough. The temperature control can be precise and set at any suitable temperature within any suitable temperature range. In a preferred embodiment the conduit 6324 may include AMENDED SHEET

a suitable portion of static mixing conduit as may be supplied by Statiflo, alternatively auger 6326 may be driven by a suitable driver at any suitable speed.
Conduit 6324 may be connected to a suitable positive displacement pump or other suitable pump so that any goods that may have been processed by the apparatus shown in FIGURES 207-208, can be directly transferred thereto and then pumped at a desired rate into suitable holding containers or directly into further processing and/or packaging equipment.
Pre-conditioning Apparatus Referring now to FIGURE 209 a side elevation of a ground meat pre-conditioning apparatus intended for use in pre-conditioning ground meats and any other suitable goods, is shown.
Preferably, the pre-conditioning apparatus is intended for use to pre-condition such perishable goods as ground meats in a continuous process (as opposed to a batch process where the perishable goods may be transferred into a pressure vessel which is then sealed prior to removal of any undesirable gases and provision of desirable -and suitable gases therein). The continuous process may be arranged so -that the ground meats are continuously transferred through an entry orifice that restricts the transfer into a vessel in such a manner so as to provide a seal.
The vessel can be filled with any suitable gas at any suitable pressure and maintained at any suitable temperature. The vessel can be arranged to accommodate any suitable quantity of the ground meats for any suitable period of time or residence time. The ground meats can be arranged to exit the vessel after a suitable period of time by transfer through a restricting exit orifice. The exit orifice and the entry orifice can be arranged to restrict transfer of ground meats therethrough in such a manner so as to prevent suitable gases provided in the vessel from escaping therefrom.
A meat hopper 8000, meat grinder 8002 and drive motor 8004 is arranged to grind meat which passes from the meat grinder 8002 directly into a first conical shaped connection to a tube 8010. Tube 8010 includes a length of high pressure stainless steel tube or other suitable material, and connects with a second conical shaped connection 8012 to grinder 8008. First conical connection 8006 is provided so as to elevate the pressure of the ground meat as it is transferred from said grinder 8002 to tube 8010. Tube 8010 may follow any convenient path and is arranged to have any suitable length and, save two end portions of convenient length, is located in an insulated tank enclosure 8014 that contains a suitable liquid cooling medium 8016, such as brine or glycol. Tube 8010 can be completely immersed in E ~~~AMENDED SHEET

the cooling medium 8016 which can be maintained at a desired and suitable temperature that may be set between about 32 and about 33 degrees F. Another tube 8018 connects the tank enclosure 8014 to a heat exchanger 8020 via a suitably sized pump 8022. Tube 8024 connects the tank enclosure 8014 to the heat exchanger 8020. The pump 8022 is arranged in such a manner that cooling medium 8016 can be pumped at a controlled rate through the heat exchanger 8020 so as to maintain 8016 at a desired temperature. Tube 8026 connects the heat exchanger with a source of suitable gas 8028, such as carbon dioxide, provided at a suitable volume, temperature and pressure. Tube 8030 is arranged to carry any excess quantities of gas 8028 away from heat exchanger 8020 as may be required.
Tube 8026 is arranged to connect gas 8028 supply to tube 8010 via the heat exchanger 8020 and connects to the tube 8010 at connection 8032. Connection is arranged to allow a constant flow of gas 8028 directly into or through suitable valves attached to tube 8010 at a position approximately equal distance from each 1 S end of tube 8010.
Meat, which may have been dipped in or sprayed with any suitable -bactericide such as natural citric acids, is loaded into the. meat hopper 8000 at a convenient rate and is processed by grinding in the meat grinder 8002. Meat grinder 8002 is driven by drive motor 8004 at a suitable speed and ground meat which may be coarse ground, is forced into the first conical connector at a suitable pressure. Ground meat is therefore forced under suitable pressure into and along tube 8010. Due to the immersion in the medium 8016, the temperature of the tube 8010 is approximately equal to the temperature of the medium 8016 and therefore temperature of the coarse ground meat is affected and will be either heated or cooled accordingly. The coarse ground meat can be held in the tube 8010 for such a period of time that will allow the temperature of the coarse ground meat to become substantially equal to the temperature of the medium 8016 by transfer of heat through the walls of the tube 8010. The coarse ground meat can pass through the entire length of the tube 8010 and into the second conical shaped connection 8012 to grinder 8008. Grinder 8008 i~ driven by motor 8034 and is arranged to grind the coarse ground meats and can be further arranged to produce fine ground meat from coarse ground meat. A speed controller can be arranged to control the speed of motor 8034 and the corresponding production rate or output of the grinder 8008 can thereby be controlled as may be required to correspond with the speed and output of the grinder 8002. Suitable gas 8028 can be injected at a suitable rate, into tube 8010 AMENDED SHEET

via tube 8026, at a suitable temperature which may be equal to the temperature of medium 8016, and at a suitable pressure which may be about 200 psi. Gas 8028 may be carbon dioxide and can therefore dissolve into coarse ground meat as it passes through tube 8010. The diameter of tube 8010 can be arranged to be smaller than the internal diameter of grinders 8002 and 8008. The source of gas 8028 can be arranged to provide gas at a suitable pressure and in quantities sufficient to meet the desired rate of absorption by the ground meat passing through the tube 8010 and also the quantity required to maintain medium 8016 at the desired temperature. If the volume of gas 8028, required to maintain the suitable temperature of medium 8016 exceeds the volume of gas required to be provided into tube 8010 then excess gas can be.
vented to atmosphere through tube 8030. Conversely, if the quantity of gas required to be provided into tube 8010 is greater than the quantity required to maintain the temperature of medium 8016 at a suitable level, such that the temperature of medium 8016 is otherwise thereby depressed, then a heater can be provided. The heater can be arranged to heat gas 8028 as required to ensure and maintain the temperature of medium 8016 as required.
y A suitable device to vary the quantity of medium 8016, that is pumped by pump 8022 through tube 8018 can be provided. Gas 8028 may be injected into the tube at any suitable gas pressure that may be 200 psi, however, under such conditions gas 8028 will be soluble and therefore dissolve in liquids contained in tube 8010, resulting in a pressure drop as the gas and liquids are transferred along tube toward grinder 8008.
The quantities of gas b028 and ground meat present in tube 8010 and the length of tube 8010 can be arranged so as to allow partial or complete dissolving of gas 8028 into ground meat while still present within tube 8010.
It may be important that ground meats are not exposed to conditions that will either partially or fully freeze the ground meats during processing in the pre-conditioning apparatus. Accordingly, heat exchanger 8020 can be arranged so as to provide a method of transferring heat between the ground meat within the tube and gas 8028, and medium 8016 as required and in such a manner that will inhibit and/or prevent freezing of the ground meat during the pre-conditioning process. Heat exchanger 8020 can be arranged so as to provide a method to ensure that, irrespective of the temperature of the meat provided in the hopper 8000, the temperature of the ground meat 8036 will be maintained at a suitable temperature that may vary within a limited range of plus or minus about 0.5 degrees F. Ground meat 8036 can be lfi7' AMENDED SHEET

processed in the pre-conditioning apparatus so as to saturate or partially saturate, to any suitable level, the ground meat with any suitable dissolved gases.
Preferably, any suitable gas such as nitrogen may be provided directly into grinder 8002 through tube 8038 shown, so as to substantially purge and remove any air that may be present with the meat in hopper 8000. The quantity of meat transferred along tube 8010 and the quantity of gas 8028 injected into the tube 8010 at connection 8032 can be measured and controlled with motors 8004 and 8034 and pump 8022, by a programmable logic controller (PLC). Ground meat pre-conditioning apparatus may be controlled by any suitable controller so as to provide an automatic process. The apparatus can be manufactured to suit any required rate of production.
An auger or other pump to assist in transfer of the ground meat through tube 8010 may be located between the meat grinder 8002 and the first conical connection 8006 or any other suitable location.
A suitable tube (not shown) and valves to open and close the tube, may be provided to connect the second conical connection 8006 to the meat grinder thereby allowing any re-cycling of ground meats that has passed through tube 8010.
Such a re-cycling would allow for further pre-conditioning of any goods that had not been correctly processed during a first passage through tube 8010.
Vents to allow excess gas may be provided at suitable locations in tube 8010 or at any other suitable location.
Ground meat 8036 may be further processed by direct transfer from grinder 8008 to any other suitable processor such as a pattie forming machine or directly into a vacuum packaging machine. The transfer of the ground meat 8036 may be via an enclosed mode of transfer so as to eliminate or minimize exposure to ambient atmosphere prior to further processing or packaging.
The pre-treatment of any perishable goods, such as ground beef, as described herein can enhance the keening qualities of the perishable goods. Preferably, the goods can be placed into a sealed pressure vessel with a known quantity of suitable gases at any suitable pressure for a suitable period of time and maintained at a suitable temperature. Preferably, the suitable gas pressure may be selected at a pressure above ambient air pressure. The quantity of the suitable gas can be increased by providing additional controlled quantities into the pressure vessel as desired. Preferably, the suitable pressure, time and pre-treatment temperature can be precisely controlled and arranged so as to allow the suitable gas to dissolve into any ~~g', AMENDED SHEET ~~' water and oils and/or other substances contained in the goods. The quantity of suitable gas that dissolves into the goods, can therefore be controlled and may be equal to the maximum amount that can dissolve therein at any suitable gas pressure and thereby saturating the goods with the suitable gas in solution.
Preferably, a known amount of gas can be dissolved into the goods at a given gas pressure and pre-treatment temperature. The perishable goods can then be removed from the pressure vessel and packaged in any suitable packaging such as a hermetically sealed vacuum package that may include a gas barrier plastic pouch of suitable size.
Preferably, after vacuum packaging the perishable goads into the suitable gas barrier pouch at ambient air pressure, the goods can be stored in ambient atmosphere and maintained within a suitable storage temperature range. The suitable storage temperature range can be maintained at a suitable level above the pre-treatment temperature.
Preferably a quantity of dissolved gas can emerge from the perishable goods and partially inflate the gas barrier pouch. The size of the gas barrier pouch can be arranged to accommodate the partial inflation without damage to the hermetic sealing of the pouch. The emerged gas then contained within the gas barrier pouch can enhance the keeping qualities of the perishable goods. The emerged gas can subsequently dissolve into the goods a,ain and re-emerge corresponding to any temperature fluctuations that may occur within the suitable storage temperature range.
Preferably, a quantity of free suitable gas can be maintained in gaseous condition with the goods within the packaging and the quantity of free gas can be arranged and controlled at a minimum suitable quantity. However, if the temperature of the goods in the gas barner pouch is increased as a result of failure of refrigeration or any other type of temperature "abuse" to an unacceptable high level (for example 50 degrees F) for an unacceptably prolonged period so that the quality of the goods is compromised, additional gas will be released from solution therein and cause further expansion of the gas barner pouch. The gas barrier pouch can be sized such that it will accommodate a known amount of released gas. The known amount of the released gas can be limited to such an amount that will be released by goods at an acceptable temperature and if the acceptable temperature is exceeded any additional release of gas can cause rupturing of the gas barrier pouch (or any other suitable packaging material). Rupturing of the packaging, therefore, can be used as an indication that goods have endured an unacceptable level of abuse.
In yet another preferred embodiment, goods may be treated by exposure to an adequate quantity of suitable gases at a suitable temperature and pressure in such a manner so as to allow a specific quantity of suitable gas to dissolve in the goods.
The specific quantity of suitable gas can be arranged so as to equal an amount that will saturate the goods with the suitable gas dissolved therein to a suitable level. The goods can then be packaged in any suitable packaging of suitable size which may include an additional quantity of suitable gas contained and hermetically sealed in the suitable packaging with the goods therein. Preferably the total volume of the goods with specific quantity of suitable gas dissolved therein plus additional quantity of suitable gas can be arranged so as to completely fill the suitable packaging of suitable size to provide a finished package with goods and the gas sealed therein.
Therefore, any change in temperature of the finished package and the goods therein will result in a change in the total volume of the goods plus the additional quantity of suitable gas.
The packaging, the goods with the suitable gas dissolved therein plus the additional quantity of suitable gas can be arranged so as to accommodate a known variation (increase or decrease) in the total volume, as desired. The known variation can be used as an indicator of the temperature history of the finished package. For example, the packaging may be provided with a valve indicator that will permanently open or break if the temperature of the finished package with the goods, increases to an unacceptable level and extent so that the volume of gas therein and corresponding pressure thereof increases to an unacceptable level.
Primal Meat Portion Shaping-Apparatus Referring now to FIGURE 210, an apparatus for shaping primal meat portions includes a container 2800 and plug 2802. Container 2800 and plug 2802 may be manufactured by injection molding a plastics material such as nylon or alternatively a gas permeable and porous material such as a chemically foamed polypropylene or polyester plastic material. Alternatively the container and plug may be manufactured from a stainless steel mesh. The apparatus includes a container 2800, with lugs 2842 and 2844 that are engaged with rails 2814 and 2846.
The rails may include, for example, parallel, round, stainless steel bars, suitably mounted to framework, conveniently spaced apart and horizontally disposed, extending for any convenient and desired length that may have bends and curves allowing for the powered ~r manual movement of the containers 2800 there along while maintaining engagement between the lugs and horizontal rails. The cross-section shown in FIGURE 210 provides detail of the container, plug and apparatus through one cross-section only. Other views are not considered necessary since the profile of the container and plugs, across a different section may be similar, .x.7(1: AMENDED SHEET

differences may only include variations in for example, length. The mechanism, container and plug may be arranged in any suitable and desired shape and size to suit the requirements for each portion of pre-rigor fresh rcd meat. Generally, the internal volume of an assembled container with a corresponding and matching plug in position, is approximately equal to the volume or displacement of the corresponding fresh red meat primal shown as 2822. The plug 2802 can slide inside the opening of the corresponding container 2800 such that rim 2810 remains in contact with the inside surfaces of the container wall. The displacement of similar fresh red meat primal that have been harvested from different animals will vary. Therefore, in order to accommodate the variation of similar fresh red meat primals, the internal volume, shown as space 2812, of the assembled container and plug can be adjusted to suit the actual displacement of the corresponding fresh red meat primal. The fresh red meat primal 2822 is located in the container and a plug 2802 is located inside the upper portion of the container such that substantially all air has been excluded from the enclosed cavity containing the primal, under the plug. The container 2800 is shown located in close proximity with a press base 2848, with perimeter wall 2850.
The press base is mounted onto an elevating shaft 2852 thereby providing a means to elevate the press base so as tv contact and retain the lower portion of the container 2800, and also lower the press base parallel with shown center line, such that the 2800 will be suspended on the rails 2814 and 2846 and the press base will not contact or interfere with 2800 and allow the container to slide freely along the length of the rails when the press base is in a lowered position. An assembly, including an outer wall 2816 with a series of driven, concentrically mounted clamps, about a central clamp and located therein, is positioned directly above and aligned with the press base 2848. The wall 2816, and clamps marked 2818, 2828, 2826, 2824 are independently driven in a reciprocating and vertical direction, parallel with the center line shown. A concentric slot 2860 is provided around the perimeter of the clamp 2816, such that a vacuum can be applied to the upper side of the container. A
side view of an alternative profiled plug 2856 is shown in FIGURE 211.
The container includes a rectangular, round or oval plan profile with a flat bottom and substantially vertical walls extending upwardly from the base. The base and walls are continuously attached via a suitably radiused confluence. Two lugs are conveniently located, one on each opposing side of the container. The consistency of container 2800 is such that it will deform slightly when subjected to pressure but will ''171; AMENDED SHEET

i return to its original shape when the pressure is released. A bevel 2806 is molded as shown to provide an easy penetration by the plug 2802.
Plug 2802 includes a "rigidly" flexible, relatively shallow cup with a flat or profiled face 2808, and flexible walls with tapering thickness and flaring outwardly at an angle of about 5 degrees from vertical. The upwardly extending walls are connected to the plug face with a radius therebetween as shown. The upper rim, 2810, of plug wall is tapered and flexible.
The profile and dimensions of the plug are arranged so as to provide an easy penetration into the matching opening of the corresponding container. However as the plug penetrates the container opening, the tapered disposition of the walls provides for intimate contact and sealing between rim 2810 and inner surface of container vertical walls. The container and plug, when assembled together, provide an enclosed space 2812 that is substantially sealed and isolated from external atmosphere. Space 2812 has a volume that can be varied within the limitations of the container, by moving the plug position, relative to the container, within the container.
In all positions, however, the intimate contact between rim 2810 and the inside surface of the container walls is maintained in a substantially "airtight"
fashion.
Preferably, containers and matching plugs of different sizes and suitable profiles rnay be manufactured to suit various sizes of primal portions of fresh red meat, however, in each case the container and corresponding plug are sized to provide a limited but variable i:~ternal volume of space shown as 2812.
Preferably, primal meat portions, of limited varying size and profile can be accommodated within the same containers provided for similar primal portions.
It should be noted that animals used as a source of primal meat portions vary in profile and size but are typically graded prior to slaughter such that the corresponding primal portions are approximately similar.
This present invention provides for de-boning of carcasses that are still in pre-rigor mortis condition, immediately after animal slaughter and preparation while the temperature of the carcass remains close to normal body temperature. The de-boning of the carcasses at such temperatures is very much easier and provides for much more rapid completion of the de-boning process, thereby substantially reducing costs.
Furthermore, pre-rigor mortis disassembly provides the opportunity to control and "mold" the primal meat portion profile such that when the primal portions are chilled, the firm, rigor mortis condition occurs after shaping within the container and plug.
172: AMENDED SHEET

More specifically, according to this present invention, the pre-rigor mortis primal meat portion, having been de-boned, is sprayed with or dipped into a solution of one or more of the following: carbonic acid, acetic acid, ascorbic acid, citric acid and any other suitable substance that can be used to inhibit or eliminate bacterial growth on the primal meat portion. Primal meat portion is then placed into a container of correspondingly suitable dimensions and a plug is inserted into the open end of the container. The assembled container, primal meat portion and plug is located with plugs engaged onto rails 2814 and positioned directly and in alignment above the press base. The press base is elevated so as to closely retain the container.
The wall 2816 is lowered so as to engage with the outer surface of the.upper portion of the container walls as shown in FIGURE 210. Clamp 2818 is then lowered and penetrates opening of the container with radius 2820 end with bevel 2806 and stretching the container opening outwardly thereby clamping it against the inner surface of wa112816 and providing an airtight seal therebetween. Wa112816 is attached to an upper plate (not shown) forming a chamber that is isolated from external air. A vacuum source is attached and air is evacuated from between clamping assembly and plug. Progressively, Clamp 2818 is lowered so as to compress the plug against primal, followed by clamp 2826 and finally clamp 2828 is lowered. Clamps 2828, 2826, 2824 are then in contact with the upper surface of the plug and all applying suitable pressure. The vacuum source is then disconnected, allowing atmospheric air to apply pressure to the outer surface of the plug.
In this manner, substantially all air can'~e removed from within the container assembly.
The container assembly can then be immersed into brine or other suitably treated, bacteria free, temperature controlled medium that may be elevated to as much as about 140 degrees F and held for a suitable period so as to cause death of bacteria that may be present. Following the desired reduction or elevation of the primal temperature, the container assembly can be relocated within a pressure chamber and exposed to an ultra high pressure on the order of about 30,000 psi or more. This procedure can tenderize the primal and also kill bacteria that may be present.
Alternatively, sequentially or simultaneously, the container assembly can be attached to an electrical source so as to provide passing a high voltage current through the primal and thereby treat by way of "Ohmic" heating. In this manner, any bacteria that may be present with the primal can be substantially eliminated or killed.
17y AMENDED SHEET ~~~' ~3~~'~~~f~~.,, The assembled container can then be removed from the pressure chamber and again immersed in a cooling medium when the temperature of the primal can be reduced to a desired and optimum temperature prior to removal from the container and followed by automatic slicing. In this manner rigor mortis occurs such that the shape of the primal meat portion after cooling within the container is similar to the inner profile of the container, providing a more efficient shape for slicing with automatic slicing equipment.
Refernng now to FIGURE 212, an adjustable container arranged to provide a desired internal profile that can be used to contain, and thereby mold, a suitable cut of meat that has been separated by cutting from an animal carcass immediately after slaughter of the animal and prior to rigor mortis of the animal carcass.

shows details of a molding assembly apparatus constructed according to the present invention including an adjustable container 2830, constructed from any suitable metallic or plastics material, that provides a desired internal space with a suitable profile, is shown. Apparatus can be used to contain in the internal space, and thereby shape by molding to the profilE therein, any suitably cut meat primal, that has been separated by cutting devices from an animal carcass immediately after slaughter of the animal and prior to rigor mortis of the animal carcass and primal cuts.
The apparatus may be arranged in any suitable manner including the arrangement shown in FTGLTRE 212 which is constructed from four components, including a "trough"
shaped member 2832, a_ mating closure 2834 and two identical plugs 2836.
Plugs 2830 are profiled to act as "pistons" in a conduit that is arranged by assembly of the components 2832 and 2834. The conduit includes member 2832 with mating member 2834 which, when in a closed and operating position, has an irregular cross-section profile and the "piston" like plugs, 2836 are arranged to sealingly fit, closely within the conduit. The conduit has parallel horizontally disposed walls that provide the conduit along which the "piston" like plugs can be positioned at any desired location within the conduit and thereby providing a space, between plugs 2836, into which item 2838 can be locate3. The apparatus is arranged to be stackable and the lower, outer surface of member 2832 is profiled to mate with the upper external surface of member 2834 by "nesting" therewith when stacked in a vertically arranged column.
A suitable (pre-rigor mortis) primal cut of meat, 2838 such as a New York Strip primal, can be placed in trough 2832, with plugs 2836 positioned, one at each end of primal, to provide a defined space with primal located therein. Member i74' AMENDED SHEET

can be mated with member 2832 and closed so as to contact plugs 2836.
Members 2832 and 2834 can be fixed in position relative to each other and plugs 2836 can be moved, by mechanical powered devices and under pressure toward each other so as to compress item 2838 to the extent required that will cause item 2838 to adopt a profile identical to the internal profile of the space defined by members 2832 and 2834 and plugs 2836. Assembly including members 2832, 2834 and plugs 2836 with item 2838 contained therein can be fixed by any suitable method to a finished configuration and stacked with other similar assemblies such as on any suitable pallet. Pallet with assemblies stacked thereon, can then be re-located into a temperature controlled chamber. Temperature controlled chamber can be set at any suitable temperature that may be elevated up to not more than about 140 degrees F
for a selected period of time after which the temperature may be gradually reduced to about 29.5 degrees F. Item 2838 will therefore cool and rigor mortis will cause "setting" of the profile of item 2838. Item 2838 can then be removed from molding assembly and sliced. Slicing can be conducted automatically while located inside an oxygen free chamber and with carbon dioxide or any other suitable gas or blend of gases provided at any suitable pressure, present therein.
In another preferred embodiment smaller portions of pre-rigor boneless meat such as beef can be placed into the container assembly and processed therein in such a manner that will result in smaller pieces of pre-rigor boneless meat adhering together to form a single piece that can then be sliced into consumer desirable slices.
Pre-rigor boneless beef may include portions of fat and muscle tissue that can be placed into the container, prior to processing, in any desired arrangement such that after processing, the single piece of meat will have a similar appearance to a primal such as a New York strip. In this way, less valuable smaller pieces of boneless beef can be used to produced larger and more valuable primal cuts of beef.
Containers and Plugs for Shaping Meat Primals FIGURE 215 shows a container and plug 3802, which may be manufactured by injection molding and from a plastics material such as nylon or alternatively a gas permeable and porous material such as a chemically foamed polypropylene or polyester plastics materials may be manufactured from a stainless steel mesh.
Preferably, a plurality of profiles of the containers and plugs that facilitate an adjustable volume feature will be required in order to provide for all primal shapes and sizes. For example about 80 different containers and plugs would be required to ~i_75' AMENDED SHEET

accommodate all of the various shapes of primal meat portions that are typically produced in the dis-assembly of a single beef cow.
The container may typically include a rectangular, round or oval plan profile with a flat bottom and substantially vertical walls extending upwardly from the base.
The base and walls are continuously attached at a suitably radiused confluence. One, two or more lugs 3804 can be conveniently located, one or more on each opposing side of the container to locate the container onto rails 3800 so as to retain and hold the container in a desired position at a desired height from the floor. The rails may be arranged with an electrically or pneumatically powered driver to move or slide the .10 container along the rails,. to another position for further processing such as placing the plug 3802 in position by automatic or mechanical apparatus, after loading the primal into space 3808. The consistency of the material from which the container is manufactured can be such that it will deform slightly when subjected to pressure but will return to its original shape when the pressure is released. A beve13810 is provided as shown so as to facilitate an easy penetration by the plug 3802 or 3812, into the opening in the container.
The plug may be provided in various profiles. An alternative plug 3812 is shown in FIGURE 216 with additional details shown in enlarged cross-sectional view of FIGURES 218-219. The plug includes a "rigidly" flexible, relatively shallow (shallower than the container 3800), "cup" shaped plug, with a flat or suitably profiled face 3814, and upwardly extending, flexible walls 3816 with tapering thickness, flaring outwardly and terminating at a rim 3818. The flexible walls can be provided at an angle of about 5 degrees from vertical relative to horizontal face 3814.
The upwardly extending walls are joined to the plug face 3814 with a suitable radius therebetween as shown. The upper rim 3818 of the plug wall is tapered to provide a thin cross-section at the outer edge of the lip and is flexible. An additional rim 3820 located on the opposite side of recess 3822 as shown, that follows a path around the perimeter of face 3814 thereby providing a recess. Slots 3824 are provided through rim to a depth equal to the height of the rim such that the base of each slot is on the same plane and level with face. Slots allow liquids such as liquid purge and blood to escape therethrough and then between the flexible walls of the plug and the inner surface of the container 3800. A controlled and pre-determined pressure P can be applied to the plug 4101 as shown in FIGURE 221 so as to cause the liquid purge to be expelled from space 4107 through sides 4105. The pressure P is equal to the weight W of red meat pri_nal contained therein multiplied by a constant x.

- l yr)-Constant x is determined by the type of meat being processed and could be equal to W, or several times W and is determined by customer quality requirements.
The profile and dimensions of the plug are arranged so as to provide an easy penetration into the matching opening of the corresponding container, however, as the plug penetrates the container opening, the tapered disposition of the walls provides for intimate contact and sealing between the rim 3818 and the inner surface of the container vertical walls. The container and plug, when assembled together as shown in FIGURE 216 provide an enclosed space 3808 that is substantially sealed and isolated from external atmosphere. The space 3808 has a volume that can be varied within the limitations of the container, by moving the plug position, relative to the container. Preferably, however, the intimate contact between the rim 3818 and the inside surface of the container walls is maintained in a substantially "airtight"
fashion.
More specifically, according to this present invention, the pre-rigor mortis primal meat portion, having been dc-boned, is sprayed, washed or dipped in a solution including one or more of the following: carbonic acid, acetic acid, ascorbic acid, citric acid and any other suitable substance that can be used to inhibit or eliminate bacterial growth on the primal meat portion. The primal meat portion is then placed into the container of correspondingly suitable dimensions and the plug is inserted into the open end of the container. The assembled container, primal meat portion and plug can be located with the lugs engaged onto the rails and positioned directly and in alignment above the press base. The press base is elevated so as to closely retain the container as shown. The wall 3830 is lowered so as to engage with the outer surface of the upper portion of the container walls as shown in FIGURE 215. Clamp 3832 is then lowered and penetrates opening of the container with radius 3834 engaging with bevel 3810 and stretching the container opening outwardly thereby clamping it against the inner surface of wall 3830 and providing an airtight seal therebetween. Wall 3830 can be attached to an upper plate (not shown) forming a chamber that is isolated from external air. A vacuum source is attached and air is evacuated from between clamping assembly and plug.
Progressively, 3836 is lowered so as to compress the plug against prima13838, followed by clamp 3840 and finally clamp 3842 is lowered. Clamps 3842, 3840, 3836 are then in contact with the upper surface of the plug and all applying suitable pressure. The vacuum source is then disconnected, allowing atmospheric air to apply AMENDED SHEET

pressure to the outer surface of the plug. In this manner, substantially all air can be removed from within the container assembly.
The container assembly is opened as follows: A port 3$44 is shown in the container base. The port is provided to allow connection to a source of compressed clean gas or clean air. The compressed gas can then be injected through the port and assist in the removal of the prir.~al when desired or after the primal has been stored in the container for a desired period of time.
The assembled container and plug with the primal contained therein may be immersed into clean water, brine or other suitably treated, bacteria free, temperature controlled medium that is temperature controlled by refrigeration.. Following the desired reduction or elevation of the primal temperature the container assembly can be relocated within an ultra high pressure (UHP) chamber and exposed to an ultra high pressure on the order of about 30,000 psi to about 100,000 psi or more.
This procedure can tenderize the primal and also kill bacteria that may be present.
UHP
equipment used may be similar to such equipment manufactured by Flow International, Incorporated of Kent, Washington, USA.
Alternatively, sequentially or simultaneously, the container assembly can be attached to an electrical source so as to pass a high voltage current through the primal and thereby treat by way. of "Ohmic" heating. Preferably, any bacteria that may be present with the primal can be substantially eliminated or killed.
The container and, plug assembly can then be removed from the pressure chamber and again immersed in a cooling medium when the temperature of the primal can be reduced to a desired and optimum temperature prior to removal from the container and followed by automatic slicing. In this manner rigor mortis occurs so that the shape of the primal meat portion after cooling within the container is similar to the inner profile of the container, providing a more efficient shape for slicing with automatic slicing equipment.
In another preferred embodiment the container may be arranged and used to process several, smaller, (thinner) fresh primals simultaneously. This can be achieved with the use of partitions or separating plates. The separating plates can be interposed between the smaller fresh primal portions in an arrangement that can include placing a first primal into the container followed by a separating plate, followed by a second primal, followed by a second separating plate, followed by a third primal, followed by a plug. Any quantity of fresh primal portions, that can fit within the container, can be processed in this manner.
'l78' AMENDED SHEET

Containers and Plugs for Shaving-Multiple Meat Primals In another preferred embodiment, the container may be arranged and used to process several primals simultaneously. FIGURE 217 shows an assembly constructed according to the present invention that includes container 3900, a first 3902, second 3904 and third 3906 primal with first 3908 and second 3910 separating plates therebetween. The plug is shown in position after insertion and all air has been removed from the space between the container base and the plug 3812.
The assembly can then be immersed in cooling medium for further processing and chilling.
In yet another preferred container embodiment, the container may be arranged and used to process several primals simultaneously without the use of separating plates. FIGURE 220 shows detail of a cross-section through an assembly constructed according to the present invention that includes a container 4000 with a first and second 4004 tenderloin contained therein. The plug 4006 is shown in position after insertion and substantially all air has been removed from the space between the container base and the plug. The assembly can then be immersed in a cooling .
medium for further processing and chilling. This process can provide an apparatus of attaching two tenderloins together to produce a single tenderloin of uniform profile and cross-sectional shape. The tenderloin can then be removed and sliced into slices of equal profile size and weight.
In yet a further preferred embodiment, the primal meat portions can be removed from the container 4100, after chilling and rigor mortis, and sliced automatically and without separation of slices. Preferably, after slicing and while still generally held together in a single item, the sliced primal meat portion can be placed into a preformed gas barner bag and sealed therein or alternatively placed into a gas barner packaging tray that has been automatically thermoformed, in-line on a machine such as a Multivac 8530 (Manufactured by Multivac Sepp Haggenmuller GmbH & Co. The gas barrier packaging tray can be profiled and shaped so as to be similar and/or identical in internal profile to the container 4100. The gas barrier packaging tray can then be located into a vacuum chamber and a substantially gas barrier lid, that may be a skin vacuum package (otherwise known by those skilled in the arts, as SVP), and conveniently heat sealed therein at flanges around the cavity of the gas barner packaging tray. Preferably, a hermetically sealed primal meat portion package can be produced that contains the primal meat portion that has been conveniently sliced according to a customer specification and requirement. The 1~9: AMENDED SHEET

vacuum or SVP packaging process, that can be automatically performed with the use of 8530 can rapidly and automatically produce a plurality of the hermetically sealed primal meat portion packages can be stored in temperature controlled storage conditions. Preferably, a hermetically sealed primal meat portion package can be further processed by UHP apparatus prior to sale and delivery to customers.
Plant Layout Referring now to FIGURE 222, a preferred equipment layout according to the present invention includes three rectangular components being identified by the reference numera13350. Preferably, the equipment includes three similar components. Each component . is arranged to form a horizontally displaced, rectangular or square tube with doors at each end. The tube is conveniently position so that access to the doors at each end of the tube can be accessed for loading of packaging materials into the tube. When the doors are shut, the tube is sealed to provide a fully enclosed container or enclosure in which the EPS or FP trays can be stored. Conveniently located ports are provided into the walls of the tube such that suitable gasses can be introduced as required within the tube thereby displacing substantially all atmospheric air and most particularly atmospheric oxygen there from.
The tube is loaded with quantities of EPS and/or FP trays and the doors are closed to provide a sealed container. Most preferably nitrogen, other inert and/or any other suitable gasses are provided into the tube so as to displace substantially all air from the interior of the tube and thereby providing a condition where the gas is in contact with the surface of the EPS and/or FP trays. Preferably, an ozone generator may be installed and chlorine gas may be provided within the enclosure. Any gasses and most particularly oxygen, that may be present within the cells of the trays can therefore freely diffuse and exchange with the gas in contact with the tray surfaces.
With the passage of time, gas contained within the cell structure of the tray walls will therefore be displaced with gas in contact with the outer surface of the trays.
Preferably, oxygen gas will be substantially removed from the cell structure.
Oxygen will gradually accumulate and the level of "free" residual oxygen remaining in the tube can be monitored by automatic gas analysis and maintained at a minimum and desired level. This is achieved by extracting gasses from within the tube at a point near an end of the tube while providing an equal quantity of additional oxygen free gas into the tube at a point near to the opposite end of the tube from the extraction point at the other end of the tube.
'180 AMENDED SHEET ~' ~~~~j°
E

Equipment 3302 is a tray sealing apparatus which is arranged to produce packages, including tray, web and perishable goods contents shown as ground meat.
The perishable goods may be portions of beef, pork or any other suitable perishable goods.
Referring now to equipment 3318, a representation of an apparatus is shown for producing substantially gas barrier "master containers" from a roll of suitable material 3316. Equipment 3318 may be a Multivac R 530 that has been adapted to suit the production system of the present invention. Equipment 3320 shown at can be provided for (optionally) locating an oxygen absorber into each master container with the retail packages before sealing a barrier lid to the master container.
'f'he barrier lid material 3322 includes a roll of the barrier plastics lid material.
Apparatus 3334 shown in FIGURE 222 represents a typical carousel style vacuum packing machine, such as an "Old Rivers" equipment that has 8 vacuum chambers fitted thereto. The carousel style vacuum packing machine, 3332, is shown fitted with 8 vacuum chamber assemblies similar to that as shown in FIGURE 223 and described herein. Referring now to FIGURE 223, a closed vacuum chamber 2700 including upper vacuum chamber 2702 and lower vacuum plate 2704 is shown. A rack 2706 with 2708 trays containing perishable goods 2705, red meat, are shown inside closed vacuum chamber 2700. An evacuation port 2710 in direct communication with a source of vacuum is provided. A switch is attached to the vacuum source so as to provide on/off control. Two continuous and concentric 'O' rings 2712 are located between the edges of 2702 and 2704 and spaced apart providing a space 2714 ther~between. The distance between 'O' rings is arranged such that when multiplied b~ the length of space 2714 the total projected area between the concentric 'O' rings can be calculated. Total projected area shall therefore be equal to PI x 'L1'. When a vacuum is applied to port 2710, the closing force created between 2702 and 2704 can be determined. Assuming that vacuum can be represented in terms of 8C% of atmospheric air pressure, at approximately 14 psi, then the chamber total closing force, in pounds, would be equal to DI x LI x .8 x 14.
A gas or blend of desired gasses can be provided within the closed vacuum chamber at a pressure above atmospheric pressure which will provide a chamber opening force. However, in this arrar:gement, the closing force can be arranged to exceed the opening force thereby providing a method of maintaining a pressure with the closed chamber at a level above that of the prevailing atmospheric air pressure while the closed vacuum chamber remains closed due to the closing force provided. A
further ,:181,.: AMENDED SHEET

evacuation port 2716 is provided in 2702 and a gassing port 2718 is provided also.
The upper vacuum chamber 2702 is arranged so that it can be lifted vertically upward and away from 2704 allowing removal of the rack with trays and another rack with trays can be placed therein such that a continuous production process can be undertaken. The upper vacuum chamber 2702 and the lower vacuum plate 2704 may be arranged with clamping and structural supports so as to allow an increase of gas pressure to gas provided therein to any desired pressure such as 500 psi or more.
Perishable goods are located in an EPS (foamed polystyrene) tray with inherent or enhanced gas permeability. A gas permeable web is positioned above the EPS tray. The web has adhesive applied to the region of the web that will come into contact with flanges of the tray so as to provide a seal between web and tray.
The web is then sealed to the flanges of the tray. The flange of the tray may be compressed as shown to provide improved structural integrity and strength.
The EPS tray with intzerent or enhanced gas permeability can quickly transfer, remove and exchange substantially all oxygen gas from foam cells during "carousel evacuation and gassing process".
The web may be printed on one or both sides with panels that can be seen from the upper side after sealing to the tray. A bar code can be applied to label on the underside of the package. The bar code can include code information such as the specific weight of tray contents, date packaged and type of content goods.
Information can be read by- a scanner at any time after packaging and converted to consumer readable information that can be printed by, for example, ink jet printers onto the panel prior to retail display.
A device to cause oscillation of gas pressure within the chamber at a frequency that will cause improved and more rapid exchange of air and oxygen contained within cells of EPS tray with desired gas provided in chamber, can be provided. Furthermore, the oscillation of gas pressure within the chamber, can cause the permeable web to raise and lower and provide a space between the web and upper surface of the goods thereby allowing the gas provided in the chamber to directly contact the tray contents beneath the web. Oscillation can also provide improved contact with the goods an ~ enhanced absorption of the gasses by the goods.
The oscillation may be set at a range of gas pressures that are above or below prevailing atmospheric pressure. The gas may include other substances in vapor, atomized or powder form and the composition may be selected and include the most suitable blend of one or more of the following: nitrogen, oxygen, argon, carbon dioxide, 182'. AMENDED SHEET

hydrogen, krypton, neon, helium, xenon, 03, F2, H2, 02, KMnO4, HCIO, C102, Br2 and I2.
A desirable blend of gasses such as carbon dioxide and ozone can be provided within the closed chambers 2702 and 2704 with the rack with trays contained therein.
Refernng now to FIGURE 222, racks with trays can be automatically loaded into open vacuum chambers 3332 which are then closed. A vacuum source is then applied to port 2710 and a desired gas provided into closed vacuum chambers after removal of atmospheric air there from. The carousel is rotated, intermittently, in the counterclockwise direction shown in FIGURE 222 and stopped such that after each vacuum chamber assembly 3332 has fully traveled around the perimeter of the carousel the rack with trays can be automatically removed from each vacuum chamber and replaced with another. Therefore a continuous and automatic process of treating trays containing perishable goods with desired gasses can be provided.
Refernng now to equipment 3326, a diagrammatic representation of an automatic carton erecting, filling and sealing equipment is shown. A supply of cartons is also shown as 3324.
Referring now to equipment 3328, a representation of ,an automatic-carton palletizer, such as model FL 100 manufactured by Columbia Machine, Inc., Vancouver Washington, is shown. The palletizer is arranged to automatically palletize finished cartons of packaged perishable goods with a supply of empty pallets 3330. Finished cartons can be automatically transferred from equipment to the palletizer 3328.
Equipment 3304 is a representation of equipment configured to locate tray flange covers prior to loading of the perishable goods into the tray. The flange covers are described in Australian patent application PM8415. Equipment 3308 is a representation of a section of the packaging equipment that is exposed as require to facilitate efficient loading of the perishable goods into the trays. Equipment 3310 is a representation of equipment configured to remove tray flange covers and as generally described in Australian patent application PM8415. Equipment 3306 is a representation of the direction of flow of an alternative perishable goods to be optionally loaded into the trays.
Equipment 3336 is a representation of equipment configured to receive, grind, condition and process meat and other similar perishable goods like the one shown in FIGURE 186. Equipment 3340 is a meat grinder. Equipment 3342 is a pressure vessel. Equipment 3344 is a secondary meat grinder. Equipment 3346 is a '183: AMENDED SHEET ~~

pressure vessel. Equipment 3338 represents the perishable food item, such as portions of meat, that is to be processed and packaged. Equipment 3304 is a diagrammatic representation of equipment configured to locate tray flange covering members prior to loading of the perishable goods into the tray. Equipment 3308 is a diagrammatic representation of a section of the packaging equipment that is exposed as require to facilitate efficient loading of the perishable goods into the trays.
Equipment 3312 is a representation of a roll of plastics lid material intended for sealing to flanges of the trays after perishable goods have been placed therein.
Equipment 3314 is a representation of an optional feature and equipment for locating labels onto the underside or, after adjustment, upper side of the retail packages after sealing of lid material to flanges of the trays. Equipment 3318 is a representation of an apparatus for producing substantially gas barrier "master containers" from a roll of suitable material 3316, locating an optional oxygen absorbing material into each master container with the retail packages and sealing a lid to the master container that is unwound from a roll of plastics lid material shown as 3322. Equipment 3334 is a representation of a typical carousel type vacuum packaging machine that has been modified according to the description provided herein, and located adjacent to both packaging equipment items 2 and 3, so as to facilitate easy transfer of finished ' packages therebetween. Equipment 3332 is one of 8 vacuum chambers mounted to the carousel and as shown in FIGURE 223. Equipment 3326 is a representation of an automatic carton erecting, filling and sealing equipment with a supply of cartons 3324. Equipment 3328 is a representation of an automatic palletizer.
Equipment 3300 is a representation of equipment configured to exchange air and more particularly, atmospheric oxygen, contained within the cell structure of foamed polystyrene trays (EPS trays) and foamed polyester trays (FP trays).
FIGURE 240 shows a cross-sectional side view of half of the arrangement and FIGURE 241 shows a cross-section across the full width of the arrangement, through parts of a preferred apparatus and packaging.
Equipment 3350 is a diagrammatic representation of an alternative equipment configured to exchange air and atmospheric oxygen, contained within the cell structure of foamed polystyrene trays (EPS trays) and foamed polyester trays (FP
trays).
Thermoforming Apparatus AMENDED SHEET' Referring now to FIGURE 224, a plan view of equipment layout according to the present invention is shown that can be used to produce trays constructed according to this invention.
The equipment layout is shown in a convenient arrangement for the efficient production of the trays. Primary extruder 4600 is arranged adjacent to secondary extruder 4602 in a normal condition for production of expanded polystyrene foam sheet. Direction of flow is shown traveling toward wind-up mechanism 4604 with spool 4606 attached thereto. A roll of EPS sheet material 4608, is shown adjacent to tube 4610. Tube 4610 follows a path that is conveniently arranged parallel with IO tube 4612. A cross-section through tube 4610 is shown in FIGURE 225. Tube 4b10 extends to a point of termination adjacent to thermoforming machine shown as 4614.
A second EPS foam extrusion system with primary extruder 4616 and secondary extruder 4618 is located adjacent to the first EPS foam sheet extrusion system and 4602. Second extrusion system extrudes sheet in direction of flow as shown and I5 toward winder 4620, spool 4622 and roll 4624 adjacent to the entry end of tube 4612.
The construction of tube 4612 can be identical to tube 4610. Tube 4610 and tube 4612 are parallel to each other and follow a concentric path such that terminates at an end in close proximity to thermoforming machine 4626. Tubes and 4612 follow parallel and concentric paths that spiral upwardly thereby providing 20 an extended length of tubes 4610 and 4612 and contained within a convenient area.
Refernng now to, FIGURE 225, a section through tube 4612 is detailed.
Spool 4606 can be seen inside tube 4612 resting on belt 4628 and belt 4630.
Belt 4628 and belt 4630 are held taught and arranged to engage with drive sprockets conveniently located so as to engage the belts. Belts can, thereby, carry spool 4606.
25 Carrying members extend throughout the full length of tubes 4610 and 4612 thereby carrying spools 4606 through tube 4612 and 4610. A dish 4632 is mounted to a pneumatic cylinder 4634 such that when extended the dish can elevate the spool upwardly so as to lift the spool away from driving belts 4628 and 4630. Tube is shown mounted directly onto a floor, however the tube can be elevated above the 30 floor by suitable frame members. Gas 4636 is provided in tube 4612, gas may be nitrogen gas. A three dimensional sketch of spoo14606 is shown with roll of material 4638 wound thereon. Spools 4606 can be loaded into the entry end of tubes 4612 and 4610 which are conveniently located adjacent to the winding members attached to foam extrusion equipment. Spools can be carried through 35 tubes 4610 and 4612 on bel~a 4628 and 4630 that may be operating continuously.
AMENDED SHEET

Dish 4632 is located conveniently between belt 4628 and belt 4630. Dish 4632 and spool 4606 can thereby be elevated, by activating pneumatic cylinder, upwardly and away from contacting belts 4628 and 4630. Pneumatic cylinder 4634 with dish attached thereto may be provided in sections that extend throughout the full length of tubes 4610 and 4612. By operating belts 4628 and 4630 with forward driving motion and pneumatic cylinder 4634 and dish, spools 4606 can be carried through tubes 4610 and 4612 according to demand.
Preferably, tubes 4610 and 4612 can be flooded with a suitable gas such as nitrogen or a blend of gasses including argon, carbon dioxide, nitrogen and a quantity of oxygen that does not exceed about 5% and is not less than about 1000 PPM of blend of gasses, through ports 4640 and 4642. Spools with rolls of EPS foam material can be stored in tubes 4610 and 4612 for a period of time as may be required in the normal aging of EPS foam material. This period of time may be in the order of twelve hours and accordingly the length of tubes 4610 and 4612 will be arranged so as to accommodate sufficient spools of material required for production of trays and also allowing for the twelve hour residence time as required. After storing the . , spools 4606 in tubes 4610 and 4612 quantities of spools can be removed from the exit end of the tubes adjacent to the thermoforming machines. Spools can be loaded onto the thermoforming machines and thermoformed trays with flaps can be manufactured, as required.
Referring now to F1GURE 227, a cross-section through a thermoforming machine oven is shown. The oven includes a substantially sealed and enclosed rectangular tube with heaters 4633, 4635 arranged above and below EPS sheet that can be carried therethrough. The EPS sheet can be fed into the oven through a slot that is slightly larger than a cross-section through the EPS sheet. Tube 4646 is attached to the under section of the oven and tube 4644 is attached to the upper section of the oven. Gas can be provided at a pressure above the ambient atmospheric pressure, from a "nitrogen generator" directly into tube 4646. Gas can be extracted from tube 4644 that follows a path along path 4648 and through cooler 4650. Tube 4644 aelivers the gas and an additional quantity of air along tube 4644 and into the nitrogen generator. The nitrogen generator generates nitrogen gas by way of separating oxygen from air and allowing only nitrogen to pass into and through tube 4646. Gas may be provided into tube 4646 directly from tube 4644 if required.
1$G AMENDED SHEET

Referring again to FIGURE 224, a plan view of tubes 4660, 4662, 4664, 4666 are shown passing through a wall. The tubes may be filled with a suitable gas.
Fully formed trays with flaps can be loaded into the tubes for direct transfer and use on packing machines.
Preferably, the thermoforming apparatus herein described can be incorporated into the plant layout schematic of FIGURE 222. Referring now to FIGURE 228, a slight modification to a previous equipment plan is shown for producing trays according to the present invention. Equipment includes four tubes 4700, 4702, 4704, and 4706. Each item is arranged to form a horizontally displaced, rectangular or square tube with doors at each end. Each tube is conveniently positioned so that access to doors at each end of tube can be accessed for loading of packaging materials into tube. When the doors are shut, the tube is sealed to provide a fully enclosed container or enclos~zre in which the EPS or FP trays can be stored.
Conveniently located ports are provided into the walls of the tube such that suitable gasses can be introduced as required within the tube thereby displacing substantially all atmospheric air and most particularly atmospheric oxygen there from.
. Each tube is loaded with quantities of EPS and/or FP trays and doors are closed to provide a sealed container. Most preferably nitrogen, other inert and/or any other suitable gasses are provided into the tube so as to displace substantially all air from the interior of the tube and thereby providing a condition where gas is in contact with the surface of EPS andlor FP trays. Additionally, an ozone generator may be installed and chlorine gas may be provided within the enclosure. Any gasses and most particularly oxygen, that may be present within the cells of the trays can therefore freely diffuse and exchange with the gas in contact with the tray surfaces.
With the passage of time, gas contained within the cell structure of the tray walls will therefore be displaced with gas in contact with the outer surface of the trays.
Most importantly oxygen gas will be substantially removed from the cell structure.
Oxygen will gradually accurmlate and the level of "free" residual oxygen remaining in the tube can be monitored by automatic gas analysis and maintained at a minimum and desired level. This is achieved by extracting gasses from within the tube at a point near an end of the tube while providing an equal quantity of additional oxygen free gas into the tube at a point near to the opposite end of the tube from the extraction point at the other end of the tube.
Ouen and Closed Cell Structures '1'$?- AMENDED SHEET

Referring now to FIGURES 229-237, cross-sectional and enlarged views of expanded polystyrene (EPS) foam sheet are shown, wherein FIGURE 229 shows a cross-section through a portion of co-extruded EPS foam including three layers 4500, 4502 and 4504. FIGURE 230 shows a cross-section through a portion of extruded EPS foam sheet including three layers 450b, 4508 and 4510 and wherein layers and 4510 include skin similar to the section shown in FIGURE 233.
Referring to FIGURE 229, outer layers 4500 and 4504 sandwich an inner layer 4502. Outer layers 4500 and 4504 include closed cell EPS foam as shown in FIGURE 232. "Closed cell" EPS foam describes a physical condition where the cells or bubbles, that are filled with gas, generally include enclosed spherical spaces where. . .
the cell, bubble or sphere is not fractured and therefore any gas contained therein can enter or exit the spheres by diffusion through the spherical wall only and not through fractures or openings in the sphere wall. FIGURE 232 shows a grouping of cells or bubbles that contain a gas which may be air. Layer 4502 includes a layer of open celled EPS foam as shown in FIGURE 235. "Open cell" EPS foam is a physical condition where most cells or bubbles are fractured and allow gas and other matter to invade the internal space of the open cells readily. Production of open cell EPS foam can be effected by introducing contaminants into the polystyrene melt prior to foaming. The contaminants may include a surfactant to enhance liquid absorbing properties, can cause fractures in the cell walls to appear. Closed cell EPS
foam is produced by ensuring that there are no contaminants in the polystyrene melt prior to foaming. Closed cell foam generally provides a more mechanically stable and rigid structure than does open cell foam. Therefore in order to produce a more mechanically stable and rigid packaging tray, closed cell polystyrene is a preferred construction material. However closed cell EPS foam resists absorbing liquids such as blood, water and purge. In order to produce a superior EPS foam packaging material that has both liquid absorbing and structurally sound properties use of a combination of both types of open and closed cell foam is preferable. A
preferred material would include three layers of co-extruded multi-layer foam sheet where layers 4500 and 4504 include closed cell EPS foam and layer 4502 includes open cell EPS foam.
Referring now to FIGURE 230 a cross-section through a preferred material is shown where a three layer material includes two outer layers 4506 and 4510 and a center layer 4508. Layers 4506 and 4510 are similar and include a skin that can be 3S induced by exposing a mono extruded layer of EPS foam, before the foam has cooled ~jgg AMENDED SHEEI-and solidified, to relatively cool air applied thereto under regulated pressure. By applying the regulated compressed air in this way a skin can be formed by deflating the open or closed cell structure at one or both surfaces of the EPS sheet.
The layer 4508 includes a layer of open cell EPS foam.
Refernng now to FIGURE 231, the closed cells are shown schematically, as being exposed to gas pressure that is higher than gas pressure inside the closed cells.
Enlarged view of closed cell FIGURE 237 shows a ratio of a pressure differential where P equals the external gas pressure and P1 the closed cell internal gas pressure.
FIGURE 234 shows a grouping of closed cell EPS foam cells where the internal pressure P1 is greater than the external gas pressure P.
The present invention to provides a method to substantially remove oxygen gas that may be retained within the cell structure of the EPS foam packaging materials and to also reduce the amount of oxygen and/or slow the rate at which oxygen may re-enter the cell structure after removal from storage and processing in a suitable gas. The following steps disclose a method that can be used to achieve this condition. Any or all of the following steps may be effected in the sequence shown or any other sequence that enhances the most efficient and rapid removal of undesirable gasses, including oxygen, from the structure of the packaging materials:
Place a quantity of EPS foam packaging materials, such as trays with flaps, in a gas tight and sealed pressure chamber, with evacuation and gassing ports therein and valves attached so as to allow evacuation and gassing, with suitable gas, of the pressure chamber as desired.
Provide a vacuum inside the pressure chamber, by lowering gas pressure therein, and maintain for a period of time so as to enhance the removal of oxygen from the structure of the packaging materials in a desired manner.
Introduce a suitable gus into the pressure chamber at an initial selected and suitable pressure that may be below ambient atmospheric pressure.
Maintain the selected and suitable pressure for a period of time that enhances the removal of oxygen from the structure of the packaging materials in a desired or optimised manner.
Progressively increase the pressure of the suitable gas in the pressure chamber, in a continuous or intermittent manner, over time, until the gas pressure is above atmospheric pressure.
y$g:' AMENDED SHEET

Maintain the gas pressure for a period of time that enhances the removal of oxygen from the structure of the packaging materials in a desired or optimized manner.
By heating and/or cooling apparatus, maintain the temperature of the packaging materials and the suitable gas in the pressure chamber, at a temperature that enhances the removal of oxygen from the structure of the packaging materials in a desired or optimized manner.
During the process, described above, exchange the suitable gas, while maintaining the suitable gas pressure in the pressure chamber as required, which can continuously occur during the process, at a suitable rate of exchange to ensure that any undesirable gas, including oxygen, that may become present in the suitable gas, is substantially removed from within the pressure chamber.
Remove the packaging materials from the pressure chamber and allow the packaging materials to physically expand as can occur due to a higher relative gas pressure that may exist in the closed cell structure of the EPS packaging materials.
Maintain the packaging materials at a suitable temperature for a suitable period of time, after removal from the pressure chamber.
The steps disclosed above may be repeated, sequentially or otherwise and in a manner that provides an efficient process to remove undesirable gasses from the structure of the packaging materials and to enhance the expansion of the packaging materials in a desired manner.
In this way oxygen gas can be removed, from within the open and closed cell structure of EPS foam material, and replaced with the suitable gas at a pressure above atmospheric pressure. The packaging materials can then be used for packaging.
The higher pressure within the closed cell structure can gradually equilibrate with that of the prevailing ambient atmospheric air pressure, however during this equilibration period the rate of re-entry of atmospheric oxygen into the structure of the packaging materials can thereby be reduced.
In another preferred embodiment, adhesives such as any suitable bonding medium may be applied to surfaces of the flaps of tray and the tray walls and base by any suitable "ink jet" apparatus. Furthermore, colored graphic printing and any desired information can be printed and/or applied to any desired surfaces of'the tray and flaps by any suitable "ink jet" apparatus. The "ink jet" equipment is manufactured by several companies such as Hewlett Packard, Xerox, SciTex, Marconi/Video Jet and others. The equipment can be arranged to apply inks, AMENDED SHEET' lacquers and adhesive materials as required by, for example, arranging the ink jet equipment adjacent to a conveyor that can transport the trays with flaps at a suitable speed and in such a manner Zs to allow application of the inks and other materials to the trays and flaps, as required. The conveyor may be arranged adjacent to and S integrated with thermoforming machinery such that immediately after producing trays with flaps, the trays can be automatically transferred onto the conveyor. The conveyor can be arranged to carry trays with flaps at a controlled speed and as required to allow application of inks and any suitable materials thereto by ink jet printer.
Tray Treatment Method and Apparatus for the Removal of Oxy"gen ..
Referring now to FIGURE 238, details of an apparatus for storing foam (EPS
or polyester foam) trays, for exchanging gas in cells with a preferred gas is shown.
This apparatus provides a method to substantially remove any residual oxygen that may be retained in the cell structure of EPS packaging materials intended for use in packaging fresh red meats in a "low oxygen" master container, case ready packaging system. The method disclosed herein can provide a process to remove and replace the residual oxygen, with a desired gas, more rapidly than occurs when the EPS
packaging materials are stored in a chamber containing desired gas in a static condition at ambient atmospheric pressure. The apparatus includes a rectangular or suitably profiled tube 4200 . The tube 4200 is arranged to have two open ends and 4204, one at each end of the tube 4200. The tube is provided with evacuation port 4206 and gas entry port 4208. The tube can be filled with precut foam (EPS) trays with flaps, or sheets of foam 4210. The tube can be arranged to have a suitable length and be configured in such manner as to allow automatic loading from the trim press of a suitably modified thermoforming and tray trimming apparatus. The tube can further be arranged so as to allow automatic removal of one tray with flaps at a time for subsequent automatic processing of the tray with flaps to form a finished tray with bonded and sealed flaps.
Open ends 4202 and 4204 can be arranged to mate with covering caps (not shown) in such a manner as to completely enclose the tube and provide airtight seals at both open ends. The completely enclosed tube 4200 can thereby provide a vacuum chamber containing the trays with flaps such that when a vacuum source is connected to evacuation port 4206 substantially all air contained therein can be removed. After evacuation of the air from the tube, the vacuum within the tube can be maintained for a period of time, the period of time being sufficient to allow removal of substantially °~g1 AMENDED SHEET

all retained air and oxygen from the cell structure of the trays with flaps.
After removal of substantially alI air and oxygen from within the cell structure, a suitable gas such as nitrogen or carbon dioxide can be provided into the tube via gas entry port 4208. The gas can be retained within the enclosed and sealed tube 4200 for a period of time sufficient to allow the cell structure to become filled with the suitable gas. Alternatively, evacuation of air from within the tube can be adjusted to provide a remaining gas or air pressure therein at any pressure between zero and ambient atmospheric air pressure and suitable gases can be provided in the tube so as to blend with any remaining air contained therein after evacuation to a desired pressure. Such process of evacuation and gassing can be repeated in accordance with an optimized process that will result in the most rapid exchange of retained oxygen in the cell structure with a desired gas.
In another preferred embodiment, the evacuation port 4206 may be provided in the sealing cover over open end 4204 and the gas entry port 4208 may be provided in the sealing cover over the open end 4204. The preferred embodiment can thereby provide an arrangement where a vacuum source can be attached to the evacuation port and a gas source can be attached to gas entry port and provide a continuous flow of gas through the tube from one end to the other so as to contact the surface of the trays with flaps contained 'herein. The pressure of the gas flowing through the tube can be arranged at a level most suitable to achieve the most rapid removal of air and oxygen that may be contained within the cell structure of the trays with flaps and thereby exchange the oxygen with the desired gas.
Referring now to diagram FIGURE 238, details are shown of an apparatus for storing foam (EPS or polyester foam) trays, for exchanging gas such as oxygen that may be contained in the cell structure of the trays, with a preferred gas. The apparatus removes any residual oxygen that may be retained in the cell structure of the EPS trays that are intended for use in packaging fresh red meats in a "low oxygen" master container, case ready packaging system. The apparatus and method disclosed herein can provide a process to remove and replace the residual oxygen, with a desired gas, more rapidly than occurs when the EPS packaging materials are stored in a chamber containing desired gas in a static condition at ambient atmospheric pressure.
The apparatus includes a rectangular or suitably profiled tube 4200. The tube is arranged to have two open ends 4202 and 4204, one at each end of the tube.
The tube is provided with evacuation port 4206 and gas entry port 4208. The tube can be AMENDED SHEET

filled with precut foam (EPS) trays with flaps, or sheets of foam 4210. The tube can be arranged to have a suitable length and be configured in such manner as to allow automatic loading from the trim press of a suitably modified thermoforming and tray trimming apparatus. The tube can further be arranged so as to allow automatic removal of one tray with flaps at a time for subsequent automatic processing of the tray with flaps to form a finished tray with bonded and sealed flaps as described above.
The open ends 4202 and 4204 can be arranged to mate with covering caps (not shown) in such a manner as to completely enclose the tube and provide airtight seals . at both the open ends. The completely enclosed tube can thereby include a vacuum chamber containing the trays with flaps such that when a vacuum source is connected to evacuation port 4206 substantially all air contained therein can be removed. After evacuation of the air from the tube, the vacuum within the tube can be maintained for a period of time, the period of time being sufficient to allow removal of substantially all retained air and oxygen from the cell structure of the trays with flaps. After removal of substantially all air and oxygen from within the cell structure, a suitable gas such as nitrogen or carbon dioxide can be provided into the tube via gas entry port 4208. The gas can be retained within the enclosed and sealed tube for a period of time, which may be 1 to 2 hours, sufficient to allow the cell structure to become filled with the suitable gas. In a preferred procedure, the air will be substantially evacuated through the evacuation port 420b and then a gas such as nitrogen will be introduce~:l Through port 4208 at a suitable low pressure.
The gas will be held at the suitable low pressure for a period of dme and then, the low pressure of the gas will be gradually increased, over a period of time, and until the gas pressure is increased to a maximum gas pressure above ambient atmospheric pressure. The maximum gas pressure may be 60 psi or more.
Alternatively, a partial evacuation of air from within the tube 4200, to a level that does not completely evacuate the tube but lowers the air pressure therein to a pressure above zero and belovf ambient atmospheric air pressure. A suitable, oxygen free, gas such as nitrogen can be provided into the tube, through the port 4208, so as to blend with the remaining air contained therein. This process of partial evacuation followed by gassing can be repeated, sequentially until the oxygen gas contained in the EPS cell structure is removed and in an optimized process that will result in the rapid exchange of the retained oxygen in the cell structure with a desired gas.
~~'g3AMENDED SHEET

In another preferred embodiment the evacuation port 4206 may be provided in the sealing cover over the open end 4204 and the gas entry port 4208 may be provided in the sealing cover over the open end 4202. A vacuum source can be attached to the evacuation port 4206 and a suitable gas source, such as nitrogen or a blend of gasses including argon, carbon dioxide, nitrogen and a quantity of oxygen that does not exceed 5% a:~d is not less than 1000 PPM, can be attached to the gas entry port 4208 and thereby providing a continuous flow of gas through the tube from port 4208 to evacuation port 4206 so that the suitable gas contacts the surface of the trays with flaps contained herein. The pressure of the gas flowing through the tube can be arranged at a level most suitable to achieve the most rapid removal of air and oxygen that may be contained within the cell structure of the trays with flaps.
In yet another preferred embodiment, a plurality of the rectangular tube 4200, may be conveniently stacked together and located inside a suitably sized vacuum chamber. Substantially all air may be evacuated from within the vacuum chamber and held with the vacuum source attached thereto for a period of time sufficient to allow removal of substantially all gas from within the expanded polystyrene foam cell structure. A suitable gas, such as nitrogen can then be provided into the vacuum chamber, at a pressure equal or greater than ambient atmospheric pressure so as to completely fill the vacuum chamber and contact all surfaces of foam trays in the tubes. After a period of time the plurality of tubes can be removed from the vacuum chamber.
Referring now to FIGURE 239, another embodiment of a rectangular tube having top bottom open ends is shown. Preferably, the rectangular tube may be manufactured from any suitable material such as stainless steel or other plastics material and may be arranged to have any convenient length. Preferably, the rectangular tube can be manufactured with longitudinally parallel sides and a cross-section that corresponds with the cut size of the trays that are shown therein. More specifically the rectangular tube will have a cross-sectional opening that is sized so as to be slightly larger that the cut size of the trays contained therein. For example, if the plan, cut size dimensions of the trays is 5 inches long by 4 inches wide the opening in the rectangular tube will be about 5.125 inches long by about 4.125 inches wide.
A gas entry port 8102 is shown located in the wall of the rectangular tube at about equal distance from each end of the rectangular tube. A plurality of additional gas entry ports may be provided at any suitable location in the wall of the rectangular y g4.= AMENDED SHEET

tube. Most preferably, a suitable gas or blend of gasses, such as nitrogen, may be provided inside the rectangular tube through the entry port 8102. The gas may be provided by an injector into the rectangular tube through one or more of gas entry ports at a set pressure and volume. Gas may be provided at a pressure that is varied by normal methods or alternatively by way of a set pitch sound that may also be varied in a manner to enhance gas exchange. Preferably, length of rectangular tube 8100 can be arranged such that when trays are passed through the rectangular tube, the residence time of trays within the rectangular tube will be sufficient to allow gas exchange to occur between suitable gas provided through the entry port and into . the rectangular tube and gasses such as oxygen that may be contained within the cell structure of the trays. Trays may be loaded through an opening at the open tope of rectangular tube and unloaded through the open bottom.
Preferably, rectangular tube is vertically disposed such that gravity will provide sufficient force to cause the trays to pass through the opening through the rectangular tube, when trays are removed from the bottom of rectangular tube.
Alternatively, the rectangular tube may be horizontally disposed and a driver such as an auger (not shown) may be provided to transfer the trays through the rectangular tube. Preferably, the rectangular tube may be arranged so as to connect with an automatic tray dispenser so that trays can be automatically removed, one or more at a time, and subsequently be positioned onto a packaging machine in readiness for loading of perishable goods such as fresh red meat therein. A plurality of rectangular tubes may be arranged together in a grouping so as to process a plurality of trays simultaneously.
The rectangular tube can be manufactured to suit trays of any size.
Tray Forming_Apparatus Referring now to FIGURES 240-241 where a cross-section of the tray forming apparatus 2200 is illustrated. The apparatus is intended for used in a method for removing oxygen gas from the structure of expanded polystyrene packaging materials that are intended for use in packaging perishable goods that could be deleteriously affected by the presence of oxygen in quantities that exceed 500 PPM.
The method includes but is not limited to the use of any suitable gas at any suitable pressure arranged to pass through the packaging materials by providing the suitable gas to one side of the packaging materials at a pressure above what is the gas pressure of any gas that is present on the opposing side of the packaging materials.
The suitable gas will thereby be caused to pass through the packaging materials and AMENDED SHEET

furthermore cause a reduction in oxygen contained in the structure of the packaging material s.
The apparatus includes two parts. The first part shown in FIGURE 240 is a side view cross-section with the apparatus in a closed position and a tray clamped between an upper chamber 2252 and a lower chamber 2254. FIGURE 240 shows half of the apparatus with a center line marked through what would be the center of the apparatus. The other half of the apparatus is a mirror image of the part that is shown. FIGURE 241 shows a cross-section across the entire width of the upper and lower chambers 2252 and 2254.
The apparatus 2200 includes an upper and lower chamber which are arranged so as to be moveable toward and away relative to each other, thereby allowing trays to be processed in a continuous mode.
A porous mold 2256, that is profiled to follow the contours of the tray and to neatly fit within the confinement of the chambers 2252 and 2254, is provided and can be fixed to the upper chamber. A gassing port 2258 is provided in the lower chamber 2254 and an evacuation port 2260 is provided in the upper chamber 2252.
The porous mold 2256 can he manufactured from a suitable porous material and may have grooves and slots machined across the surface of the profiled face 2262 that are all connected to evacuation. port 2260, thereby allowing gasses to be evacuated therethrough and through port 2260. The apparatus can be configured to accommodate one or more trays, however, for ease of explanation the apparatus shown in FIGURES 240-241 preferably accommodates one tray. A blade 2264 is provided within chamber 2254 which is attached to a moving member. The blade 2264 can be arranged in a continuous length to provide a knife edge that follows the perimeter of what will become the processed and cut tray. Space is provided between the surface of the profiled mold 2256, as shown, providing a space into which a suitable pressurized gas can be provided.
A tray 2268, having extended flanges, 2270, is located on the porous mold 2256 and the chambers 2252 and 2254 are closed so as to clamp the flange 2270 around the full perimeter of the tray. The tray 2268 may be thermoformed from expanded polystyrene and therefore has a porosity and can therefore allow pressurized has to pass therethrough. Pressurized nitrogen gas can then be provided into the space through port 2258 at a suitable pressure. A
vacuum source can be attached to port 2260. The gas thereby passes through the porous tray walls and can displace oxygen gas that may be present therein. The pressurized gas 196,: AMENDED SHEET

can be provided into the space and passed through the tray porous walls far sufficient time to displace substantially all oxygen gas that may have formerly been present therein. The blade 2264 with knife edge can be activated and moved by the moving member 2266 so as to cut through the tray flange 2270. Chambers 2252 and 2254 S are opened allowing the tray 2268 to be removed in readiness for additional trays to be processed in a similar fashion as described above. Trays 2268 can be removed and replaced on the porous mold 2256 in a continuous, intermittent and automatic procedure. The porous mold 2256 can be interchanged with other molds having different profiles to suit other trays of different size and profile.
Flange 2270 and any other part of the tray 2270 and the flap 2272 may be compressed, as desired, to substantially remove gas from the foam cells thereby forming a substantially solid section in the tray, flap 2272 and flange 2270 as required. In this way the solid section can be arranged to provide a continuous solid section around the perimeter of the tray such that a web of material such as pPVC
can be sealed to the solid section along a strip like path around what will become a perimeter of a finished package: The solid section may be located at the connection between the flap 2272 and the tray 2268 such that the flap 2272 and the tray 2268 can be hinged and folded so as to allow contact of tray flange 2270 with the tray 2268.
The apparatus is similar to a standard expanded polystyrene thermoforming machine, where two parallel platens are arranged in close relative proximity and with a powered device for moving the platens toward and away from each other.
Matched tools including two parts, are typically mounted onto the platens such that a heated sheet of expanded polystyrene or other suitable sheet, can be located between the platens and separated matched tool parts. The platens can be moved toward each other to a position that clamps the heated sheet between the two parts of the matched tool, thereby imparting a three dimensional profile that corresponds to the profile of the matched tool, into the sheet. After the sheet cools, the platens and the matched tool open and the profiled sheet can be removed automatically to allow the positioning of another sheet of EPS sheet therebetween. The EPS sheet is typically arranged in a continuous web.
As disclosed in the aforementioned description, trays can be processed in an automatic and continuous mode, such that any oxygen gas that may be retained in the EPS cell structure can be substantially removed and replaced with a desired gas such as nitrogen. The method and apparatus described herein, can also be incorporated 197°AMENDED SHEET

into standard thermoforming machinery used for production of thermoformed EPS
trays.
In a preferred embodiment, the trays with flaps can be produced on an automatic apparatus that heats a web of EPS sheet in an oven that substantially excludes oxygen so as to ensure that during any expansion of the EPS sheet during heating, immediately prior to thermoforming of the EPS sheet, oxygen gas will be substantially prevented from entering into the cell structure of the EPS
sheet. This can be achieved by providing a suitable gas such as nitrogen in the oven during the heating of the EPS sheet, the nitrogen gas being in direct contact with the surfaces of the EPS sheet. The EPS sheet can then be transferred directly into a forming station that is arranged to substantially exclude oxygen gas therefrom and furthermore, apply pressurized nitrogen gas to one side of the tray with flaps during the forming process and causing the nitrogen gas to pass into and through the tray and flaps during the forming process. Adhesive or solvent can then be applied to selected areas of the flaps and the tray, either before or after trimming the tray with flaps from the sheet of EPS material. Then automatically fold the flaps and mechanically apply sufficient pressure to the flaps to hold against the walls of tray and cause bonding between the flap and the tray at desired regions therebetween.
A preferred embodiment includes, but is not limited to automatically or manually performing the following steps:
1. Providing .a tray that may be thermoformed from expanded polystyrene (EPS) with flaps as shown in diagram. The tray having dimensions that will provide for the efficient use of the internal capacity of typical, refrigerated transport vehicles.
2. Exposing the tray to a gas that excludes oxygen and allowing the gas to exchange with any gasses contained within the cells of the EPS thereby substantially displacing any atmospheric oxygen from the cells.
3. Providing perishable goods onto the base of the tray. The perishable goods having been treated arid processed to substantially eliminate any bacteria thereon.
4. Sealing a gas permeable material such as pPVC to the flanges of the tray.
5. Folding and then sealing the flaps to flanges of the tray.
6. Placing the tray or a plurality of similar trays into a gas barrier master container.
AMENDED SHEET

7. Displacing substantially all atmospheric gas, and particularly atmospheric oxygen, within the master container, with a desired single or blend of desired gasses.
8. Sealing a lid over the opening in the master container to form a hermetically sealed package containing the trays with perishable goods and desired gas.
9. Placing the master container inside a carton such as can be manufactured from corrugated cardboard and enclosing the master container.
10. Locating a plurality of the closed cartons onto a standard (GMA
. specified) pallet (Dimensions of 40" x 48") so as to maximize the efficient use of the area provided by the pallet.
Tra~Materials of Construction A mufti-layer, co-extruded plastics sheet product extruded through an annular die is disclosed, including substantially amorphous polyester polymers, with additives, sinular, but not exclusively, to the structures shown in FIGURES

where at least one of the layers is a foamed polyester and where at least one or more other layers includes at least about 30% regrind material derived from the skeletal scrap remaining after prod~.~ction of thermoformed trays from the sheet, with the balance of the regrind layer including a chosen virgin amorphous polyester polymer.
FIGURE 242 shows a multilayer coextruded plastic sheet constructed according to the present- invention including five layers. Beginning from the uppermost layer 2900, the c~~-extruded first layer 2900 includes a mix of blended components about 50% Eastman 6763 and about 50% Eastman 19411. The first layer 2900 is about 0.001 inches thick. The second co-extruded layer 2902 includes Eastman 9921 and is about 0.0025" thick. The third co-extruded layer 2904 includes a blended mix of foamed Eastman 9663 and Eastmann additive G4ZZZ-3AZZ, and is about 0.012" thick. The fourth co-extruded layer 2906 includes Eastman 9921 and is about 0.0015" thick. The filth layer 2908 includes regrind material recovered from tray thermoforming processes, and is about 0.002" thick. The overall thickness of the sheet material shown in FIGURE 242 is about 0.018" thick.
FIGURE 243 shows a multilayer coextruded plastic sheet constructed according to the present invention. The sheet material includes four layers.
Starting from the uppermost layer, the first co-extruded layer 2909 includes a blended mix of about 60% Eastman 9921 and about 40% Eastman 6763. The first layer 2909 is about 0.002" thick. The second co-extruded layer 2910 includes a blended mix of 199'. AMENDED SHEET ~~=~~

foamed Eastman 9663 and Eastman additive G4ZZZ-3AZZ, and is about 0.011"
thick. The third co-extruded layer 2912 includes regrind material derived from skeletal scrap recovered from the tray thermoforming process, and is about 0.0015"
thick. The fourth co-extruded layer 2914 includes a blended mix of about 60%
Eastman 9921 and about 40% Eastman 6763 and is about 0.002" thick. The overall thickness of the material shown in FIGURE 243 is about 0.0165" thick.
FIGURE 244 shows a multilayer, coextruded plastic sheet including three layers. Beginning with the uppermost layer, the first co-extruded layer 2916 includes a blended mix of about 20% Eastman 6763, 50% Eastman 9921, and about 30% of regrind material. The first layer 2916 is about 0.0025" thick. The second co-extruded layer 2918 includes a mix of blended and foamed Eastman 9663 and Eastman additive G4ZZZ-3AZZ. The second layer 2918 is about 0.011" thick. The third co-extruded layer 2920 includes a mix of about 20% Eastman 6763, about 50%
Eastman 9921, and about 30% regrind material. The third layer 2920 is about 0.0025" thick. The overall thickness of the sheet material of FIGURE 244 is about 0.016" thick.
FIGURE 245 shows a multilayer, coextruded plastic material constructed according to the present invention. The sheet material includes five layers.
Beginning with the upp:,rmost layer, the first co-extruded layer 2922 includes a blended mix of about 50% Eastman 19411 and about 50% Eastman 6763. The first layer 2922 is about 0.001" thick. The second co-extruded layer 2924 includes a blended mix of about 90% Eastman 9921 and about IO% of regrind material derived from skeletal scrap recovered from the tray thermoforming process. The second layer 2924 is about 0.006" thick. The third co-extruded layer 2926 includes a blended mix of about 90% of regrind material derived from skeletal scrap from the tray thermoforming process and about 10% of Eastman 9921. The third layer 2926 is about 0.003 inches thick. The fourth co-extruded layer 2928 includes a mix of blended and foamed Eastman 9663 and Eastman additive G4ZZZ-34ZZ. The fourth layer 2928 is about 0.019 inches thick. The fifth co-extruded layer 2930 includes a mix of about 90% Eastman 9921 and about 10% of regrind material. The fifth layer 2930 is about 0.0005" thick. The overall thickness of the sheet material of FIGURE 245 is about 0.03" thick.
FIGURE 246 shows a multilayer, coextruded plastic sheet material constructed according to the present invention. The sheet material includes five layers. Beginning with the uppermost layer 2932, the layer 2932 includes about 50%
AMENDED SHEET

blended Eastman 6763 and about 50% Eastman 19411. The first co-extruded layer 2932 is about 0.0015" thick. The second co-extruded layer 2934 includes about 10% blended Eastman 9921 and about 90% regrind materials derived from skeletal scrap recovered from tray thermoforming process. The second layer 2934 is S about 0.0015" thick. The third co-extruded layer 2936 includes blended and foamed Eastman 9663 and Eastman additive G4ZZZ-3AZZ. The third layer 2936 is about 0.010" to about 0.019 thick. The fourth co-extruded layer 2938 includes about 10%
blended Eastman and about 90% regrind materials derived from skeletal scrap recovered from tray thermoforming process. The fourth layer 2938 is about 0.0015"
- 10 thick. The fifth co-extruded layer 2940 includes about 5U% blended Eastman 6763 and about 50% Eastman 19411. The fifth layer 2940 is about 0.0015" thick. The overall thickness of the sheet material of FIGURE 246 is about 0.016" thick.
T_ray Materials of Construction . Refernng now to FIGURE 247, a cross-sectional view through a portion of 15 material constructed according to the present invention is shown. Polyester sheet material is co-extruded in a three layer construction having two outer layers 2000 and 2002 of Eastman APET 9921 (about 0.002" thick, each) and an inner layer 2004 of foamed Eastman 9663 with an Eastman recommended quantity of Eastman melt strength enhancer G4ZZZ-3AZZ. Inner layer 2004 is about .015" thick. Inner 20 layer 2004 is foamed with a suitable quantity of nitrogen gas, substantially excluding air from foam cells. The total thickness of co-extruded sheet is approximately .019"
thick. The gas barner properties of the outer layers of Eastman 9921 are such that air will be substantially prevented from permeating into the inner layer of foamed polyester. Sections of the material have been compressed so as to solidify the inner 25 layer of foamed Eastman Polyester 9663 with the melt strength enhancer.
Both edges of co-extruded sheet are sealed together, by any suitable sealer, preferably immediately after co-extrusion and prior to winding onto a roll. Sealing edges substantially prevents air from permeating into inner layer 2004 of foamed polyester.
Material is wound onto a roll and is then stored, most preferably in a temperature 30 controlled storage area and at a temperature below 10°C. Following storage, the roll of co-extruded polyester material is substantially converted into trays of a desired profile and size by a thermoforming apparatus such as shown in FIGURE 248 where a cross-section through such a tray is shown. Thermoforming apparatus includes a typical method of pre-heating the sheet, clamping convenient rectangular sections of 35 the heated sheet and vacuum (or pressure) forming the sheet onto a suitable tray 1 ' AMENDED SHEET

forming mould, however, at the moment of thermoforming and prior to cooling of the sheet, a suitably shaped tool, that may also be heated to a desired temperature, can be pressed against the flange regions, or edge of the flange regions, of the trays during the forming process and thereby compress the flanges. Most desirably the compression of the flanges will cause substantially all gas to be expelled from the inner layer of foamed polyester in the flange regions only. Said trays are severed, by a cutting member, from the sheet of material such that the edges of the flange are substantially sealed together. Such a process can provide a tray with gas barrier outer layers of polyester and an inner foamed layer of polyester such that the inner layer is substantially prevented from direct contact with ambient air. In this way ambient air will be substantially prevented from permeating into the inner layer and also providing a gas barrier to substantially prevent nitrogen gas within the foam cells from escaping and exchanging with air.
FIGURE 249 shows a cross-section of the material showing an upper 2000, an inner 2004, and a lower 2002 layer. The upper layer 2000 is about 0.002"
thick, the inner layer 2004 of foam polyester is about 0.15 thick and the lower layer 2002 is . about 0.002" thick. FIGURE 250 shows the material of FIGURE 249 when the material is compressed according to the present invention. Outer layers 2000 and 2004 remain substantially about 0.002" thick, but inner layer 2004 has been compressed to about 0.001" thick.
Tray Rib Forming_Apparatus Referring now to FIGURE 251 a tray with ribs formed in accordance with this invention is shown. The inventor has previously invented a system whereby a low oxygen modified wing system including a "master container" (container) with trays therein, is evacuated. During evacuation, all contents of the container are exposed to a very high level of vacuum, furthermore, the pressure of nitrogen gas, contained within the inner layer foam cells which is approximately equal to the prevailing ambient atmospheric pressure, will exert an "exploding" pressure against the inner surfaces of the outer layers. Pressure can cause distortion resulting in, at least, partial separation of in.~er layer from outer layers. Furthermore, in extreme cases tray walls could rupture and burst open. Clearly, such an event is undesirable and this present invention provides a method, equipment and production of a tray (product), that can minimize this undesirable event. By including regions of dense material, the inventor has discovered that trays can withstand the low pressure atmosphere used in the above application.
~p2' AMENDED SHEET

FIGURE 251 shows a three dimensional section of a tray that has been thermoformed from sheets of material similar to those described in the structures shown in FIGURES 242-246. FIGURE 253 is a view of a section through a wall of the tray with ribs 2100 provided therein. Referring now to FIGURE 254, an apparatus that can be used to provide ribs 2100 is shown. Ribs can be provided by closing heat bank 2118 onto wall of tray 2114 when tray 2114 is supported by pad 2116. Heat bank 2118 can thereby weldlheat seal a portion of the inner surface of the outer layers 2108, 2112 to each other after compression of inner layer foam cells such that the outer layers become welded/ heat sealed to each other at the point of contact. Radius 2106 of ribs 2100 as shown in FIGURE 253 ran be adjusted and also the distance of pitch from radius to radius can also be adjusted by production of equipment providing the desired adjustments. Adjustments can be made in order to provide for optimized configuration of radius 2106 and pitch such that the exploding effect of exposure to high vacuum that could otherwise result in the rupturing of the tray, as described above can be minimized.
In a preferred embodiment, an apparatus for compressing a web of . material 2124 to provide ribs therein is detailed in FIGURE 255. Heat banks and 2124 are arranged, as required, in a mechanism so as to enable compressing of material therebetween and thereby bond outer layer 2126 and inner layer 2130 together with compressed foamed polyester layer 2128 therebetween. A cross-sectional view through a portion of compressed material 2124 with an aperture punched therethrough is shown in FIGURE 256. Additionally a mechanism for providing perforations in an outer layer of a tray wall thermoformed from the material shown in FIGURE 247, is also detailed in FIGURE 257. Perforations can be provided to allow communication and transfer of gasses from the foamed polyester layer 2128 and through perforations 2136.
Rib Fornling Apparatus Referring now to FIGURE 258, a cross-section through a tooling assembly of tool parts 2200 and 2202, with a section of material 2124 (after processing/forming), is shown. Tooling part 2200 is temperature controlled by passing liquid 2206 through conveniently located passageways shown as ports 2204. Liquid is preconditioned to a specified and desired temperature and is passed through ports 2204 at a rate sufficient to control the temperature of tooling part 2200.
Similarly part 2002 can be temperature controlled in a similar manner (not shown).
Evacuation holes 2208 are located in part 2200 and evacuation ports 2210 are also DEMANDE OU BREVET VOLUMINEUX
LA PRESENTE PARTIE DE CETTE DEMANDE OU CE BREVET COMPREND
PLUS D'UN TOME.

NOTE : Pour les tomes additionels, veuillez contacter 1e Bureau canadien des brevets JUMBO APPLICATIONS/PATENTS
THIS SECTION OF THE APPLICATION/PATENT CONTAINS MORE THAN ONE
VOLUME

NOTE: For additional volumes, please contact the Canadian Patent Office NOM DU FICHIER / FILE NAME
NOTE POUR LE TOME / VOLUME NOTE:

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A method of packaging goods, characterized in that the goods are packaged in a selected gas.

2. The method of Claim 1, comprising providing a base, placing goods over said base, applying a web of oxygen permeable material over said goods, and locating said packaging in a master container by stacking directly one above another without any other packaging materials therebetween with a desired gas between packaging which will enhance the keeping properties of said goods by contacting the surface of said goods and sealing said lid to said master container with said gas therebetween, said web of oxygen permeable material then holding said goods relative to said packaging and being of a size permitting viewing of a major portion of an upper surface of said goods and allowing said gas to contact said goods by permeating said web.

3. The method as claimed in Claim 2, wherein said web is stretched over a portion of said goods in each package and held to said packaging so said web is maintained stretched to firmly hold said goods to the packaging.

4. The method as claimed in Claim 2, wherein a machine readable barcode is applied to said tray prior to applying said web on a portion of said tray that is visible after applying said web to said packaging whereby at a future point in time said barcode can be machine read and human readable information can be applied to the web.

5. The method as claimed in Claim 2, wherein said goods are meats and said gas is typically 80% CO2 and more than 19% N2 and less than 0.03% O2.

6. The method as claimed in Claim 2, comprising selecting.the height from said bottom of said package to said lip of said gas permeable tray web to be higher than the height of said goods, and effecting sealing so said gas permeable web is not contacting the upper surface of said goods when said goods are on said remaining web.

7. The method as claimed in Claim 1, comprising the steps of: providing in a master container;
providing packaged trays having perforations to allow evacuation and flushing of gases, wherein the trays are stacked inside the master container;
evacuating the master container and trays of ambient atmosphere;
flushing the master container and trays with a selected gas; and hermetically sealing the master container.

8. The method as claimed in Claim 1, comprising;
providing sealing plates, wherein the plates have apertures for locating trays;
wherein the apertures are sized smaller than tray dimensions, so as to inwardly urge the tray sidewalls, locating a tray with a flange a within the aperture; and sealing a web material to the flange while the tray is in the inwardly urged configuration.

9. The method as claimed in Claim 1, including the steps of:
providing a substantially gas barrier master container comprising a rectangular cavity with a space enclosed by a base and four upwardly disposed walls terminating at a flange; said flange being displaced from said base in distance equal to a height and said cavity having a length and a width. Said height, length and width so arranged to allow enclosure of a volume of packaging trays that are directly stacked together in multiple layers and in a grouping. Said grouping having height, length and width dimensions that are arranged such that said grouping of stacked trays will neatly fit within said space;
providing a range of different sized packaging trays each of which can be stacked together and having dimensions substantially equal to said grouping;
wrapping a plurality of said trays with a web of suitable plastics material and enclosing goods therein;
stacking wrapped trays with goods arranged in a grouping into the master container space so as to substantially fill the cavity so that a minimum free space remains and wherein said volume of free space is substantially similar or less than the total volume of goods contained in the master container cavity;
flushing the master container and free space with a volume of selected gas, so as to displace substantially all air contained therein;
hermetically sealing a gas barrier lid material to the flanges of said master container and over said space so as to hermetically seal said master container with trays, goods and selected gas in said space; and placing said master container in a carton and sealing therein.

10. A method of processing goods, characterized in that the goods are brought in contact with a selected gas to enhance the keeping qualities of the goods.

11. The method as claimed in Claim 10, comprising:
placing meat portions in a pressure vessel that is substantially filled with at elevated pressure to dissolve CO2 in liquids and oils; and packaging the meat portions with an overwrap web such that the web is in contact with a portion of the meat so as to hold toward the meat portion toward the base, such that when stacked below another similarly packaged tray, the met does not contact the underside of the tray above it.

12. The method as claimed in Claim 10, comprising:
placing pre-rigor mortis meat in a perforated mold;
chilling the meat, but not allowing muscle fiber shortening to occur;
placing the molds with meat in contact with CO2;
storing the mold with meat to allow a quantity of CO2 to dissolve into the meat; and packaging the meat.

13. The method as claimed in Claim 10, comprising:
a) placing goods in an enclosed vessel containing a gas to enhance the keeping of the goods;
b) allowing the gas to contact and dissolve in water, liquids and oils present in the goods;
c) restricting the formation of oxymyoglobin in substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the goods, with the gas;
d) providing a retail package comprising a substantially gas barrier plastics pouch; and e) transferring the goods from the vessel into a said pouch without allowing significant formation of oxymyoglobin on surface of the goods.

14. The method as claimed in Claim 10, having the following steps:
a) placing goods in an enclosed vessel containing a gas to enhance the keeping of the goods;
b) allowing the gas to contact and dissolve in water, liquids and oils present in the goods;

c) restricting the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the goods, with the gas;
d) providing a retail package including two overlapping webs with a space therebetween, with at least one of the webs being gas permeable;
and e) transferring the goods from the vessel to a position between the two overlapping webs and into the space without allowing significant formation of oxymyoglobin on surface of the goods.

15. The method as claimed in Claim 14, wherein said two overlapping webs are sealed so as to provide a hermetically sealed and liquid tight package.

16. The method as claimed in Claim 14, wherein the goods are fresh meats and the gas is a substantially oxygen free gas

17. The method as claimed in Claim 10, comprising the steps of placing meat in a pressure vessel containing carbon dioxide; and dissolving carbon dioxide in the meat at a pressure above ambient pressure.

18. The method as claimed in Claim 17, further comprising packaging the meat in a tray and sealing with a permeable web.

19. The method as claimed in Claim 17, wherein the pressure is about 50 psi or greater.

20. The method as claimed in Claim 17, further comprising the step of controlling the temperature of the pressure vessel between about 25 degrees F
and about 40 degrees F.

21. The method as claimed in Claim 18, further comprising the step of loading the packaged tray in a master container.

22. The method as claimed in Claim 17, further comprising grinding the meat.

23. The method as claimed in Claim 10, comprising:
cutting meat containing deoxymyoglobin in an atmosphere substantially deficient of oxygen; and inhibiting contact between the cut meat surface with oxygen.

24. A method of processing and packaging goods, characterized in that the goods are brought in contact with a selected gas during processing and packaging that will enhance the keeping qualities of the goods.

25. The method as claimed in Claim 24, comprising:
a) placing goods in an enclosed vessel containing a gas to enhance the keeping of the goods;
b) allowing the gas to contact and dissolve in liquids and oils present in the goods;
c) restricting the formation of oxymyoglobin by substantially displacing ambient air, that may otherwise contact the surface of the goods, with the gas;
d) providing a retail package including two overlapping webs with a space therebetween, with at least one of the webs being gas permeable;
and e) transferring the meats from the vessel to a position between the two overlapping webs and into the space without allowing significant formation of oxymyoglobin on surface of the meats.

26. The method as claimed in Claim 25, wherein the goods are fresh red meats and the gas is a substantially oxygen free gas.

27. The method as claimed in Claim 24, comprising:
a) locating and processing the fresh red meat containing de-oxymyoglogin in a vessel with a gas that is substantially free of oxygen;
b) transferring the fresh red meat, with de-oxymyoglobin, from the vessel and into a substantially gas barrier package that contains a substantially oxygen free gas;
c) sealing the fresh red meat, with de-oxymyoglobin, in the package; and d) performing steps a), b) and c) in such a manner so that any contact of the fresh red meat containing de-oxymyoglobin with atmospheric oxygen during the transfer, prior to subsequent exposure of the red meat with de-oxymyoglobin to ambient atmospheric gas after packaging, will be minimized to the extent that any oxymyoglobin that may consequentially become present at the surface of the fresh red meat, as a result of brief contact with any atmospheric oxygen, will not be subsequently cause generation of metmyoglobin to an extent that is visibly recognizable as a brown discoloration by human eye.

28. The method as claimed in Claim 24, including the steps of:
a) locating and processing the fresh meat containing de-oxymyoglogin in a vessel with a gas that is substantially free of oxygen.
b) transferring the fresh red meat, with de-oxymyoglobin, from the vessel and into a substantially gas barrier package that contains a substantially oxygen free gas.

c) sealing the fresh red meat, with de-oxymyoglobin, within the package;
d) performing steps a), b) and c) in such a manner so that any contact of the fresh - meat containing de-oxymyoglobin with atmospheric oxygen during the transfer, prior to subsequent exposure of the red meat with de-oxymyoglobin to ambient atmospheric gas after packaging, will be minimized to the extent that any oxymyoglobin that may consequentially become present at the surface of the fresh red meat, as a result of brief contact with any atmospheric oxygen, will not subsequently cause generation of significant quantities of metmyoglobin to an extent that is visibly recognizable as a brown discoloration by human eye.

29. The method as claimed in Claim 24, comprising the following steps:
a) transferring goods into an enclosed first vessel and a gas to enhance the keeping of the goods, and wherein said first vessel is substantially sealed so as to inhibit entry of atmospheric gas therein;

b) controlling gas pressure and temperature in said first vessel and thereby controlling dissolving of said gas into said goods;
c} mixing of said goods;
d) inhibiting the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the goods, with the gas;
e) transferring said goods from said first pressure vessel into a second pressure vessel; and f) transferring said goods into a substantially gas barrier package without allowing significant formation of oxymyoglobin on surface of the goods, and hermetically sealing said goods therein.

30. The method as claimed in Claim 24, comprising the following steps:
a) transferring ground meats into an enclosed first vessel with a gas to enhance the keeping of the ground meats, and wherein said first vessel is substantially sealed so as to inhibit entry of atmospheric gas therein;
b) controlling gas pressure and temperature in said first vessel and thereby controlling dissolving of said gas into said ground meats;
c) mixing of said ground meats;
d) inhibiting the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the ground meats, with the gas;
e) transferring said ground meats from said first vessel into a second vessel via pumping means in a substantially continuous stream through an enclosed conduit and substantially exclude voids in said stream;
f) measuring fat content of said ground meats continuously during transfer from said first vessel to said second vessel;
g) mixing said ground meats; and h) transferring said ground meats into a substantially gas barrier package without allowing significant formation of oxymyoglobin on surface of the goods, and hermetically sealing said ground meats therein.

31. The method as claimed in Claim 24, the method having the following steps:
a) treating goods with agents to reduce the quantity of bacteria present in said goods and ensuring that said quantity of bacteria does not exceed the maximum acceptable level for goods intended for human consumption, as required by prevailing government regulations;

b) transferring goods into an enclosed vessel containing a gas to enhance the keeping of the goods;

c) providing a package including overlapping gas barrier web material with a space therebetween;

d) providing a gas in said space; gas selected for having properties to enhance the keeping of the goods;

e) transferring the goods from the vessel to a position between the overlapping gas barrier web material and into the space;

f) hermetically sealing said overlapping gas barrier web material to enclose said goods and said gas therein, to provide a finished package; and g) storing said finished package in a temperature controlled space ensuring that the quantity of bacteria present in said goods does not exceed the maximum acceptable level for goods intended for human consumption, as required by prevailing government regulations, prior to removing said goods from said finished package for use.

32. The method as claimed in Claim 24, the method having the following steps:
a) providing a first quantity of fresh meat portions comprising proportions of fat, water and protein content;

b) providing a second quantity of fresh meat portions comprising proportions of fat, water and protein content;

c) treating both first and second quantities of fresh meat with agents to reduce the quantity of bacteria present in said goods and ensuring that said quantity of bacteria does not exceed the maximum acceptable level for goods intended for human consumption, as required by prevailing regulations;

d) transferring said first quantity of fresh meat into a first enclosed vessel containing a gas to enhance the keeping of the goods and mixing said goods thereby;
e) transferring said second quantity of fresh meat into a second enclosed vessel containing a gas to enhance the keeping of the goods and mixing said goods thereby;
f) measuring at least the fat content of said first quantity of fresh meat while transferring into a third enclosed vessel containing a gas to enhance the keeping of the fresh meat and mixing therein, wherein method of transfer is provided via an enclosed conduit connected directly to said third vessel, through which said first quantity of fresh meat is transferred;
g) measuring at least the fat content of said second quantity of fresh meat while transferring into said third enclosed vessel and mixing therein with said first quantity of fresh meat, wherein method of transfer is provided via an enclosed conduit connected directly to said third vessel, through which said second quantity of fresh meat is transferred;
h) providing a package including overlapping gas barrier web material with a space therebetween;
i) transferring the combined first and second streams of fresh meat from said third vessel to a position between the overlapping gas barrier web material and into the space; and j) hermetically sealing said overlapping gas barrier web material to enclose said fresh meat, and excluding substantially all ambient air therefrom.

33. The method as claimed in Claim 24, comprising the processing or packaging of meat in a substantially enclosed series of connecting conduits, vessels and enclosures wherein any free space therein is substantially filled with a selected gas.

34. Apparatus to provide finished processed and packaged goods according to the method of Claim 33.

35. A method as claimed in Claim 33 wherein more than two streams of fresh meat are processed, measured and packaged.

36. The method as claimed in Claim 24, comprising of an apparatus for the removal of oxygen in a step in the processing or packaging, followed by the introduction of a suitable gas or agent at a suitable pressure and temperature, and for a suitable time period to cause the dissolution of the gas or agent into the beef, such that upon return of the beef to ambient temperature and pressure, the gas or agent is released from the beef, thereby delaying the onset of bacterial growth and the formation of metmyoglobin on the beef.

37. The method as claimed in Claim 24, comprising of a step in the processing or packaging of removing oxygen from in and around the beef, followed by the introduction of a suitable gas or agent into the beef at a suitable pressure and temperature, and for a suitable time period to cause the dissolution of the gas or agent into the beef, such that upon return of the beef to ambient temperature and pressure, the gas or agent is released from the beef, thereby delaying the onset of bacterial growth and the formation of metmyoglobin on the beef.

38. A goods packaging tray including a base with upwardly extending side walls that terminate at a flange that extends around a perimeter of the tray to provide a cup-shaped recess, the tray having at least one extension connected to the flange at a hinge, the extension including a cup-shaped flap that can be folded about the hinge and be sealed to at least one of the upwardly extending side walls to provide an enclosed space, the tray having apertures at a base of the side wall of the tray so as to provide communication between the enclosed space and the tray that will allow liquids to pass from the tray cup-shaped recess to the enclosed space.

39. Packaging for perishable goods, comprising:
a stackable base over which goods are placed, the base having upwardly extending walls terminating at a peripheral lip extending around a perimeter of said base, and wherein each wall comprises an inner layer and an outer layer of plastics material, wherein said outer layer is substantially vertical to said base and said inner wall extends upwardly and away from said base, thereby providing a space between said inner and outer walls;
a web of gas permeable material, having two parallel edges, wherein said web is first sealed to itself along a path that is close to said parallel edges to form a tubular section, positioned with said base enclosed within said tubular section, and wherein said tubular section is stretched prior to further sealing to itself along second and third substantially parallel paths close to opposite ends of an end of said tubular section and perpendicular to said first seal, so as to hermetically seal and enclose said base, and allowing said tubular section to shrink after severing from said web, and firmly contact portions of the outer surface of said base, walls and peripheral lip;
space within said tubular section with said goods and said base;
a gas in said space, said gas selected for enhancing preservation of the packaging goods by contacting the surface of said goods;
said gas contacting said goods by permeating said tubular section stretched over said goods and held to said packaging so said tubular section is maintained stretched to firmly contain said goods within the packaging; and said tubular section permitting viewing of a major portion of an upper surface of said goods.

40. A master container, wherein one or more packages of Claim 39 are stacked together in a second substantially gas barrier master container fabricated from plastics material and having a substantially flat base with upwardly extending walls terminating at a lip extending around the perimeter of said base to provide a continuous wall, and thereby providing a cavity above said base and within said walls, into which said packages are stacked, and thereby fill said cavity with said first packages and space therebetween.

41. Master container as claimed in Claim 40, wherein a lid of substantially gas barrier web material is hermetically sealed to said lip after providing a suitable gas or blend of selected gases in said space and substantially displacing any residual oxygen.

42. Master container as in Claim 41, wherein an oxygen absorbing agent is provided into said space prior to hermetically sealing said lid to said lip.

43. Packaging as claimed in Claim 39, wherein said peripheral lip configuration is displaced in height from said base, and wherein said goods are contacting said base, and a portion of the upper surface of said goods is above the upper surface of said lip, and said tubular section extends over the top of said goods and is held to a portion of the peripheral lip and a portion of the upper surface of said goods.

44. Packaging as claimed in Claim 39, wherein said base has a bottom displaced in height from a peripheral lip and wherein said goods are contacting said bottom, and a portion of said tubular section held to said packaging at a position below a portion of the top of said goods.

45. Packaging as claimed in Claim 39, wherein said tubular section is held to the bottom of said base.

46. Packaging as claimed in Claim 39, wherein a portion of the top of goods is below said peripheral lip and a portion of the top of said goods is above a portion of said peripheral lip.

47. Packaging as claimed in Claim 39, wherein the top of said goods is below said peripheral lip and there is provided a tubular section of gas permeable plastics material held to said peripheral lip with a space between said tubular section and the upper surface of said goods and a gas in said space for enhancing keeping of said goods by permeating said tubular section and wherein said package is removable from said gas barrier container and whereby oxygen can permeate said tubular section from atmosphere to bloom said goods to a red color following discoloring of said goods from extended packaging in an oxygen depleted gas.

48. Packaging as claimed in Claim 39, wherein packaging materials used to manufacture said lid and said base have been treated with a bactericide that remains effective in killing bacteria, virus, and fungi after use of said base in packaging.

49. Packaging including a base that comprises a thermoformed, nestable, tray with a floor, walls and at least one flap attached by a hinge to a wall, wherein said flap comprises a cup shaped flap with at least one depression and a continuous substantially flat section at a path close to the perimeter of said flap, such that when folded against the corresponding wall a hermetic seal can be provided between said flap flat section and said wall enclosing a space between said walls.

50. Packaging as claimed in Claim 49, wherein capsules of any chosen agent or substance may be provided in said space between said walls.

51. Packaging as claimed in Claim 49, wherein apertures may be provided along the outer edge of said tray floor and at the lower section of said inner wall and thereby providing a communication between said cavity and said space between said walls.

52. Packaging as claimed in Claim 49, wherein a selected gas is provided in said space and all other spaces in said packaging and maintained at ambient pressure for a period of time after hermetically sealing said flaps.

53. Packaging as claimed in Claim 49, wherein a selected gas is provided in said space and maintained at a pressure above ambient pressure for a period of time after hermetically sealing said flaps.

54. Packaging as claimed in Claim 49, wherein a chosen agent or substance comprises a bactericide contained in a capsule that can be ruptured by exposure to micro wave, a magnetic field, or Radio Frequency from a remote source.

55. Packaging as claimed in Claim 49, wherein a web of plastics material containing an oxygen absorbing agent is laminated to a surface of said tray prior to fabrication, wherein said oxygen absorbing agent contained in said web of plastics material is only rendered substantially active and capable of absorbing oxygen after exposure to a suitable micro wave source, magnetic field or radio frequency from a remote source.

56. Packaging as claimed in Claim 49, wherein a web of plastics material containing any desirable agent that can perform any desirable function such as a bactericide, is laminated to a surface of said tray prior to fabrication, wherein said oxygen absorbing agent contained in said web of plastics material is only rendered substantially active and capable of absorbing oxygen after exposure to a suitable micro wave source, magnetic field or radio frequency from a remote source.

57. Packaging as claimed in Claim 49, wherein said chosen agent or substance comprises an oxygen absorbing ferric element or gel contained in a capsule wherein said capsule can be ruptured by exposure to micro wave, a magnetic field, or Radio Frequency from a remote source after package assembly thereby providing a means to absorb any residual O2 that may be present in the interstices of packaging materials used in the packaging.

58. Packaging as claimed in Claim 49, wherein said first packaging tray is manufactured from a foamed plastic, wherein said chosen agent or substance comprises an oxygen absorbing ferric element in granule/powder form applied to a portion of the inner surfaces of space between said first package walls, and wherein granules are individually and substantially enclosed in a covering layer of water barrier material wherein said water barrier material can be ruptured or modified by exposure to micro wave, a magnetic field, or Radio Frequency from a remote source after package assembly thereby allowing gas contact of said ferric element to gases enclosed in said first package and thereby providing a means to absorb any residual O2 that may be present in the interstices of packaging materials used in the packaging.

59. Packaging as claimed in Claim 49, wherein said walls are arranged such that when more than one packaging trays are stacked together in a single stack with a tray located directly above another, the base of an upper tray contacts the lip of the lower tray immediately below it such that there is a minimized distance or space between the surface of the underside of said upper tray and the upper surface of the portion of the tubular section web material directly below the upper tray.

60. Packaging as claimed in Claim 39, wherein one or more apertures are provided in the tubular section web at a location adjacent to said outer walls and in such a position that will allow communication of gas between the tray cavity and external to said package but also restricting communication of any free liquids that may be in said cavity.

61. Packaging as claimed in Claim 39, wherein portions of said tubular section web is printed with inks, and/or heat activated adhesives and/or pressure sensitive adhesives whereby when heat and or pressure is applied to urge portions of said web against any contactable portion of said tray a bonding will occur therebetween at selected portions of said web and said tray.

62. Packaging as claimed in Claim 39, wherein said tubular section web is fabricated from plasticized polyvinyl chloride.

63. Packaging as claimed in Claim 39, wherein said tubular section web is fabricated from any suitable transparent web of material.

64. Packaging as claimed in Claim 39, wherein said tubular section web is fabricated from any suitable transparent web of material that has been treated with anti-fog agents.

65. A goods packaging tray including a base with upwardly extending side walls that terminate at a flange that extends around a perimeter of the tray to provide a cup-shaped recess. The tray having at least one extension connected to the flange at a hinge. The extension including a cup-shaped flap that can be folded about the hinge and be bonded to at least a portion of one of the upwardly extending side walls to provide an enclosed space.

66. A package as in Claim 65, having apertures at a base of at least a portion of one side wall of the tray so as to provide communication between the enclosed space and the tray that will allow liquids to pass from the tray cup-shaped recess into the enclosed space.

67. A packaging tray for use in the method of Claim 1, comprising;
a thermoformed web of material, wherein the web is formed to have a bottom and at least four sides, wherein at least two of the sides are reclining, at least a first member, integrally formed with the tray, wherein the member is movable between a first position and a second position, and wherein at the second position, the member is substantially level with the upper horizontal surface of the tray to provide a support.

68. A packaging tray for use in the method of Claim 1, comprising:
a thermoformed web of material, wherein the web is formed to have a bottom and four sides, a perforation in the tray allowing evacuation and flushing of gases between the interior of the and and ambient atmosphere.

69. A packaging tray for use in the method of Claim 1, comprising:
a web of thermoformed material, comprising:
a bottom and four sidewalls extending horizontally from the bottom base to form an opening, wherein the opening is surrounded by a flange on at least two sides, and wherein the sidewalk are formed with areas of higher concentration material.

70. A package for perishable goods for use in the method of Claim 1, comprising:
a first web defining a base;
a plurality of first walls extending upwardly and outwardly from the base to define a depression in the web with an opening, wherein the perimeter of the opening defines a lip;
a plurality of second walls extending from the lip downward to define a space between a wall from the first walls and a wall from the second walls, wherein at least one of the second walls includes a ledge substantially level with the web base; and a second web of gas-permeable material, wherein the second web is sealed or stretched on the first web in a modified atmosphere environment.

71. A tray for use in the method of Claim 1, wherein a plastics web used to produce the tray comprises a sheet material that has been extruded from any suitable source of polymer, such as polypropylene, but with a quantity of suitable bactericide provided therein that remains active and capable of reducing levels of bacterial contamination such as bacteria contained in goods in contact with a surface of the tray.

72. A packaging tray for use in the method of Claim 1, comprising:
a thermoformed web of material including a bottom and four sides; and a first and second flap located at opposite sides, wherein the first and second flaps are foldable between a first and second position.

73. A package for perishable goods for use in the method of Claim 1, comprising:
a first web defining a base;

a plurality of first walls extending upwardly and outwardly from the base to define a depression in the web with an opening, wherein the perimeter of the opening defines a lip;
a plurality of second walls extending from the lip downward to define a space between a wall from the first walls and a wall from the second walls, wherein at least one of the second walls includes a ledge substantially level with the web base; and a second web of gas-permeable material, wherein the second web is sealed or stretched on the first web in a low oxygen environment.

74. Apparatus for producing packaging trays, comprising:
means for thermoforming plastics sheet to form and trim a packaging tray with a base and upwardly extending side walls that terminate at a flange that extends around a perimeter of the tray to provide a cup-shaped recess with at least one extension connected to the flange at a hinge including a cup-shaped flap that can be folded about the hinge and be sealed to at least one of the upwardly extending side walls to provide an enclosed space;
means to seal the flap to the tray wall around a perimeter of the flap; and means to provide apertures in the side wall of the tray recess so as to provide a communication between the enclosed space and the tray recess.

75. Apparatus for producing packaging trays, comprising:
means for thermoforming plastics sheet to form and trim a packaging tray with a base and upwardly extending side walls that terminate at a flange that extends around a perimeter of the tray to provide a cup-shaped recess with at least one extension connected to the flange at a hinge including a cup-shaped flap that can be folded about the hinge and be sealed to at least one of the upwardly extending side walls to provide an enclosed space;

means to seal the flap to the tray wall around a perimeter of the flap; and means to provide apertures in the side wall of the tray recess so as to provide a communication between the enclosed space and the tray recess.

76. An apparatus for forming trays comprising:
a first chamber, having a porous mold for forming a web; and a second chamber, suitably arranged to move toward the first chamber; and a plurality of ports for attaching to a vacuum source and a preferred gas.

77. An apparatus for sealing a master bag, comprising:
a first vacuum chamber;
a second vacuum chamber suitably configured to mate with the first vacuum chamber enclosing a container with packages therein; and a web dispenser to pass a web over the opening of the master container; and a sealer to seal the web to the master container.

78. Apparatus for packaging perishable goods in a gas environment to enhance the keeping properties of said goods comprising means for stacking packages in a master container, evacuating said master container without rupturing said packages and providing said gas therein applying a lid and hermetically sealing to said master container said gas contacting said goods by permeating said web and being of a size permitting viewing of a major portion of an upper surface of said goods.

79. Apparatus for printing or applying a method of packaging perishable goods in packaging so said goods will be in a gas environment which will enhance the keeping properties of said goods said method comprising providing a base, placing goods over said base, applying a web of oxygen permeable material over said goods, and locating said packaging in a master container by stacking directly one above another without any other packaging materials therebetween with a desired gas between packaging which will enhance the keeping properties of said goods by contacting the surface of said goods and sealing said lid to said master container with said gas therebetween, said web of oxygen permeable material then holding said goods relative to said packaging and being of a size permitting viewing of a major portion of an upper surface of said goods and allowing said gas to contact said goods by permeating said web.

80. An apparatus for automatically stacking and locating packages in a master container wherein a portion of the top of goods in each package is below said peripheral lip and a portion of the top of said goods is above a portion of said peripheral lip and wherein there is no other packaging materials provided between the packages and wherein the underside of an upper package does not contact the goods contained in a lower package.

81. A goods master container, said master container having two gas barrier webs and intermediate gas permeable webs, goods between a pair of gas permeable webs and said gas permeable webs being sealed together by a seal extending completely around and near the perimeter of the packaging, a gas sealed in a gas barrier manner in the master container and contacting said goods, said gas selected for enhancing the keeping of said goods, and wherein said pair of gas barrier webs comprises a gas permeable webs that said goods are between is of tray like configuration with a bottom displaced in height from a peripheral lip, said seal being on said peripheral lip and wherein said height is greater than the height of said goods so when said goods are resting on said gas barrier web said gas permeable web is not touching said goods.

82. A goods package as claimed in Claim 81, wherein said gas permeable web has openings therein to allow said gas to pass through said openings.

83. A goods package as claimed in Claim 81, wherein said gas permeable web is stretched and said package is sealed with it stretched so it remains taut over said bottom.

84. A goods package as claimed in Claim 81, wherein said gas is typically 80% CO2 and more than 19% N2 and less than 0.05% O2.

85. A method for sealing a master bag container, comprising:
providing a first and a second vacuum chamber, wherein one of the chambers includes a heat bank, the first and second chambers being opposedly configured to open and close, locating the master bag container within the first or second chamber, when chambers are in open position, wherein the master bag defines an opening;
extending a web across the opening of the bag;
closing the first and second chamber to define an enclosed space;
evacuating the enclosed space;
flushing the enclosed space; and sealing the web to the bag.

86. Apparatus for packaging goods in a gas environment to enhance the keeping of said goods, comprising a gas flushing and sealing chamber means for holding a first web of a gas barrier material with said goods over said first web, and characterized by means for feeding an intermediate web of gas permeable material over said first web, and means for applying a further web of gas barrier material over said first web, and means for applying a further web of gas barrier material over said first web, said gas flushing and sealing chamber being closable to bring both webs together prior to any of those webs being sealed together at a seal path near a perimeter of the packaging, and means for introducing a gas to enhance the keeping of said goods into said gas flushing and sealing chamber and sealing means in said gas flushing and sealing chamber for then sealing both webs together in said gas flushing and sealing chamber with said gas sealed in the resulting master container package.

87. Apparatus for packaging perishable goods as claimed in Claim 86, characterized that said first web has a bottom displaced in height from a peripheral lip and wherein said means for holding said first web comprises a pair of horizontally displaced gripper chains plate with an aperture therein so said bottom passes into said aperture, and said peripheral lip rests on the upper surface of said plate around the perimeter of said aperture and wherein said gas flushing and sealing chamber is sealed, evacuated and gas flushed, and said webs are sealed with said gas sealed in the resulting package.

88. Apparatus for packaging perishable goods as claimed in Claim 87, characterized that said first web has a bottom displaced in height from a peripheral lip and wherein said means for holding said first web comprises a plate with an aperture therein so said bottom passes into said aperture, and said peripheral lip rests on the upper surface of said plate around the perimeter of said aperture and wherein said gas flushing and sealing chamber is sealed, evacuated and gas flushed, and said webs are sealed with said gas sealed in the resulting package.

89. An apparatus for conditioning meat, comprising a meat grinder, with an entry and exit point, a tube connected to the exit point of the grinder, wherein the tube is passed through an enclosure containing cooling medium.

90. An apparatus for shaping meat, comprising a container, having sidewalls surrounding a lower base, so as to define an opening, a plug, suitably configured to fit in the opening slide within the interior sidewalk, a press base, attached to an elevating shaft, the press base configured to mate with the lower portion of the container, a plurality of independently driven clamps positioned above the plug.

91. An apparatus for shaping meat, comprising a container, having a base and upwardly extending parallel side-walls, so as to define a cavity with parallel sides, a plug, suitably configured to fit into the cavity and slide within the interior of side-walls and thereby define an enclosure with plug inserted, said plug having a flexible outer perimeter rim such that a substantially gas tight seal is provided to any gas outside said container after said plug is inserted and such that gas contained within said enclosure can be expelled by depressing said plug closer to said base.

92. A method for shaping meat, comprising the following steps:
a) selecting and separating a meat portion from an animal carcass following death of said animal but prior to rigor mortis of said meat portion occurring;
b) placing said meat portion in a container having a base and upwardly extending parallel side-walls, so as to define a cavity with parallel sides and an opening;

c) inserting a plug suitably configured to fit into said container opening and slide within the interior of side-walls and thereby displacing any free gas from within said container and causing said meat portion to conform to the internal shape of said container and plug;

d) locating said container, meat portion and plug into a temperature controlled enclosure and progressively lowering the temperature within said enclosure so as to lower the temperature of said meat portion and thereby cause rigor mortis to occur providing a permanently shaped portion of meat with a profile substantially identical to the inner profile of said container with plug; and e) remove said meat portion from said container and cut to produce sliced meat with slices having a profile substantially the same as each other.

93. A method for shaping meat, comprising the steps of:
placing a meat portion in a container with a plug, between a press base and a clamp;
advancing the clamp toward the press base and the plug;
applying a vacuum source between the clamp and the plug; and applying pressure to the plug with the clamp to as to substantially remove the air from the container.

94. The method of Claim 93 wherein the container is immersed in brine.

95. The method of Claim 93, wherein the container is further subjected to ultra high pressure.

96. The method of Claim 93, wherein a high voltage current is passed through the container.

97. The method of Claim 93, further comprising immersing the container in a cooling medium.

98. The method of Claim 93, wherein a plurality of meat portions are shaped.

99. An apparatus for shaping meat, comprising a container arranged to provide a desired internal profile, comprising a longitudinal trough having at least two sidewalls connected by a bottom side member, a mating closure which is received by the trough between the sidewalls; and, a first and second plug received by the trough on the first and second end.

100. An apparatus for thermoforming trays, comprising:
a tube for storing spools of web material, the tube being flooded with a suitable gas.

101. A method for the storing webs, comprising:
locating the web within a pressure chamber, evacuating the vessel by lowering the pressure, maintaining the vacuum, and increasing the pressure by introducing a suitable gas.

102. An apparatus for the exchange of ambient gas in foam webs to a preferred gas, comprising:
a tube having a first and second open ends;
a first cap located on a first one of the open ends to substantially seal the end;
a second cap located on a second of the open ends, the second cap defining a port through the cap center; and a piston enclosed within the tube.

103. The apparatus of Claim 102, wherein the tube is mounted on a rotating member.

104. An apparatus for the exchange of ambient gas in foam webs to a preferred gas, comprising:
a tube having a first and second open ends;

an evacuation port; and a gas entry port.

105. Apparatus for processing and packaging perishable goods, comprising:
a) apparatus and means to transfer goods into an enclosed first vessel with a gas to enhance the keeping of the goods, and wherein said first vessel is substantially sealed so as to inhibit entry of atmospheric gas therein;
b) means to control gas pressure and temperature in said first vessel and thereby control dissolving of said gas into said goods;
c) means for mixing of said goods;
d) means to inhibit the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the goods, with the gas;
e) means to transfer the goods from said first pressure vessel into a second pressure vessel; and f) means to transfer said goods into a substantially gas barrier package without allowing significant formation of oxymyoglobin on surface of the goods, and hermetically sealing said goods therein.

106. Apparatus for processing and packaging perishable goods, comprising:
a) an enclosed first vessel containing goods and a gas to enhance the keeping of the goods, and wherein said first vessel is substantially sealed so as to inhibit entry of atmospheric gas therein;
b) means to control gas pressure and temperature in said first vessel and thereby control dissolving of said gas into said goods;

c) means for mixing of said goods;
d) means to inhibit the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the goods, with the gas;
e) means to transfer the goods from said first pressure vessel into a second pressure vessel; and f) means to transfer said goods into a substantially gas barrier package without allowing significant formation of oxymyoglobin on surface of the goods, and hermetically sealing said goods therein.

107. Apparatus for processing and packaging ground meats, comprising:
a) a means of transferring ground meats into an enclosed first vessel with a gas to enhance the keeping of the ground meats, and wherein said first vessel is substantially sealed so as to inhibit entry of atmospheric gas therein;
b) means of controlling gas pressure and temperature in said first vessel and thereby controlling dissolving of said gas into said ground meats;
c) means of mixing said ground meats;
d) means of inhibiting the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the ground meats, with the gas;
e) means of transferring said ground meats from said first vessel into a second vessel via pumping means in a substantially continuous stream through an enclosed conduit and substantially excluding voids in said stream;
f) means of measuring fat content of said ground meats continuously during transfer from said first vessel to said second vessel;
g) means to mix said ground meats; and h) means of transferring and packaging said ground meats in a substantially gas barrier package without allowing significant formation of oxymyoglobin on surface of the goods, and means of hermetically sealing said ground meats therein.

108. Apparatus for processing and packaging goods, including:
a) means for treating goods with agents to reduce the quantity of bacteria present in said goods and ensuring that said quantity of bacteria does not exceed the maximum acceptable level for goods intended for human consumption, as required by prevailing government regulations;
b) means for transferring goods into an enclosed vessel containing a gas to enhance the keeping of the goods;
c) means to provide a package including overlapping gas barrier web material with a space therebetween;
d) means to provide a gas in said space at a controlled pressure and temperature; gas selected for having properties to enhance the keeping of the goods;
e) means to transfer the goods from the vessel to a position between the overlapping gas barrier web material and into the space;
f) packaging means to hermetically sealing said overlapping gas barrier web material to enclose said goods and said gas therein, to provide a finished package; and g) means to store said finished package in a temperature controlled space ensuring that the quantity of bacteria present in said goods does not exceed the maximum acceptable level for goods intended for human consumption, as required by prevailing government regulations prior to removing said goods from said finished package for use.

109. Apparatus for processing, measuring and packaging fresh ground meats, comprising the following:
a) means to provide a first quantity of fresh meat portions comprising proportions of fat, water and protein content;
b) means to provide a second quantity of fresh meat portions comprising proportions of fat, water and protein content;
c) means to treat both first and second quantities of fresh meat with agents to reduce the quantity of bacteria present in said goods and ensuring that said quantity of bacteria does not exceed the maximum acceptable level for fresh meat intended for human consumption, as required by prevailing regulations;
d) means to provide gas and transfer said first quantity of fresh meat into a first enclosed vessel containing gas to enhance the keeping of the fresh meat and mix said fresh meat thereby;
e) means to provide gas and transfer said second quantity of fresh meat into a second enclosed vessel containing gas to enhance the keeping of the fresh meat and mix said fresh meat thereby;
f) means to provide gas and transfer and measure at least the fat content of said first quantity of fresh meat and transfer into a third enclosed vessel containing gas and mixing means therein, wherein an enclosed conduit means of transfer is connected, via transfer and fat measuring means, directly to said third vessel from said first vessel;
g) means to provide gas and transfer and measure at least the fat content of said second quantity of fresh meat and transfer into said third enclosed vessel containing gas and mixing means therein, wherein an enclosed conduit means of transfer is connected, via transfer and fat measuring means, directly to said third vessel from said second vessel;

h) means to provide packaging including overlapping gas barrier web material with a space therebetween;
i) means to transfer the combined first and second streams of fresh meat from said third vessel to a position between the overlapping gas barrier web material and into the space; and j) packaging means to hermetically seal said overlapping gas barrier web material and enclose said fresh meat, and means to exclude substantially all ambient air from said package.

110. A method of automatically producing ground meats having a selected proportion of fat and lean meat, comprising the following steps:
a) pumping a first, independently controlled, measured stream of ground meats, with means to adjust the velocity of said stream, through an enclosed conduit connected to a fourth vessel with mixing means therein;
b) pumping a second, independently controlled, measured stream of ground meats, with means to adjust the velocity of said second stream, through an enclosed conduit connected to said fourth vessel with mixing means therein;
c) providing gas and controlling said gas pressure and temperature in said fourth vessel and thereby controlling dissolving of said gas into said ground meats;
d) mixing means of said first and second streams of ground meats;
e) inhibiting the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the ground meats, with the gas;
f) transferring said ground meats from said fourth vessel into a fifth vessel through an enclosed conduit for storage in said fifth vessel or alternatively transferring said ground meats from said fourth vessel directly into an enclosed fine grinder in a manner so as to substantially exclude voids and in a continuous stream; and g) transferring said ground meats into a substantially gas barrier package without allowing significant formation of oxymyoglobin on surface of the goods, and hermetically sealing said ground meats therein.

111. Apparatus for automatically producing ground meats having a selected proportion of fat and lean meat, comprising the following:
a) means to provide pumping of a first, independently controlled, measured stream of ground meats, with means to adjust the velocity of said stream, through an enclosed conduit connected to a fourth vessel with mixing means therein;
b) means to provide pumping of a second, independently controlled, measured stream of ground meats, with means to adjust the velocity of said second stream, through an enclosed conduit connected to said fourth vessel with mixing means therein;
c) means to provide gas and means for controlling said gas pressure and temperature in said fourth vessel and thereby controlling dissolving of said gas into said ground meats;
d) means for mixing of said first and second streams of ground meats;
e) means to inhibit the formation of oxymyoglobin by substantially displacing ambient atmospheric oxygen in air, that may otherwise contact the surface of the ground meats, with the gas;
f) means of transferring said ground meats from said fourth vessel into a fifth vessel through an enclosed conduit for storage in said fifth vessel or alternatively transferring said ground meats from said fourth vessel directly into an enclosed fine grinder in a manner so as to substantially exclude voids and in a continuous stream; and g) means of transferring said ground meats into a substantially gas barrier package and means for packaging therein without allowing significant formation of oxymyoglobin on the surface of said ground meats, and hermetically sealing said ground meats therein.

112. A method for making bacteria-detecting soaker pads, comprising steps for:
providing a first web of material;
providing a trough comprising water and an engineered polymerized molecular film that forms on the surface of the water;
contacting the web and film at a substantially similar velocity so that the film is transferred to the web;
drying the web; and applying the web to a soaker pad.

113. The method of Claim 112, wherein the engineered polymerized molecular film detects the presence of E-coli bacteria.

114. The method of Claim 112, further comprising a step for applying the soaker pad onto a perforated second web material and heat sealing the first and the second web materials.

115. A product made by the method of Claim 112.

116. An apparatus for making bacteria-detecting soaker pads, comprising:
means for providing a first web of material;

means for providing a trough comprising water and an engineered polymerized molecular film that forms on the surface of the water;
means for contacting the web and the film at a substantially similar velocity so that the film is transferred to the web;
means for drying the web; and means for applying the web to a soaker pad.

117. The apparatus of Claim 116, further comprising:
means for applying a second web, and;
means to bond the first web to the second web so as to provide a pad between the first and the second web material.

118. A method for applying iron powder onto web materials, comprising steps for:
providing a web of material;
applying an adhesive to an imprint roller;
contacting the roller with the web;
applying iron powder to the web, wherein a magnet is used to attract the iron powder to a desired position; and drying the adhesive to adhere the iron particles onto the web.

119. The method of Claim 118, further comprising a step for bonding the web material with iron particles onto a second web material to provide a cover for packaged goods.

120. An apparatus for applying iron powder onto web materials, comprising steps for:
means for providing a web of material;

means for applying an adhesive to an imprint roller;
means for contacting the roller with the web;
means for applying iron powder to the web, wherein a magnet is used to attract the iron powder to a desired position; and means for drying the adhesive to adhere the iron particles to the web.

121. The apparatus of Claim 120, further comprising means for bonding the web material with iron particles to a second web material to provide a cover for packaged goods.

122. A method for applying substances to webs for trays, comprising steps for:
providing a web of material, said material being suitable for forming into trays, spraying an adhesive onto a surface of the web material;
applying a substance onto the web material; and drying the adhesive to produce a web material with bonded substances thereto.

123. The method of Claim 121, wherein the substance is an iron powder, and a magnet is disposed underneath the web to selectively pattern the web with the powder.

124. An apparatus for applying substances to webs for trays, comprising:
means for providing a web of material, said material being suitable for forming into trays;
means for spraying an adhesive onto a surface of the web material;
means for applying a substance onto the web material; and means for drying the adhesive to produce a web material with bonded substances thereto.

125. The apparatus of Claim 124, further comprising magnets disposed underneath the web to selectively pattern the web with the substance.

126. The apparatus of Claim 124, further comprising:
means for applying a vacuum from an underside of the web, so as to direct the substance onto a localized portion of the web.

127. The apparatus of Claim 124, further comprising means for applying an energy source onto the substance to adhere the substance to the web.

128. The apparatus of Claim 127, wherein the energy source is magnetic radiation or microwave radiation.

129. A method for sealing a perishable goods tray, comprising steps for:
providing a continuous conveyor;
dispensing pre-form trays onto the conveyor;
loading perishable goods onto the pre-forms;
sealing a second web onto the trays;
providing apertures in the trays; and folding the tray flaps and bonding the flaps to the tray.

130. An apparatus for sealing a perishable good tray, comprising:
a continuous conveyor;
means for dispensing pre-form trays onto the conveyor;
means for loading perishable goods onto the pre-forms;
means for sealing a second web onto the trays;

means for providing apertures in the trays; and means for folding the tray flaps and bonding the flaps to the tray.

131. A method for packaging a perishable good, comprising steps for:
providing means for weighing a perishable good and a first web;
encoding onto a second web information concerning the perishable good;
laminating the second web to the third web to form a composite;
sealing the composite to the first web.

132. The method of Claim 131, wherein the information contains the weight of the perishable good and the date of packaging.

133. The method of Claim 131, wherein the step of encoding information is applied onto a label, the label being applied to the second web.

134. An apparatus for packaging a perishable good, comprising:
means for weighing a perishable good with a first web;
means for encoding onto a second web information concerning the perishable good;
means for laminating the second web to the third web to form a composite;
and means for sealing the composite to the first web.

135. The method of Claim 133, wherein the information contains the weight of the perishable good and date of packaging.

136. The apparatus of Claim 134, further comprising means for encoding the information onto a label and means for applying the label to the second web.

137. A product produced by the method of Claim 131.

138. A method for producing laminated webs, comprising steps for:
providing a first web of material on a roll;
providing a second web of material on a roll;
applying a tensioning force on the first material by retarding the rate of unwinding the first material;
bringing the first material and the second material together to expel substantially all the air between the first and second material; and laminating the first material to the second material to form a web composite.

139 The method of Claim 138, wherein the first material is made from a substantially impermeable material.

140. The method of Claim 138, wherein the second material is made from a permeable gas material.

141. A method for packaging a perishable good, comprising steps for:
providing a continuous conveyor;
placing a first web on the conveyor;
loading a perishable good on the conveyor;
locating the first web with the perishable good in a first vacuum chamber;
providing a composite web made from a second and third material, and;
sealing the composite web onto the first web under conditions of reduced oxygen.

142. The method of Claim 140, further comprising a step for locating the first web in a second chamber.

143. An apparatus for packaging a perishable good, comprising:
a continuous conveyor;

means for holding a first web on the conveyor;
means for loading a perishable good on the first web;
means for locating the first web with perishable good in a first vacuum chamber;
a composite web made from a second and third material, and;
means for sealing the composite web onto the first web under conditions of reduced oxygen.

144. The apparatus of Claim 143, wherein the means for sealing is a vacuum chamber.

145. The apparatus of Claim 143, wherein the means for holding a first web, inwardly compress the walls of the web.

146. The apparatus of Claim 143, wherein the means for placing the first web on the conveyor includes a sealing plate, wherein the walls of the first web are compressed inwardly.

147. An apparatus for packaging a perishable good, comprising:
a first chamber portion to carry a first web;
a second chamber portion, suitably adapted to mate with the first chamber portion, thereby forming a vacuum enclosure;
means on the enclosure for evacuating the enclosure;
means on the enclosure for introducing a suitable gas at a suitable pressure;
means for carrying a second and third web, wherein the second web is disposed between the third and the first webs, and the third web is disposed above the second web; and means for sealing the second web to the first web and the third web to the second web.

148. The apparatus of Claim 147, further comprising means for bonding the second web to the first web without bonding the third web.

149. A packaging tray, comprising:
a first web with a recessed portion, wherein said web includes a flange portion with a first and second surface, wherein the first surface is bondable to a second web, and the second surface is bondable to the second and a third web.

150. A packaging tray, comprising:
a first web having a recessed portion, said web defining an upper peripheral flange above said recess;
a second web bonded to the first web, and a third web peelably bonded to the second web.

151. The tray of Claim 150, wherein the first web is made from a substantially impermeable gas barrier material.

152. The packaging tray of Claim 151, wherein the first web is selected from the group consisting of amorphous polyethylene terephthalate, unplasticized polyvinyl chloride, and polyvinylidene chloride.

153. The packaging tray of Claim 150, wherein the second web is made from a gas permeable material.

154. The packaging tray of Claim 153, wherein the second web is selected from the group consisting of plasticized polyvinyl chloride and polyethylene.

155. The packaging tray of Claim 150, wherein the third web is made from a material that is substantially impermeable to gas.

156. The packaging tray of Claim 155, wherein the third web is selected from the group consisting of amorphous polyethylene terephthalate, unplasticized polyvinyl chloride and polyvinylidene chloride.

157. A packaging tray comprising:
a web material defining a base portion, upwardly and outwardly extending sidewalls from the base, the sidewalk defining a recess portion, wherein the sidewalk terminate at a substantially horizontal flange with relation to the base.

158. The tray of Claim 157, further comprising an aperture that allows communication between the recess portion and an exterior tray environment, wherein said communication is provided by an aperture located at a juncture portion of two sidewalls and the flange.

159. The packaging tray of Claim 157, further comprising a first and second flap, disposed on opposite edges of the peripheral flange, said flaps including ridges and an aperture that provides communication between the recess portion and the exterior tray environment.

160. The packaging tray of Claim 159, further comprising protrusions on a lower exterior surface of the base, wherein said protrusions are suitably constructed so as to mate with a top portion folded flap portion.

161. The packaging tray of Claim 159, further comprising a depressible dimple on a flap portion to seal the communication between the interior recess and the exterior.

162. The packaging tray of Claim 157, further comprising a raised central base portion, reinforcing ribs extending approximately the length of the base portion and reinforcing ribs extending vertically approximately from the flange to the base portion of the sidewalk, at least a first and second flap foldably hinged at a flange, and an aperture to provide communication between the recess and the exterior tray environment.

163. The packaging tray of Claim 157, further comprising a one-way valve.

164. The packaging tray of Claim 157, further comprising a soaker pad disposed on a lower surface of the base.

165. The packaging tray of Claim 157, further comprising at least one flap connected to the flange, wherein the flap includes a plurality of buttresses disposed along the longitudinal length of the flap, channels interconnecting the buttresses, apertures located between a first and second channel, and apertures on tray sidewalls to provide communication between the recesses and the buttresses.

166. The packaging tray of Claim 165, further comprising apertures in the base to absorb liquids in an open cell structure.

167. The packaging tray of Claim 166, further comprising a flap base, wherein the flap base extends beyond the lower surface of the tray base, when the flap base is folded to lay adjacent one of the sidewalk.

168. The packaging tray of Claim 157, further comprising at least one foldable flap, disposed on an edge of the flange, wherein the flap includes a flap base, which is substantially aligned with the tray base, when the flap is folded to lie adjacent to one of the sidewalls.

169. The packaging tray of Claim 157, further comprising at least one flap connected at an edge of a flange, wherein the flap includes a first and second peak, wherein an aperture is provided in a region between the first and the second peak so as to provide communication between the recess portion and the exterior tray environment.

170. The packaging tray of Claim 157, further comprising at least one flap connected to an edge of the flange, wherein the flap includes vertically disposed channels along an outside surface of the flap when the flap is folded over to lie adjacent one of the sidewalls.

171. The packaging tray of Claim 170, further comprising apertures located on a recessed portion of the flap.

172. The packaging tray of Claim 171, further comprising an elevated base so as to provide a depression on an underside of the packaging tray.

173. Any one of the packaging trays of Claims 149-172, further comprising substances adhered to the base or in the space formed between the sidewall and a flap when in a folded position.

174. Any one of the packaging trays of Claims 149-172, wherein the web material is made from expanded polystyrene sheet, and the base includes a plurality of apertures to absorb liquids.

175. The packaging tray of Claim 157, further comprising at least one flap foldable to lie adjacent to a sidewall, and a cover made from a substantially gas barrier shrink material, wherein apertures are provided in the gas barrier cover and a peelable gas burner label is sealed over the apertures.

176. The packaging tray of Claim 157, further comprising at least one flap connected to an edge of the flange, wherein upon folding of the flap to lie adjacent to one of the sidewalls, a flap base is formed that suitably mates with an upper portion of a tray, so as to enable trays to be stacked atop one another.

177. A packaging container for packaging a plurality of packaged trays, comprising:
a substantially impermeable gas barrier material defining a base and vertical walls extending from the base to an upper horizontal flange, and;
a peelable lid attached to the flange.

178. The packaging container of Claim 177, further comprising an oxygen scavenger located in the interior of the packaging container.

179. The packaging container of Claim 177, wherein the sealed portion between the lid and the flange can be folded so as to accommodate the container in substantially similarly sized, but slightly larger packaging carton.

180. The packaging tray of Claim 157, further comprising at least one flap connected to an edge of the flange, wherein the tray further includes a base rim that extends around the perimeter of the base, wherein depressions and perforations can be provided at the tray base.

181. The packaging tray of Claim 157, further comprising at least one flap, foldable about a hinge, and an inner structural undulating member disposed between the sidewall and a flange surface so as to create a rigid wall.

182. The packaging tray of Claim 157, further comprising at least one flap connected to the flange by a hinge, wherein the flap further includes a first and second corner flap connected at opposing edges of said flap.

183. The packaging tray of Claim 157, further comprising at least one flap connected to an edge of the flange, wherein the flap further includes a second flap connected by a hinge on a longitudinal edge of the first flap.

184. The packaging tray of Claim 157, further comprising vertical ribs approximately from the flange to the base, wherein the ribs are formed on a sidewall such that they form a hollow space therein.

185. The packaging tray of Claim 184, wherein the rib is formed by a first and a second tray half, such that the first tray half includes an inwardly extending portion of the rib and the second tray includes an outwardly extending portion of the rib, said first and second tray halves being bonded together to form the tray.

186. The packaging tray of Claim 184, wherein the outwardly extending portion of the rib is formed by a separate member attached to one of a plurality of ribs.

187. The packaging tray of any of Claims 157, further comprising ribs, wherein the ribs include a suitable gas therein.

188. The packaging tray of Claim 157, wherein the tray includes a plurality of members bonded together to form a double wall structure, including horizontal ribs enclosed within a first and second wall.

189. The packaging tray of Claim 157, further comprising a first and second hinge foldable to produce a semicircular flange about the perimeter of the tray, and including a bonded portion adjacent to the semicircular structure bonded to a tray wall near the upper portion of the wall.

190. The packaging tray of Claim 157, further comprising ribs located on the base portion, the tray sidewalls, and the tray flaps.

191. An apparatus for forming a tray, comprising:
a platen;
a fixture suitably formed to carry a preformed tray with flaps attached to the tray, said fixture attached to the platen;
a plurality of members, suitably hinged to the fixture to fold said tray flaps;
and a suitable chamber to enclose the fixture including one or a plurality of ports to provide a suitable gas within the enclosed space or to provide a vacuum.

192. A method for forming a tray, comprising steps for:
providing a preform tray;
locating the preform on a fixture; and applying a vacuum to secure the preform to the texture.

193. The method of Claim 192, further comprising the step for:
applying a suitable adhesive to a selected surface of one of a plurality of flaps of the preform and folding the flaps against the sidewalk of the preform.

194. A product made by the method of Claim 192.

195. The packaging tray of Claim 157, further comprising upwardly projecting ribs so as to engage a tower portion of a second tray which provides a space between the base of the overlying tray and the goods contained in an underlying tray.

196. The packaging tray of Claim 157, further comprising a substantially horizontal flange portion, and lateral ribs formed by a sidewall of the tray and a flap portion.

197. The packaging tray of Claim 196, further comprising apertures located on a portion of the base to allow liquids to enter the cavity formed by the tray sidewall and the flap.

198. The packaging tray of Claim 197, further comprising ribs located on a lower portion of the tray flap and bonded to the tray sidewall.

199. Any one of the packaging trays of Claims 157-198, made from polyethylene terphthalate.

200. The packaging tray of Claim 157, further comprising a first and second crest constructed from the flange portion.

201. The packaging tray of Claim 200, further comprising a radiused lower base portion made to rest on the first and second crest.

202. The packaging tray of Claim 157, further comprising an indentation constructed on a flap portion.

203. The packaging tray of Claim 157, further comprising a reduced thickness portion at a foldable hinge to facilitate folding of flap.

204. The packaging tray of Claim 157, made from a single web material having four flaps.

205. An apparatus for pumping grinds into a profiled conduit, comprising:
a tapered housing;

a tapered screw rotatably mounted in the housing, such that the external surfaces of the tapering screw can be profiled to match the internal surface of the housing, such that the surfaces are in close but not touching proximity; and a piston, suitably mounted on the housing at an exit location, such that piston is provided with a radius surface that matches the external radius of the screw, such that when the piston is closed but not touching proximity to the rotating screw, the external surface of piston will be wiped by the outermost edges of screw as it rotates, such that the piston can eliminate any voids in the grinds.

206. The apparatus of Claim 205, further comprising a plurality of piston arrangements disposed radially on an exit of the housing.

207. The apparatus of Claim 205, further comprising a profiled conduit for shaping beef patties and a cutting means.

208. The apparatus of Claim 205, further comprising temperature control means at an exit of the housing.

209. The apparatus of Claim 208, wherein the temperature is maintained at a suitable temperature so as to cause a crust freezing of the external surface of the stream of grinds to provide an improved cutting condition for slicing by the cutting means.

210. A method for producing beef patties, comprising steps for:
providing a continuous stream of grinds to an entry point of a pumping apparatus; and a piston on an exit of the apparatus, so as to provide a retractable reservoir for the continuous stream to temporarily halt the motion of the stream of grinds, to allow a cutting means to cut a beef patty while the stream is halted then resume the stream by compressing the piston.

211. An apparatus for producing fine ground beef from course ground beef, in an enclosed system that substantially excludes oxygen, comprising:
temperature control means;
a pump for propelling the beef; and means for introducing a suitable gas at a suitable pressure into the apparatus.

212. An apparatus for slicing beef in a substantially oxygen deficient environment, comprising:
pumping means to move ground beef in an enclosed conduit;
a cutting means located at an exit of the conduit;
a conveyor located adjacent to the cutting means;
plugs containing an iron core; and electromagnetic rings mounted to a drive mechanism for each of said plugs, wherein the movable rings control the movement of the beef so that said beef can be portioned according to thickness or to weight.

213. The packaging tray of Claim 157, further comprising a first and second flap, wherein the first flap is opposite of the second flap on a side of the tray, and the flaps are foldable such that each of said flaps can be bonded to an upper surface of the tray flange.

214. The packaging tray of Claim 213, further comprising a web sealed along the perimeter of the tray flange, wherein the web includes one or a plurality of apertures to enable the exchange of gases between the interior of the tray and the outside atmosphere.

215. The packaging tray of Claim 157, further comprising a tray cover to mate with the tray flange, wherein the upper surface of the tray cover provides a viewing window to view the interior contents, said tray cover lower perimeter defining a flange to bond to a lower web material, said material being bonded to the tray flange.

216. The packaging tray of Claim 215, further comprising a plurality of recesses formed from the tray cover ridges to provide for the exchange of gases between stacked trays.

217. The packaging tray of Claim 215, further comprising a recess around the exterior base portion to mate with a ridge formed on the upper cover.

218. The packaging trey of Claim 215, further comprising grooves on an edge of the tray cover, apertures on the sealing web, and a plurality of slots, to enable the exchange of gas between the tray recess and the tray exterior environment.

219. The packaging tray of Claim 215, wherein the tray cover is hinged to the tray at a reduced hinge formed from the tray flange.

220. A master gas barrier container, comprising a plurality of stacked finished packages which has been hermetically sealed after substantially all the oxygen has been evacuated and replaced with a suitable gas which is substantially oxygen free.

221. The packaging tray of Claim 157, further comprising:
vertical ridges disposed on a sidewall, said ridges having an upper horizontal surface extending from said flanged:

one or a plurality of flaps, said flaps including ridges having a defined surface area so that the surface area of the sidewall is adjacent and below the surface area of the flap when the flap is folded to lie adjacent to the upper flange surface.

222. The packaging tray of Claim 157, further comprising:
apertures located in the base portion, so as to absorb any liquids in the open cell structure.

223. The packaging tray of Claim 157, further comprising depressions in the tray base, such that the inner layer of tray base includes an open cell structure that will absorb liquids when the liquids contact said depressions.

224. The packaging tray of Claim 157, further comprising:
a flap hingedly attached to the tray cavity by a sealing web.

225. The packaging tray of Claim 157, further comprising:
at least one flap hinged to a portion of the flange, such that upon folding the flap to lie adjacent to the tray sidewall, a space is formed between the exterior of the tray sidewall and the flap;
an aperture provided at a lower portion of the tray sidewall to provide communication between the interior tray cavity and the space;
an aperture provided along a portion of the flap to provide communication between the space and the exterior environment.

226. The packaging tray of Claim 157, further comprising:
one or a plurality of flaps hingedly attached to a portion of the flange, wherein the flaps are inwardly foldable;
at least one or a plurality of depressions and perforations formed on the tray base; and wherein the tray is suitable to be placed in a shrink bag for sealing therein.

227. The packaging tray of Claim 157, further comprising depressions:
at least one or a plurality of flaps attached to an outer edge of the flange;
a radiused portion formed on a flap, and a recess portion formed on the exterior tray sidewall, such that when the flap is folded to lie adjacent to the tray sidewalk the radiused portion mates with the recessed portion.

228. The packaging tray of Claim 157, further comprising:
a flap base that corresponds to the profile of a tray flange, such that trays can be stacked atop one another without damaging contents of a lower packaged tray.

229. The packaging tray of Claim 157, further comprising:
a heat sealable lip to maintain the flap in a tray adjacent position.

230. A method of making packaging trays, comprising steps for:
providing a preformed web of material for forming into a packaging tray;
cutting in place, scrap material to form a plurality of flaps; and bonding the flaps to a corner of the tray cavity and to an adjacent flap.

231. The packaging tray of Claim 157, further comprising:
at least one ridge on a tray sidewall;
at least one recess on a flap, wherein a suitable bonding material is applied on the ridge or recess to bond the flap to the tray sidewall, and wherein said bonding occurs under the influence of a heat source, such as microwave, radio or magnetic field emitting devices.

232. The packaging tray of Claim 231, wherein the bonding adhesive is applied by suitable ink jet means.

233. A method for evacuating a master container, comprising steps for:
providing a gas barrier material;
packaging said material with one or a plurality of finished packages;
evacuating and flushing said master container with a suitable gas and at a suitable pressure and temperature to substantially remove oxygen from within the master container and from within the finished packages;
sealing a gas barrier lid on the master container.

234. An apparatus for evacuating a master container, comprising:
a lower vacuum chamber;
an upper vacuum chamber with a movable heat bank, attached to a driver;
a web unwinding assembly arranged to allow controlled unwinding of web material from a roll; and at least one or a plurality of conduits for evacuating said chamber and providing a suitable gas at a suitable temperature and pressure.

235. The apparatus of Claim 234, wherein a series of apparatus are arranged in a carousel-style assembly.

236. An apparatus for forming master containers, comprising:
a web material supply assembly;
means for thermoforming master containers;
means for punching holes in the lower web located between containers;
means for loading finished packages into the master container;
at least one or a plurality of upper chambers;
at least one or a plurality of lower chambers, wherein said upper and lower chambers can be closed around a master container to substantially evacuate the container of oxygen and provide a suitable gas at a suitable temperature and pressure to allow said gas to dissolve into, said packaged goods.

237. The method of Claim 236, wherein the pressure of the gas is greater than zero to about 200 psi.

238. An apparatus for grinding and conditioning beef, comprising:
a vessel having an entry and an exit point;
a grinding head attached to the vessel entry point, wherein a cutter is located at the entry point and compacted meat provides a substantially gas tight seal at the entry point to provide for the pressurization of the vessel;
a first screw auger to carry meat to the cutter; and a second screw auger located at a lower portion of the vessel so as to carry the meat forward to the exit point, wherein the vessel is substantially filled with a suitable gas at a suitable pressure and temperature so as to cause the dissolution of said gas into said ground meat.

239. The apparatus of Claim 238, wherein a suitable profile is formed at the exit point.

240. The apparatus of Claim 238, wherein the vessel is jacketed vessel wherein a cooling or heating medium can recirculate about the jacket thus, heating or cooling the vessel contents.

241. The apparatus of Claim 238, further comprising:
an injection point at the grinding head to provide a concentrated solution of carbonic acid.

242. The apparatus of Claim 238, further comprising:

a conduit located downstream of the vessel wherein a carbonic acid solution may be sprayed onto portions of meat while passing through the conduit.

243. The apparatus of Claim 238, further comprising:
means for collecting liquid;
means for reducing bacteria in the liquid at a suitable temperature;
means to dissolve carbon dioxide in said liquid; and means to apply the liquid onto the perishable goods.

244. A method for producing a goods stream having a desired concentration of a suitable measurable variable, comprising steps for:
feeding a first stream of goods to a first device capable of measuring a suitable variable;
feeding a second stream of goods to a second device capable of measuring a suitable variable;
joining the first and second streams after measuring the variable of each stream to form a third stream; and feeding the third stream to a blending device to form a fourth stream having a substantially uniform cross-sectional composition.

245. The method of Claim 244, wherein the streams are provided in substantially enclosed conduits that minimize contact with oxygen.

246. The method of Claim 244, further comprising a step for measuring the resulting measurable variable of the fourth stream.

247. The method of Claim 244, wherein the steps of feeding the first, second, and third streams occurs substantially simultaneously.

248. The method of Claim 244, further comprising a step for diverting the fourth stream to one of a plurality of vessels based on the measured variable measured after the blending step.

249. The method of Claim 244, further comprising the step of returning all or a portion of the fourth stream to the first or second goods streams.

250. The method of Claim 244, further comprising the step of returning all or a portion of the fourth stream as a third feed stream to the blending device.

251. The method of Claim 244, wherein the measured variable of the fourth stream is controlled by increasing the flow rate of the first or the second stream or both substantially simultaneously with feeding the third stream.

252. The method of Claim 244, wherein the measured variable of the fourth stream is controlled by decreasing the flow rate of the first or the second stream or both substantially simultaneously with feeding the third stream.

253. The method of Claim 244, wherein the measurable variable is the approximate fat, lean tissue, or water content of the goods.

254. The method of Claim 244, further comprising a step for grinding the goods of the first and the second streams before the step of feeding the first or the second streams to the first and second devices.

255. The method of Claim 254, further comprising the step of reducing bacteria on the goods, with an agent, prior to the grinding step.

256. The method of Claim 255, wherein the agent comprises a halogen.

257. The method of Claim 256, wherein the agent comprises chlorine.

258. The method of Claim 257, wherein the agent comprises an acid and sodium chlorite.

259. The method of Claim 258, wherein the acid is an organic acid.

260. The method of Claim 259, wherein the acid is citric acid.

261. The method of Claim 255, wherein the agent comprises ozone.

262. The method of Claim 244, further comprising treating the first and second streams with radiation selected from the group consisting of E beam, X-ray and ultraviolet C.

263. The method of Claim 244, further comprising a step for exposing the first and the second streams to a selected gas during the grinding step.

264. The method of Claim 263, wherein the gas comprises carbon dioxide or nitrogen.

265. The method of Claim 244, further comprising a step for exposing the first and second streams to a selected gas.

266. The method of Claim 254, further comprising a step for exposing the first and second streams to a selected gas, prior to grinding.

267. The method of Claim 254, further comprising a step for mixing the goods after the grinding step and before the measuring step.

268. The method of Claim 267, further comprising a step for exposing the first and second streams to a selected gas during the mixing step.

269. The method of Claim 268, wherein the gas is carbon dioxide or nitrogen.

270. The method of Claim 244, further comprising a step for containing the first and the second streams in an enclosed vessel before the feeding steps to allow continuous feeding through an enclosed conduit while substantially minimizing escape of any gas provided in the vessel.

271. The method of Claim 270, further comprising a step for exposing the goods to a selected gas during the containing step.

272. The method of Claim 271, wherein the gas comprises carbon dioxide or nitrogen.

273. The method of Claim 244, further comprising a step for exposing the goods to a selected gas during the blending step.

274. The method of Claim 273, further comprising a step for removing water from the gas during the blending step.

275. The method of Claim 273, wherein the gas comprises carbon dioxide or nitrogen.

276. The method of Claim 244, further comprising a step for grinding the fourth stream.

277. The method of Claim 276, further comprising a step for exposing the goods to a selected gas during the grinding step.

278. The method of Claim 277, wherein the gas comprises carbon dioxide or nitrogen.

279. The method of Claim 244, wherein the first stream comprises a plurality of two or more goods streams.

280. The method of Claim 279, further comprising the step of treating the plurality of streams under ultraviolet radiation.

281. The method of Claim 244, where the second stream comprises a plurality of two or more goads streams.

282. The method of Claim 281, further comprising the step of treating the plurality of streams under ultraviolet radiation.

283. The method of Claim 244, wherein the first stream has a lower percentage of the measurable variable in comparison with a higher percentage in the second stream.

284. The method of Claim 283, further comprising a step for substantially simultaneously blending the third stream to produce the fourth stream to have a measured composition that is between the low percent of the first stream and the high percent of the second stream.

285. The method of Claim 244, further comprising the step of substantially simultaneously forming a plurality of blended streams from the first and the second goods stream in a plurality of blending devices.

286. The method of Claim 285, further comprising a step for substantially simultaneously and automatically controlling the measurable variable of the plurality of blended streams by increasing or decreasing the flow rates of the first or the second stream or both to each of the blending devices.

287. The method of Claim 244, wherein the fourth stream feeds a controlled atmosphere packaging system.

288. The method of Claim 244, wherein the feeding of the first and the second stream is carried out by pumps that suitably compensate for surge of the streams.

289. The method of Claim 244, wherein the flowrate of the first and second streams is controlled to provide a fluid stream of substantially constant content, before the blending device.

290. The method of Claim 244, further comprising the step of reducing bacteria with an agent before the blending step.

291. The method of Claim 290, wherein the agent comprises a halogen:

292. The method of Claim 291, wherein the agent comprises chlorine.

293. The method of Claim 292, wherein the agent comprises an acid and sodium chlorite.

294. The method of Claim 293, wherein the acid is an organic acid.

295. The method of Claim 294, wherein the acid is citric acid.

296. The method of Claim 290 wherein the agent comprises ozone.

297. A product made by the method of Claim 244.

298. An apparatus, comprising:
dissolve a suitable gas that minimizes the formation of oxymyoglobin on the goods;

a transfer tube;
means for measuring the content of a suitable variable of the propelled goods;
means for blending the goods in a selected gas, wherein said goods come from a plurality of grinding means, for producing a goods stream having the blended fat content of the plurality of streams.

299. The apparatus of Claim 298, further comprising means for controlling the temperature of the goods.

300. An apparatus for pumping blended goods comprising:
means for propelling goods in an enclosed conduit and for compressing goods to eliminate voids containing a suitable gas that dissolves into the goods, said gas being capable of reducing the formation of oxymyoglobin on the goods;
means for reducing the exiting flow rate of the propelled goods by means which expand the volume of the conduit; and means for shaping the goods leaving the conduit.

301. An apparatus for grinding goods, comprising:
a vessel including an entry and an exit, wherein the vessel defines a longitudinal housing;
a member with a continuous spiraling edge portion rotatably mounted within the housing, said edge portion being substantially flush with walls of said housing;
at least one reciprocating piston mounted on a housing chamber, said chamber being located approximately at said vessel exit.

302. An apparatus for grinding goods, comprising:
means for grinding goods;

means for containing the ground goods in a substantially enclosed environment;
means for introducing a selected gas into the means for containing the goods;
and means for propelling the goods in an enclosed conduit and for compressing goods to eliminate voids containing the selected gas that dissolves into the goods.

303. The apparatus of Claim 302, further comprising a second means for grinding the goods exiting the conduit.

304. The apparatus of Claim 302, further comprising means for shaping the propelled goods leaving the conduit.

305. An apparatus for grinding meat, comprising:
a vessel having an entry and exit point for meat;
a meat grinding head attached to the entry point;
a conduit leading to the entry point, said conduit including an auger for propelling meat through the grinding head and into the vessel;
a second auger mounted at a lower portion of the vessel for discharging the contents of the vessel to an exit conduit; and at least one port on the vessel for introducing a suitable gas that reduces the formation of oxymyoglobin on the goods.

306. The apparatus of Claim 305, wherein the exit conduit has a selected cross-sectional profile.

307. The apparatus of Claim 305, wherein the exit conduit further comprises a valve.

308. The apparatus of Claim 305, wherein the exit conduit further comprises a second grinding head.

309. The apparatus of Claim 308, wherein the second auger comprises a plurality of apertures to introduce a selected gas.

310. An apparatus for blending goods, comprising:
a plurality of means for grinding and feeding a plurality of goods streams;
means for blending each one of the plurality of streams into a stream of substantially uniform cross-sectional composition; and means for introducing a selected gas to contact the goods.

311. An apparatus for blending meat, comprising:
a vessel having an entry pint and an exit point for the meat;
a plurality of augers disposed longitudinally inside the vessel to blend the meat from one or a plurality of incoming feed streams;
a port on the vessel for introducing a selected gas;
a blower in communication with the interior of the vessel to propel the gas through a gas entry and gas exit point; and a heat exchanger in communication with the interior of the vessel to remove accumulated liquids in the gas.

312. The apparatus of Claim 311, further comprising twin augers meshing inside a conduit, wherein the external surfaces are in close proximity to an internal conduit surface.

313. An apparatus for blending meat, comprising:
a plurality of conduits each having an entry point and an exit point for the meat;

a plurality of augers disposed longitudinally inside each conduit to blend the meat from one or a plurality of incoming feed streams into a plurality of streams each of substantially uniform cross-sectional composition;
an enclosure surrounding the plurality of vessels; and a port on the enclosure for introducing a selected gas.

314. An apparatus for blending goods, comprising:
means for grinding and feeding a goods stream means for blending the stream into a stream of substantially uniform cross-sectional compositions;
means for containing the goods in contact with blending means;
means for introducing a selected gas;
means for removing accumulated liquids in the gas; and means for propelling the gas through the liquid removing means.

315. The apparatus of Claim 314, further comprising:
means for returning the liquid to the means for blending.

316. The apparatus of Claim 315, further comprising:
means for reducing bacteria of the liquids.

317. A system for controlling a measurable variable in the production of goods, comprising:
means for feeding a first stream of goods in an enclosed conduit to a first device capable of measuring a suitable variable;
means for feeding a second stream of goods in an enclosed conduit to a second device capable of measuring a suitable variable;

means of joining the first and second streams in an enclosed conduit after measuring the variable of each stream, at a confluence to form a third stream;
and means for feeding the third stream in an enclosed conduit to a blending device to form a fourth stream having a substantially uniform cross-sectional composition wherein the feeding of the first, second, and third streams occurs substantially simultaneously.

318. The system of Claim 317, further comprising means for controlling the flow rate of the first and second streams to thereby control the fourth stream's composition.

319. The system of Claim 318, further comprising means for measuring the fourth stream's composition.

320. The system of Claim 319, further comprising means for diverting the fourth stream in an enclosed conduit to one of a plurality of vessels.

321. The system of Claim 317, further comprising means for grinding the goods of the first and second streams before feeding to the measuring devices.

322. The system of Claim 317, further comprising means for reducing bacteria in the goods before, after, or during blending the goods.

323. The system of Claim 317, further comprising means for contacting a suitable gas with the goods, before, during, or after blending the goods, that reduces the formation of metmyoglobin on the goods upon exposure to ambient atmospheres.

324. The system. of Claim 317, further comprising means for packaging the fourth stream of goods in controlled atmosphere packages.

325. The system of Claim 317, further comprising means for diverting a stream of goods.

326. An apparatus for blending goods, comprising:
a vessel defining a first radiused portion and a second radiused portion, the first radiused portion being larger than the second radiused portion;
a plurality of inlets to the first radiused portion for introducing goods;
a rotating member having a plurality of arm members that are in close proximity to the walls of the first radiused portion said arm members defining a constant volume between each of said arms;
a driver to rotate said rotating member; and an auger having a continuous spiraling edge in close proximity to the walls of the second radiused portion to propel the goods out of the vessel.

327. The apparatus of Claim 326, further comprising a plurality of inlets to the first radiused portion for introducing a suitable gas to the first portion.

328. An apparatus for processing goods, comprising:
a vessel having an entry and an exit for the goods;
a first port to introduce a first selected gas on a first end of the vessel;
a second port to introduce a second selected gas on a second end of the vessel; and a third port located between the first and the second port to remove the first and second gases;
wherein the vessel entry and exit are plugged with the goods to minimize the escape of the selected gases.

329. The apparatus of Claim 328, wherein the first gas is ozone and is introduced near the vessel's entry.

330. The apparatus of Claim 328, wherein the second gas is carbon dioxide and is introduced near the vessel's exit.

331. A method for producing one or more separately selected, quantities of goods each having a desired concentration of a suitable measurable variable, comprising steps for:
providing a first quantity of goods comprising at least first and second known variables of unknown relative concentrations but where the first variable comprises a greater relative amount when compared to the first variable of a second quantity of goods comprising at least first and second known variables of unknown concentrations;
providing a second quantity of goods comprising at least first and second known variables of unknown relative concentrations but where the first variable comprises a lesser relative amount when compared to the first variable of the first quantity of goods;
feeding the first quantity of goods into a first vessel containing ozone gas;
feeding the second quantity of goods into a second vessel containing ozone gas;
transferring said first quantity of goods, after substantially removing said ozone gas, from said first vessel in a first stream of goods in an enclosed conduit to a first device capable of measuring said first variable;
transferring the second quantity of goods, after substantially removing said ozone gas, from said second vessel in a second stream of goods in an enclosed conduit to a second device capable of measuring a suitable variable;

joining the first and second streams in an enclosed conduit after measuring the variable of each stream to form a third stream; and feeding the third stream to a blending device to form a fourth stream having a substantially uniform cross-sectional composition.

332. The method of Claim 331, wherein the goods are ground meat and the first component is ft and the second component is lean tissue.