NL2027542B1 - Crate and method for manufacturing a crate - Google Patents

Abstract

Crate comprising a bottom and side walls extending from said bottom for forming a holding area in said crate, wherein said crate is manufactured by a moulding technique from a first material, wherein the first material is a non-food safe plastic, such as recycled plastic or off-grade plastic, wherein the crate further comprises a food safe layer from a second material arranged on the inner walls of the side walls and the bottom by an in-mould labelling technique such that the food safe layer forms the holding area.

Description

Crate and method for manufacturing a crate The present invention relates to a crate, in particular for foodstuff, and a method for manufacturing such a crate.

A crate comprising a bottom and side walls extending from said bottom for forming a holding area in said crate, wherein said crate is manufactured by a moulding technique from a plastic, for holding food or foodstuff are as such generally known.

IO In order to be allowed to hold, let alone transport, foodstuff in a crate while the foodstuff directly contacts the crate, the crate, or any other holder, needs to conform to strict regulation in order to ensure food safety. Regulations (EC) Nos 1935/2004, 2023/2006 and 282/2008 are examples of relevant regulation dealing with materials and articles intended to come into contact with food. One of the requirements for such crates is that the material from which the crates are manufactured needs to be known and clearly defined. The use of recycled plastic or off-grade plastics is for instance not allowed for the manufacturing of crates which need to directly contact food stuff. Also in the food industry, both in production and transport, next to reducing costs, reducing the ecological footprint however becomes increasingly important.

US 2004/0112895 Al describes a crate according to the preamble of claim 1.

It is a goal of the present invention, next to other goals, to provide an improved crate wherein the above mentioned problems are at least partially solved.

This goal, amongst other goals, is met by a crate according to appended claim 1. More specifically, this goal, amongst other goals, is met by a crate comprising a bottom and side walls extending from said bottom for forming a holding area in said crate, wherein said crate is manufactured by a moulding technique from a first material, wherein the first material is a non-food safe plastic, such as recycled plastic or off-grade plastic, wherein the crate further comprises a food safe layer from a second material arranged on the inner walls of the side walls and the bottom by an in-mould labelling technique such that the food safe layer forms the holding area. By only forming the parts of the crate contacting the foodstuff from a food safe material, the remainder of the crate, not contacting the foodstuff, can be manufactured from non food safe materials. This allows the use of recycled plastics or off-grade or near-to-prime plastics. Arranging the food safe layer in the crate using an in mould labelling technique then allows an efficient and cost effective production process for the crate. A food safe material is to be understood as a material, specifically a plastic, which is allowed, according to for instance the applicable regulations as mentioned above, to come into contact with food. In particular recycled plastic is not considered food safe, as the origin thereof can not be ensured. Also off-grade and near-to-prime plastics are generally not considered food safe. As these materials are typically discarded, or at least not used for food transport, the crate according to the invention allows the use of such materials.

In-mould labelling techniques are typically used for applying labels to plastic holders. In such a process, a label of a first material is arranged in the mould on a predetermined location to subsequently introduce, for instance by injection, a second material in the mould. During the moulding process, the first and second materials will adhere to each other such that the label is adhered to the product. In these known processes, the labels are arranged on the outside of a product. In the crate according to the current disclosure, the layer, foil or sheet of material is arranged on the inside of the crate, such that after moulding of the crate, the layer or sheet of material is arranged on the bottom and the side walls such that the holding area is delimited and formed by the food safe layer. After moulding, the layer of second material and the first material are moulded or fused together. A monolithic crate is thus obtained. More generally, a crate or other holder is disclosed, comprising a bottom and side walls extending from said bottom for forming a holding area in said crate, wherein said crate is manufactured by a moulding technique from a first material, wherein the crate further comprises a layer from at least one second material arranged on the inner walls of the side walls and the bottom, in particular by an in-mould labelling technique, such that the layer of the at least one second material forms the holding area. Based on the requirements for the inside, i.e. the holding area, and the outside, suitable materials or combinations thereof can be used. It is for instance possible to use a stiffer material on the outside for providing rigidity to the crate, while the inside for instance requires a food safe material as described. In particular by using an in-mould labelling technique, a crate having different material properties can efficiently be manufactured. Although the invention is suitable for a crate, the invention may also be applied to holder in general as mentioned above. Examples of holders for products, for instance foodstuff, include boxes, cases or trays.

The crate according to the disclosure is preferably made using a moulding technique. Suitable techniques are for instance injection moulding, blow moulding, thermoforming or vacuum forming. These techniques, and how to manufacture crates using these techniques, are as such known. By inserting, preferably prior to introducing the first material in the mould, second material in the mould at the location where the inside of the crate, i.e. the holding area according to the current disclosure, is to be formed, a two or even more component crate can be manufactured.

According to a preferred embodiment, the food safe layer comprises a sheet or foil of food safe material. A sheet or foil can easily be introduced in the mould at the predetermined location of the crate. Preferably, the sheet of material is pre-cut to fit the side walls and bottom in the moulded position. Preferably, the second material is a food safe material comprising a plastic. The two or more materials of the crate can then be moulded together forming a monolithic crate.

Preferably, the inner surface of the crate, forming the holding area, is free from the first material. In other words, no first material is adjacent the holding area. This ensures that the products in the crate only contact the second material. Preferably, the layer of second material has thickness of smaller than 0.5 mm, preferably small than 0,1 mm.

Preferably, the first material defines, in moulded situation, a framework of a plurality of interconnected beams. This framework provides rigidity to the crate. The framework may be too coarse to allow articles to be contained. It is then preferred if the second material bridges at least part of the framework. The second material may also comprise a framework or mesh. It is then preferred if the framework of the second material, in moulded situation, is less coarse than the framework of the second material. The first material can then ensure proper containment of the articles, even articles smaller than the openings in the framework of the first material. It is also possible that the layer of material does not contain any openings, at least not in the side walls and/or the bottom.

Thus according to a further preferred embodiment, the crate as defined by the first material comprises a plurality of openings.

In order to ensure the food safety, seen from the holding area, the second material preferably covers at least the first material such the food safe layer forms the holding area. The first material is then preferably not exposed to the holding area.

It is further preferred if the layer of second material at least partially spans at least one of the openings. As explained, it is then preferred if the crate as defined by the first material comprises a plurality of stiffening beams, wherein the layer of second material at least partially extends between the stiffening beams.

According to a further preferred embodiment, the layer of the second material comprises a plurality of openings. These openings can for instance be used to discharge liquids or to receive any transporting tools, in particular through openings in the bottom. It is then preferred that at least at the locations of the openings in the second material, the first material is also provided with openings, in the moulded situation. And preferably, the second material preferably covers at least the first material such the food safe layer forms the holding area. This ensures that only second material extends adjacent the holding area and that no second material is exposed to this area and thus to any articles held in the holding area. It is then preferred if the total surface of openings in the first material is larger than the total surface of the openings in the second material. Preferably, the first material is completely covered, seen form the holding area, by the second material.

In order to ensure that the complete inner surface of the crate is covered by the second material, in particular when sheet like material is used, it is preferred if at least one of the corners joining two side walls or a side wall joining the bottom comprises a recess for receiving an edge of the layer of second material. The sheet may for instance be over dimensioned, such that excess length of the sheets at the edges are received in the groove. Preferably, each corner between the side walls comprises a groove.

According to a further preferred embodiment, the first and second materials comprise PE, PP, styrene or a combination thereof. The first material may for instance be an off-grade type of plastic or recycled plastic, whereas the second material is material according to specifications, particularly complying with regulations as to food safety. The second material, or the inner surface of the holder in general, may also comprise a laminate of different materials. The inner surface may for instance comprise PET and/or amide.

The invention furthermore relates to a method for manufacturing a crate, specifically a crate as described above, in a mould shaped for manufacturing said crate, wherein the crate comprises a bottom and side walls extending from said bottom for forming a holding area, comprising the steps of: a. Providing in the mould a layer of second food safe material; b. Injecting in the mould a first material onto the second material, such that the second material forms a layer on the inner walls of the side walls and the bottom such that the food safe layer forms the holding area. After moulding the combination of the first and second materials, a crate as described above is preferably obtained. The crate is thus preferably monolithic. Preferably, the crate is manufacturing using an injection moulding technique and wherein the layer of food safe material is formed using an in-mould labelling technique.

5 An efficient manufacturing process is obtained if the step of providing the layer of second material comprises providing a sheet of plastic material. The sheet may be introduced in the mould at the predetermined location, i.e. where the inner surfaces of the crate forming the holding area are to be formed, such that after moulding, the inner surfaces are formed by said second material.

An efficient fit is obtained if, according to a preferred embodiment, the sheet of material is pre-cut to fit the side walls and bottom in the moulded position. During moulding, the sheet may then adapt to the form of the mould and thereby of the crate. Preferably, the sheet is over dimensioned with respect to the bottom and inner surfaces of the wall, wherein the mould is preferably arranged to form grooves at the junctions of at least the side walls. The edges of the second material, preferably in sheet or foil form, may then be received in the grooves and ensure that no first material is exposed to the inner surface of the crate.

The present invention is further illustrated by the following Figures, which show a preferred embodiment of the device and method according to the invention, and are not intended to limit the scope of the invention in any way, wherein: - Figure 1 shows a crate in perspective view; - Figure 2a shows a sheet for forming the inner surface of a crate; - Figure 2b shows the folded sheet of figure 2a; - Figure 2c shows the basis frame of a crate; and - Figure 3 schematically shows a mould for manufacturing a crate.

In figure 1, a crate 1 is shown comprising a bottom 13 with four side walls 11, 12 extending substantially perpendicular from the bottom 13. Short walls 11 and long walls 12 are joined together at corners 14. The inner surfaces 11a, 12a of the side walls 11, 12 and the upper surface 13a of the bottom 13 define or enclose a holding area 10 wherein articles, in particular food, can be held.

The crate 1 is manufactured by injection moulding, wherein the outer part 2 (see figure 2c) is manufactured from a recycled plastic and wherein at least the surfaces 11a, 12, 13a defining the holding area 10 are formed from a sheet 3 of food safe plastic (see figure 2a). With reference to figure 3, the crate 1 is manufactured in a mould 5 comprising two mould parts 51, 52 in this example. When bringing together the parts 51, 52, indicated with the arrows A, the shape of a crate is formed between the parts. The shape of mould is schematically indicated with 51a, 52a. Before closing the parts 51, 52, a sheet 3, for example the sheet as shown in figure 2a, is brought between the parts, such that upon closure, the sheet is received in the moulding cavity. The sheet 3 will conform to this cavity 51a, 52a and be folded, see for instance figure 2b. The sheet 3 may be kept in place by for instance vacuum means associated with the mould such that the sheet 3 is properly conformed to the mould cavity. Alternatively or additionally, the sheet 3, in particular when a foil is used, is kept in place in the mould by static attraction. After injecting the first material for outer part 2 though inlet 53, the sheet 3 will be moulded or fused together to the outer part 2, such that a monolithic crate 1 is obtained. It will be appreciated that the compete inner surface 11a, 12a and 13a is formed by the sheet 3. The sheet 3 as shown in figure 2a is pre-cut to match the shape and size of the bottom 13a and side walls 11, 12 of the outer part 2. Edges 31 and 32, for example, will come together upon folding. To ensure that the complete inner surface of the crate 1 is formed by the sheet 3, such that no material of the outer part 2 is exposed to the holding area 10, the corners 14 of the outer part 2 are provided with grooves 15. Edges 31, 32 are thus received in the grooves 15. It is then preferred if the sheet 3 is over dimensioned, such that a double layer of material 31, 32 is received in the grooves 15. As an alternative, a larger foil may be used as sheet material. The sheet may be cut to size after formation of the crate.

As in particular visible in figure 2c, the outer crate 2 consists of a frame work, in this example of horizontal beams 22 and vertical beams 21 forming the side walls 11, 12. Also the bottom 13 is formed by beams 23, including diagonal beams 23a. The crate 2 as shown in figure 2c as such is not suitable to receive smaller articles; the articles would fall through the openings 25 between the beams. However, as the sheet 3 is moulded together with the outer crate 2, the crate 1 (see figure 1) can hold smaller articles. The outer crate 2 thereby functions as stiffening member, whereas the sheet 3 helps containing smaller articles. It is noted that also the sheet 3 may contain holes 34. These holes may for instance be used to handle the crate 1 by machines. It is also possible that the sheet 3 contains more openings, also in the side walls 11, 12a. It is then important that the sheet 3 at least covers the material of the outer crate 2, such that the material of the outer crate 2 is not exposed to the holding area 10. The present invention is not Hmited to the embodiment shown, but extends also to other embodiments falling within the scope of the appended claims.

Claims (15)

Conclusions A crate comprising a bottom and side walls extending from the bottom to form a retention area in the crate, the crate being made by a molding technique of a first material, the crate further comprising a layer of a second material which is applied to the inner walls of the side walls and to the bottom by an in-mould labeling technique, characterized in that the first material is a non-food grade plastic such as recycled plastic or low grade plastic. off-grade plastic). and wherein the second material is a food-safe material, the second material covering at least the first material as viewed from the holding area, such that a food-safe layer forms the holding area. 2. A crate according to claim 1, wherein the food-safe layer comprises a sheet or foil of food-safe material. 3. A crate according to claim 1 or 2, wherein the food-safe material comprises a plastic. 4. A crate according to at least one of the preceding claims, wherein the layer of the second material has a thickness of less than 0.5 mm, preferably less than 0.1 mm. 5. Crate according to at least one of the preceding claims, wherein the Crate, as defined by the first material, comprises a number of openings. A crate according to claim 5, wherein the layer of the second material at least partially spans at least one of the openings. A crate according to at least one of the preceding claims 5 - 6, wherein the crate, as defined by the first material, comprises a plurality of stiffening beams, the layer of second material extending at least partially between the stiffening beams, 8. A crate according to at least one of the preceding claims, wherein the layer of the second material comprises a number of openings. 9. A crate according to at least claims 5 and 8, wherein the total surface of the openings in the first material is larger than the total surface of the openings in the second material. 10. A crate according to at least one of the preceding claims, wherein at least one of the corners connecting two side walls or a side wall connecting the bottom comprises a recess for receiving an edge of the layer of second material. A crate according to at least one of the preceding claims, wherein the first and second materials comprise PE, PP, styrene or a combination thereof. 12. Method for manufacturing a crate, in particular according to at least one of the preceding claims, formed in a mold for manufacturing the crate, wherein the crate comprises a bottom and side walls extending from the bottom for forming of a holding region comprising the steps of: a. providing a layer of second food-safe material in the mold; b. injecting a first material onto the second material into the mold, where the first material is a non-food grade plastic, such as recycled plastic or off-grade plastic, such that the second material has a low forms on the inner walls of the side walls and the bottom, such that the food-safe layer forms the holding area. A method according to claim 12, wherein the crate is manufactured using an injection molding technique and wherein the layer of food-safe material is formed using an in-mold labeling technique. The method of claim 12 or 13, wherein the step of providing the layer of second material comprises providing a sheet of plastic material. The method of claim 14, wherein the sheet of material is pre-cut to fit the side walls and bottom in the molded position.