EP2576350B1 - Method for the portioned packaging of a food mass - Google Patents

Description

The invention relates to a method for the portioned packaging of an at least substantially incompressible food mass, in particular of processed cheese, which is filled as a flowable mass in a tubular casing having a thermoplastic plastic film. Furthermore, the invention relates to a device for carrying out the method.

For portioned packaging of such food mass various methods are known. In some processes, the food mass is poured into trays preformed from a stable film, especially plastic. The filled with the food mass individual shells are subsequently closed and separated. The disadvantage of this solution is that a separate tool or even a separate machine is required for each work step, in particular preforming, filling, closing and separating. In addition, the portioned filling of already preformed packages with such a food mass relative to the adjustment is relatively complex.

For the packaging of processed cheese, in principle, three methods are known: Firstly, it is known to bring the processed cheese in slice form and to stack these single slice "slice on slice" on the other hand, it is known, individually wrapped slices ", IWS). For this purpose, a film tube is filled with processed cheese and smoothed into a strip before it is divided into individual slices by displacement, sealing and cutting. Another way to wrap processed cheese is to surround individual portions with an aluminum foil. Such portions are in the form of triangles known, which are merged into several in a circle in a common outer packaging. The individual portions can be provided with a thread cutting the foil as a tear-open. Such a portioned packaging in aluminum foil is relatively expensive.

The DE 101 22 635 A1 discloses a method of packaging processed cheese in a foil. The film is deformed by deep drawing. The deep drawing takes place by means of compressed air, which is introduced into the film. Subsequently, the formed film is filled with the food mass. The US 4,133,162 A discloses a method for packaging milk in a flexible film tube. The tube is held in shape by means of half shells during the sealing of transverse sutures to ensure the correct volume of the packaged units.

The object of the present application is therefore to propose a process for the portioned packaging of a food mass, in particular processed cheese, in which the individual packs of the food mass can be produced in a simple and cost-effective manner in various forms and easy for the consumer to handle.

These objects are achieved by a method having the features of claim 1. Advantageous embodiments are mentioned in the subclaims.

The essential basic idea of the invention is first of all to fill the food mass into a film tube and subsequently to deform it by thermoforming while retaining the food mass. In principle, the mass of food from areas of the completely filled tube is displaced into areas in which a deep-drawing takes place virtually at the same time. A separate thermoforming stamp is not required. The food mass acts like a stamp and pushes the foil into the shape of the tool. The mass, which is too much in the areas of displacement, finds space in the newly formed areas. According to the invention, the thermoplastic film of the surrounding surrounding the food mass envelope is transformed under displacement of the food mass from seal areas to each one unit defining units in a mold. These units arranged one behind the other in a chain are delimited from each other by a seal in the sealing area and then separated from one another.

Such a unit is also referred to below as filled with the food mass cavity. The one portion of the food mass defining cavity is thus formed according to the invention in the already filled film web. The flowable food mass enveloped by the film web completes the shape of the film layer and assumes the shape of the cavity. The shape of the film web is thus accompanied by a portioning of the food mass.

The method according to the invention makes it possible to automatically produce individual packages that are easy to handle. The method can replace the subsequent filling of already preformed trays. This significantly simplifies the production of single-pack food packages and significantly increases product output. With the simultaneous deformation of the film tube and the food mass, the method is particularly suitable for the portioned packaging of processed cheese, since processed cheese with its temperature-adjustable viscosity is particularly easy to handle. The process enables continuous production. At the same time, it offers a high degree of variability with regard to the possible packaging forms. The cavities can be molded into the filled film web in almost any desired form and, in particular, their three-dimensional orientation offers a large scope for product design.

It is particularly advantageous that the reshaping of the filled film web according to the invention can be integrated into existing production plants for packaging food masses. A conversion or an extension of previously used machine lines to the new method is thus possible.

In a preferred embodiment, both film layers of a double-layer, filled with food mass film tube are formed. By molding opposing cavities in the two-ply film web, the total available volume of the individual packaging can be increased. The two-sided deformation of the double-layered film web also allows a symmetrical design of upper and lower part of the single pack. For example, in the case of asymmetric shaping, an upper part of the forming means is made smooth while the lower part has forming cavities.

According to the invention, a negative pressure in a forming agent is applied to support the formation of the cavities in the film layer. The negative pressure causes a kind of deep-drawing effect in the film layer. It is applied while the forming segment of the forming agent closes in the sealing areas of the double-layered film web. Before opening the forming agent, the vacuum is deactivated again. The film layer is not only pressed into the mold segment, but also sucked. She lies down on its walls and takes on its shape. The negative pressure causes a precise molding of the given shape by the thermoplastic film.

The food mass is not only displaced from the seal areas, but also sucked into the mold segment follows the shape of the film layer and fills the mold segment. In sealed areas, only a slight residue of food mass remains due to the combined suction and displacement effect acting on the food mass, which simplifies the subsequent sealing of the film layers in the sealing area. It is particularly advantageous if the negative pressure in height and duration of the food mass is adjusted.

A temporary and local heating of the thermoplastic plastic film helps to mold the cavities into the film web. For this purpose, the areas of the forming agent which come into contact with the film to be formed are heated.

Thermoplastic plastics of different types and film thickness can be processed with the method or the device. In particular, films of PE, PET and PP are suitable. The preferred film thickness is between 20 μm and 100 μm. The method also makes it possible to use film tubes made of film webs of different materials. For example, film webs of thermoplastic and aluminum foil can be combined.

Preferably, a separating segment of the forming agent is first retracted into the food mass enveloped by the film web. This separating segment designed in the manner of a hold-down device moves into the production line before the individual packages are formed. This delimits the part to be formed from the rest of the film tube. This subdivision of the product strand defines the area of the filled film tube available for the forming process. The segment prevents food mass from flowing during the formation of the cavities from the rest of the production line into the part of the film web to be formed. Fluctuations in the volume of the individual packs produced can thereby be minimized.

To ensure the release of the product strand from the forming means, the cavities of the shaping means are preferably subjected to overpressure. For this purpose, it is advisable to use the vacuum connection also for supply with overpressure.

Preferably, the forming means comprises a means for sealing the sealing area located between the successive hollow bodies. By not only forming the cavities in the filled film web, but also sealing the seal area, this working step can be combined in one tool. This requires that a change in shape of the individual packaging is easier to perform. Such changes in shape are usually associated with a change in the shape and location of the Siegefbereichs between the individual packages. When changing the packaging form, the set-up effort at the packaging installation is thus reduced.

In a particularly preferred embodiment, the sealing region separating the cavities is sealed by means of ultrasound. Sealing by means of ultrasound has the great advantage over sealing with heat that a seam sealed with ultrasound can be better opened again later, ie has an improved "Pealfähigkeit". In addition, the ultrasound displaces remaining amounts of food mass from the sealed area. A product inclusion in the sealed seam is avoided. This ensures a uniform strength of the sealed seam. In addition, a product inclusion in the seal area reduces the quality of the customer. The clean seal increases the quality feel of the finished product. In this case, the sealing by means of sonotrode and sealing anvil can be carried out in a separate working step. Preferably, the shaping means itself, in particular the lateral boundaries of its shaping cavity entering the sealing area, is designed as a sonotrode. The sealing components are thus in the Umformmitte! integrated.

At the end of the process, the film web is severed in the sealing area. The separate packs of food mass are then fed individually to the further packaging process. Preferably, the individual steps of forming, sealing and separating the individual packs are combined in direct sequence. Thus, only the forming agent and the separating device have to be exchanged for converting the production line to another type of packaging. In a particularly preferred embodiment, the separating device is part of the forming agent.

In a further particularly preferred embodiment, the food mass is cooled before forming the filled film web. In contrast to the pouring of a liquid food mass into a preformed packaging mold, the food mass is pressed into the cavity according to the invention and preferably also sucked. For the filling of the molded into the film web cavities for the food mass thus no liquid, but only a still flowable consistency is required. When forming the cavities in the film layer, the food mass is already largely cooled. On a complex cooling of the molded individual packaging to prevent deformation in the further course of the manufacturing process and the placement of the secondary packaging can be omitted. For cooling in advance of the forming of the food mass is preferably performed in known manner via cooling belts along a cooling section or passed through a cooling water bath. This ensures a uniform Cooling the food mass. The film feed can be done before or after the cooling.

In a further particularly preferred embodiment, the edge regions of the two film layers protruding from a longitudinal sealing seam form an opening tab for opening the packaging. With the longitudinal sealing seam, the two film layers are joined together before molding the cavities. Depending on how the two-ply film web was laid, it has one or two longitudinal seal seams. If a single film is applied to a double-layered film web, it has on one side a longitudinal sealing seam which connects the lateral end regions of the two film layers. The variant of a two-layered film web made of two film layers has longitudinal sealing seams on both sides. The film layers are dimensioned such that, after the sealing of the longitudinal sealing seam, film edge regions of the connected film layers survive. A pulling apart of the projecting edge areas of the film first opens the longitudinal sealing seam and, in the further course, the sealing areas of the individual packaging. The packaging portion can thereby be completely opened in a simple manner and remove its contents without residue from the packaging.

The projecting film edge regions are preferably cut off in such a way that the remaining film edge region of the two film webs is in the form of a tab protruding from the single package. The tab shape is intuitively recognized by the customer as an opening mechanism for the single pack, so that further instructions on the packaging are not required.

In a further preferred embodiment, the two-ply film web is in continuous forward motion. This creates an endless, constantly renewing product strand of the filled film web. An automatic tracking of the forming agent during the forming process allows continuous production of individual packages of food mass with a correspondingly high production output.

The method according to the invention makes it possible to produce packaging portions in the most varied forms. In addition to the known and popular with the consumer cheese corner shape and square or rectangular cavities can be formed in the film web. The indentation of the cavities can be made into a film web, indentations in both film webs can be symmetrical or asymmetrical with respect to one another. Another variable is the material choice of the slides. The possibilities of variation thus range from a symmetrical packaging with plastic film webs which have been identically formed on both sides and a sealing seam running around the middle of the package to a unilaterally formed package with an off-centered sealing seam whose unformed aluminum foil seals the packaging in the manner of a lid.

In contrast to the known aluminum foil packaging, the use of a transparent plastic film allows the consumer a direct view of the packaged product. Additives such as herbs or nuts do not have to be imaged on the label alone, but are visible to the consumer in the product itself. Preferably, the contents of the packaging can be identified via the coloration of the packaging via a variety-specific coloring of a film web.

- Figur 1:

ein geöffnetes Umformwerkzeug mit einem noch unverformten Produktionsstrang der eingehüllten Lebensmittelmasse;

- Figur 2:

Einen Schnitt entlang der Linie A-A der Figur 1;

- Figur 3:

Das sich schließende Umformwerkzeug zu Beginn des Einfahrens in den Produktstrang;

- Figur 4:

Einen Schnitt entlang der Linie B-B der Figur 3;

- Figur 5:

Das sich schließende Umformwerkzeug mit geschlossenem, in den Produktstrang eingedrungenem Trennsegment;

- Figur 6:

Einen Schnitt entlang der Linie C-C der Figur 5;

- Figur 7:

Das Umformwerkzeug nach Beendigung des Umformvorganges;

- Figur 8:

Einen Schnitt entlang der Linie D-D der Figur 7;

- Figur 9:

Ein Niederhalter des Umformwerkzeuges;

- Figur 10:

Eine Grundplatte des Umformelements mit Formsegmenten;

- Figur 11:

Ein schematische Darstellung der verschiedenen formgebenden Schritte am Produktstrang.

An embodiment of the invention is described below with reference to FIGS. 1 to 11 described. It shows

- Figure 1:

an open forming tool with a still undeformed production strand of the wrapped food mass;

- Figure 2:

A section along the line AA the FIG. 1 ;

- Figure 3:

The closing forming tool at the beginning of retraction into the product strand;

- Figure 4:

A section along the line BB the FIG. 3 ;

- Figure 5:

The closing forming tool with closed, penetrated into the product strand separation segment;

- Figure 6:

A section along the line CC the FIG. 5 ;

- Figure 7:

The forming tool after completion of the forming process;

- Figure 8:

A section along the line DD the FIG. 7 ;

- Figure 9:

A hold-down of the forming tool;

- Figure 10:

A base plate of the forming element with mold segments;

- Figure 11:

A schematic representation of the various forming steps on the product line.

The FIGS. 1 to 8 1 shows a forming agent according to the invention in the form of a forming tool 1. The forming tool 1 is represented in a sequence of different phases of the forming process of the film web 2 filled with food mass.

In the Figures 1 and 2 the upper part 3 and a lower part 4 comprehensive forming tool 1 is open and has no contact with the production line of the film web 2. Upper part 3 and lower part 4 of the forming tool 1 are aligned to the top or bottom of the production line and are mirror images of each other. The upper part 3 and the lower part 4 are substantially identical, so that information on features or movements of one part 3, 4 of the forming tool 1 mirror image always refer to the other part 3, 4 with.

Each part 3, 4 of the forming tool 1 comprises a base plate 5 and arranged on the side facing the production strand of the base plate 5 and releasably connected to it mold plate 6. In the direction of the production line is on part 3, 4 a separation segment 7 in the manner of a hold-down in front. The base plate 5 and the hold-down are connected to one another via a guide 8. The guide 8 is biased by springs 9 and allows movement of the hold-down relative to the base plate 5. The base plate 5 further comprises a vacuum or

Compressed air connection 10, which is connected to an inserted into the mold plate 6 hollow chamber 11. Via the hollow chamber 11, a negative pressure is applied to a mold segment of the forming tool 1.

The hollow chamber 11 is product strand side bounded by a shelf 12, which is spaced by means of a spacer sleeve 13 of the base plate 5. The shelf 12 forms together with laterally in the direction of the production line at the shelf 12 projecting webs 14 of the mold plate 6 to a filled film web 2 out open mold segment 15, in which the film web 2 is formed. The mold segment 15 thus forms a negative mold for the film web 2 filled with the food mass 16.

The filled with food mass 16 film web 2 has two film layers 17, 18, which are connected on both sides via longitudinally extending sealing seams 19 with each other. Along the foil edge regions 20 of the double-layered film web 2, which are provided on longitudinal sealing seams 19. For temporary and local heating of the thermoplastic film layer 17, 18, the mold plate 6 has two temperature-controlled heating cartridges 21.

The FIGS. 3 and 4 show the forming tool 1 at the beginning of the closing process. At this time, there is an outer surface of the blank holder 7 in height of the still undeformed product strand of the filled film web 2. In order to heat the thermoplastic film to be formed, the hold-7 has a not shown here heating element. The heated hold-down 7 is arranged on both sides offset from the filled food mass 16 and above the film edge regions 20 of the double-layered film web 2. In order to prevent heating of the film edge region 20 by contact with the heated down holder 7, the hold-down 7 carries on both sides a longitudinally extending insulating member 21, which adjoins the outside of a projecting in the direction of the production strand longitudinal ridge 22 of the hold-down. The hold-down 7 also has two transverse webs, not shown here, extending transversely to the production line, which contact the two-ply film web 2 in this position of the closing operation.

in the FIGS. 5 and 6 the hold-downs 7 of upper part 3 and lower part 4 of the forming tool 1 are closed, so that the foil edge regions 20 are held between the longitudinal webs 22 and the insulating elements 21. In this position of the forming tool, the transverse webs of the hold-7 are completely penetrated into the product strand. The arranged with respect to the production line at the beginning and at the end of the blank holder 7 transverse webs thus close the area of the production line, which is to be transformed by the forming tool 1 from.

The FIGS. 7 and 8 show the forming tool 1 with fully closed upper and lower parts 3, 4. With application of the negative pressure in the mold segments 15 moves in both parts 3, 4, the pressure plate 5 together with the mold plate 6 in the direction of the production line. The heated webs 14 of the mold plates 6 penetrate into the product strand in opposite directions, deform the thermoplastic film layer 17, 18 at this point and displace the food mass 16 located in this region of the product strand. The food mass 16 thereby presses the film layers 17, 18 into the Mold segments 15. The at least nearly incompressible food mass 16 acts like a deep-drawing die which presses into the foil segments 17, 18 into the mold segments 15. In this case, individually successive cavities 23, each defining a portion of the food mass 16, are formed in the film layers 17, 18.

In addition, the film layer 17, 18 is pulled by the voltage applied in the mold segment 15 negative pressure against the heated shelf 12. The negative pressure is applied after the hold-down 7 has completely penetrated into the product strand. The strength and duration of the vacuum is adjusted to the food mass. The still flowable food mass 16 displaced from the region of the closing webs 14 completely fills the forming cavity 23.

In the exemplary embodiment described here, two opposing cavities 23 each form a single portion of the food mass 16. The shape of the portion is defined by the mold segments 15 of the parts 3, 4.

The colliding webs 14 of the mold plates 6 compress the film layers 17, 18 and define a single-package sealed seal area 24. For the permanent formation of the single packs, the seal area 24 is sealed by a conventional ultrasonic sealing process. In this case, the webs 14 act as a sonotrode, so that the sealing components sonotrode and seal anvil are integrated into the forming tool. The two work steps can also be carried out by two tools that follow each other in the production process.

After the formation of the individual packs, the negative pressure in the mold segment 15 is no longer maintained. The parts 3, 4 of the forming tool move apart and release a strand of finished shaped, successive individual packs of food mass 16.

While with the FIGS. 1 to 8 described method steps, the forming tool moves at a speed V _wz , which corresponds to the speed v _{p of} the continuously moving production line. After opening, the forming tool 1 moves counter to the transport direction along the production line back to a starting position, from which a new cycle starts. From the starting position of the forming tool 1, the rear web 25 of the hold-down 7 in the direction of production moves when closing the forming tool 1 into the boundary of the strand section formed by the front web 25 in the preceding working cycle.

The FIG. 9 shows a hold-down 7 of the type described in axonometric view. Clearly visible are the parallel to the production line extending webs 22, against which the two-sided insulating elements 21. The webs 22 are connected to each other via two generally transverse, when closing the blank holder 7 in the production line penetrating webs 25. The webs 25 limit the portion of the producible in a working cycle of the forming tool production line. The side of the holddown 7 are arranged the Feeds 26 for the heating element, not shown, and the associated sensors.

FIG. 10 shows an axonometric representation of a base plate 5 with attached mold plate 6. On the mold plate 6 are the side of a mold segment 15 define webs 14 before. The bottom of the mold segments forms the shelf 12. The choice of the mold segments 15, here in the form of cheese corners, defines the shape of the individual packs.

The FIG. 11 shows a production line of the filled film web 2 to various, in the production line successively arranged times of the molding process. Cavities 23 are formed in the double-layered film web 2 filled with foodstuff material 16 and sealed by two longitudinal sealing seams 19 which are separated by a sealing region 24 into cavities 23 arranged one behind the other and defining the individual foodstuff packing 27. The seal areas 24 circulating around each individual pack 27 are sealed by an ultrasound sealing agent, as a result of which residues of the food mass 16 displaced from the seal area 24 by the webs 14 are not yet removed. In a further method step, the successive single-ply 27 are separated from each other. The film edge regions 20 are cut off in such a way that a remaining film edge region of the two film layers 17, 18 forms an opening tab 28 for the single package 27.

Claims (6)

1. Method for the portioned packaging of an at least substantially incompressible food mass (16), particularly of soft cheese, which is introduced as a flowable mass into a tubular wrapping having a thermoplastic plastic film,
   wherein units (23) of the wrapping arranged one behind the other, each of which defines a portion of the food mass, are delimited with respect to each other by sealing in sealing areas (24) and are subsequently separated from each other, wherein the tubular wrapping is moulded in a deep drawing process while the food mass remains,
   characterised in that
   the thermoplastic plastic film of the wrapping (2) that surrounds the food mass (16) is moulded in a tool mould into individual units (23) with displacement of the food mass (16) out of sealing areas, wherein the food mass is displaced from areas of the completely filled tube and into areas in which deep drawing is taking place practically simultaneously, so that the food mass acts like a punch and presses the film into the tool mould.
2. Method according to claim 1,
   characterised in that
   a vacuum that suctions the plastic film into the mould is generated in a moulding means (1) in order to assist the moulding of a unit (23) in the film layer (17, 18).
3. Method according to claim 1 or 2,
   characterised in that
   the vacuum is generated after one segment (7) of the moulding means (1) has been extended completely into the food mass (16) surrounded by the film web (2).
4. Method according to any one of the preceding claims,
   characterised in that
   the sealing is carried out using ultrasound, wherein in particular parts of the moulding means are used as ultrasonic generators, particularly a sonotrode.
5. Method according to claim 4,
   characterised in that
   the portions are separated from one another by cuts in the sealing area.
6. Method according to any one of the preceding claims,
   characterised in that
   the tubular wrapping is formed by a film web (2) which is sealed on the longitudinal side, wherein adjacently disposed film edge regions (20) remain and form the opening tabs (27) for the individual package (27).

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