NZ533339A - Returnable can carrier - Google Patents

Description

NEW ZEALAND PATENTS ACT, 1953 No: 533399 Date: 4 June 2004 COMPLETE SPECIFICATION IMPROVEMENTS IN PACKAGING AND PACKAGING METHODS RELATING THERETO We, ALTO PACKAGING LIMITED, a company duly incorporated under the laws of New Zealand of Level 6, LJ Hooker House, 57-59 Symonds Street, Auckland, New Zealand, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention relates to an improvement to packaging and a packaging method devised particularly though not solely for use in modified atmosphere packaging of meat.

Traditionally meat exporters have used vacuum packing and gas flush packaging systems to package meats. Such techniques aim to extend shelf life of fresh chilled meats to be sold in supermarkets or to be exported. Gas flush packaging techniques are generally referred to as modified atmosphere packaging or MAP.

Due to rapid growth in consumer demand for chilled or non-frozen meat products, technologies for packaging meat have been developed over the years to enable meat processors to export their product by chilled sea freight or air freight to every corner of the world economically, with the aim of maintaining the texture and quality, and extending the shelf life of the meat. It is also important that the meat is handled and packed in a hygienic environment to ensure clean, contamination-free products are delivered to the customers.

One current method for wrapping and packaging, for example meat primals (such as lamb legs, shoulders etc.), utilises a piece of absorbent wrap, which incorporates a film or films laminated to four layers of tissue paper. The film is perforated with needles to allow air and blood flow. The wrap is wrapped around a majority of each meat primal cut prior to it being placed in either a barrier pouch or a barrier thermoformed master pack. The or at least one of the films also has bone puncture resistant properties to reduce the incidence of a bone of the cut so wrapped from puncturing the master pack.

The ambient atmosphere is then withdrawn from the master pack and replaced by a preservative gas or gas mixture that delays the growth of spoilage organisms thus allowing meat to be stored for a longer period of time. Thereafter the barrier pouch or master pack is sealed to ensure no egress of the preservative gas and no ingress of ambient gas, in particular, oxygen. Oxygen will cause the formation of brown metmyogloblin on the surface of meat. It is thus important to keep the oxygen levels low so that the meat will bloom back to a fresh red meat colour when the pouches or the waster pack are opened, and the contents are exposed to normal atmosphere.

Intellectual Property (jft't - *" v 19 FEB 2007 There are a number of benefits of this absorbent wrap and its use in MAP, including: 1) it allows much of the ambient atmosphere around each meat primal to be withdrawn. However, at times this is not completely efficient. For example, when adjacent meat primals are packed, some may be touching each. A void may be created between touching pieces of meat or between touching absorbent wraps (ie the touching bone puncture resistant film), at which the ambient atmosphere may be trapped. Likewise air may be trapped between meat and plastic film of the wrap and also the outer barrier plastic pack. This may have critical effects as even tiny amounts of residual oxygen can cause the meat to turn brown irreversibly; 2) It absorbs any exudate (blood or fluid) given up from the cut surfaces of the meat thereby minimising staining of the fat surfaces of the meat and removing an environment that has potential to propagate microbial growth, 3) It provides some degree of bone puncture resistance thereby minimising the instance of bone puncture through the outer barrier pouch or master pack.

Nevertheless the current wrap does not perform a very effective role in minimising bone puncture especially if the packed meat (in boxes for example) is dropped. This is due to the thin and weak nature of the film and the weakening of the tissue over time due to blood absorption. Over time the whole structure becomes an ineffective bone guard. The bone can perforate through the outer barrier pack exposing the meat to oxygen in the atmosphere. This causes the meat to go off.

Also, the current method of wrapping the meat primals is very labour intensive (as it is performed by hand) and there is a demand to minimise such labour cost which will in turn keep the prices of premium chilled meats low if not competitive. The labour cost can be significantly reduced by automating the wrapping process. Furthermore we have found that puncturing of the master pack predominantly occurs at the bottom of the master pack. Hence the wrapping of each primal with a wrap which includes a bone puncture resistant film, other than those primals located at the bottom of the master pack, has little or no additional impact on reducing the incidence of master pack bone puncture.

Also the prior art wraps that include both absorbent properties, breathing properties and bone puncture properties have a significant thickness. If such is provided as roll stock for automated processing, roll changes would be very frequent due to the reduced roll length for an given roll diameter. In addition, a think wrap also become difficult to handle and heat seal into a pouch formation due to high temperature and/dwell time heat sealing requirements therefore not conveniently or efficiently lending itself to automated processing. It is hence that primals are manually wrapped by such prior art wraps.

Accordingly it is an object of the present invention is to provide a packaging and packaging method for meat and/or combinations or assemblies which addresses the above disadvantages or which will at least provide the public with a useful choice.

In a first aspect the present invention consists in a modified atmosphere pack that contains at least (a) a meat cut that is at least in part enveloped by a flexible sheet that includes a breather layer of a gas permeable configuration, and (b) a pad provided in a location to be capable of being in fluid connection with said at least one meat cut, said pad including an absorbent material and a ply of plastic film, said pad located intermediate of (i) said at least one meat cut and said flexible sheet and (ii) part of said pack.

Preferably said breather layer comprises of non woven roving of at least one material selected from (a) polyethylene and (b) polyester.

Preferably said breather layer comprises of at least one material selected from at least one of (a) fibres of polyethylene and (b) fibres of polyester.

Preferably said breather layer is captured between a sealing layer and a meat contact layer, said meat contact layer contiguous the meat proximate more to be disposed major surface of said breather layer, wherein said meat contact layer is gas permeable.

Preferably said meat contact layer is liquid permeable.

Intellectual Property i )tt»f >. v \ij y* 1 9 FEB 2007 e C £ I v e r Preferably said meat contact layer is perforated.

In a further aspect the present invention consists in a method of packaging meat cuts, said method being a precursor to modified atmosphere sealing of the meat cuts in a modified atmosphere environment, said method comprising: a. placing a meat cut within and adjacent the leading edge of a tube of a flexible and gas permeable configuration, b. sealing the leading edge of said tube to close the tube thereat, c. sealing said tube to itself a pouch length inwardly from said leading edge in the longitudinal direction of said tube, to enclose said meat cut within a pouch so formed, and severing said pouch from said tube, and d. placing said meat cut containing pouch in barrier pouch that has a pad provided at the bottom of the barrier pouch and in a location to be capable of being in fluid connection with said meat cut, said pad including an absorbent material and a ply of plastic film.

In a further aspect as part of a modified atmosphere packaging system for packaging meat cuts in a modified atmosphere, (i) a master pack to contain a plurality meat cuts each at least in part enveloped by a flexible sheet that includes a breather layer of a gas permeable configuration, and (ii) a pad provided in a location to be capable of being in fluid connection with said at least one meat cut, said pad including an absorbent material and a ply of plastic film, said pad located at the bottom of the master pack to offer a puncture resistant lining at the bottom of the master pack.

Preferably there is included a flexible sheet material that includes a breather layer.

Unless otherwise herein specified, or unless clearly unable to meet the purposive nature of the plies of layers of material, it is to be appreciated that the layers of plies are disposed to a side of another layer but with limitation to there being layers intermediate.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or Intellectual Property tJftlf ->" V \! 7 1 9 FEB 2007 collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

A preferred form of the present invention will now be described with reference to the accompanying drawings in which; Figure 1A is sectional view of a layer of flexible sheet material of one preferred embodiment of the present invention, Figure IB shows a coating layer applied or laminated on the layer of sheet material of Figure 1A, Figure 1C shows a perforated or gas and liquid permeable third layer, which is to be exposed for fluid contact or direct contact with the meat, is applied or laminated on the layers of sheet material of Figure IB, Figure 2 is a perspective view of packaged meat, Figure 3 shows an automated process of wrapping the meat from a roll of sheet material, Figure 4 is a perspective view of a pad of one preferred embodiment of the present invention, Figure 5 is a cross sectional view of the pad in Figure 4 Figure 6 is a perspective view of a pad of another preferred embodiment of the pad, Figure 7 is a cross sectional view of the pad in Figure 6 Figure 8 is a cross section view of a further preferred embodiment of the pad.

Reference will now be made to preferred embodiments including two novel components, and the application of the packaging system for packing meat or meat primals.

The first component is hereinafter referred to as the "wrap" component and the second component is hereinafter referred to as the "pad" component. Each may be Intellectual Property Qli'i, , v o 7 19 FEB 2007 used independent of each other or in combination taking advantage of the benefits offered by both.

A. The Wrap The wrap component of the packaging system of the present invention relates to the awrap material and use thereof with meat.

The wrap material in the preferred embodiment is a matting that consists of or includes a non-woven mass/mat of plastic fibres 1 such as polyethylene (PE) or polyester (PET). The wrap may optionally have a polyethylene (PE) coating or laminated ply 2 provided to the mat 1 to the sealing side thereof. Other layers may also be provided of other materials but so long as the mass/mat of fibres is able to be exposed for fluid contact or direct contact with the meat 20. A perforated or otherwise fluid permeable film 3 may for example, cover the mat 1 at the meat contact side of the wrap material, opposite the sealing side. In this configuration the mat 1 is captured intermediate of the plies of film 2, 3.

The meat may then be wrapped by the wrap material to enclosc the meat in a pouch like enclosure defined by the wrap (see page 2). Once the meat 20 has been wrapped, the meat is placed in a master pack. The ambient atmosphere may then be removed, and finally a preservative gas or gas mixture may be admitted.

The optional PET ply 2 provides for toughness so as to assist in preventing the bone puncturing the packaging material such as the barrier pouch or master pack in the event that the packaged meat is dropped on the ground.

Each individual cut is wrapped by the wrap. Hence preferably each package formed by the wrap hence has only one cut of primal meat in it, preventing such a primal contacting other primals.

Advantages of the Novel Wrap Material The nature of the wrap material allows the wrapping process as illustrated by the schematic components 30 of Figure 3 to be automated. Overall the materials used to define the wrap are light and cost effective and because they offer high linear length per roll 32 they significantly reduce the number of roll changes in an automated intellectual Property 1 9 FEB 2007 process using the wrap. Hence it equates to more machine up time and reduced operator time spent on roll changes.

A second advantage of the use of this wrap is in the evacuation of the ambient air from adjacent the wrap. As the polymer fibres of the mat 1 in the non-woven fabric allow air flow through its structure, this material creates a gas pathway between adjacent primals to remove ambient atmosphere.

Another advantage is that the fibres, when coated or conditioned appropriately, the can be hydrophilic thereby allowing the blood or liquid to be drawn away from the meat by capillary action along the fibres. The capillary action draws the blood into the structure of the pad and creates an osmotic pressure which in turn causes the blood to be drawn away from the meat along the hydrophilic fibres to the absorbent pad.

B. The Pad The second component of the system is a pad 40 for use or the use of such a pad when the wrapped meat is placed in a master pack such as a barrier pouch thermoformed master pack.

The pad 40 is placed at the base of the pouch or master pack with the aim of imparting puncture resistance (and preferably also to absorb juices from the meats). However the invention is not restricted to being placed at the base.

It is preferably placed at the bottom of the pouch or master pack because in the vast majority of cases the bone puncture is through the bottom surface of the barrier pouch or master pack as a result of the carton or box or packaging of meat being dropped or tossed into a container during loading and unloading. Further, as the blood flow is assisted by gravity it is also the most appropriate place to locate the pad so that if the pad includes an absorption material, it functions as a means for absorbing juices. However, other locations of the pad in relation to the meat may also be envisaged within the scope of the invention.

There are a number of different structural embodiments of the pad which are appropriate, although it will be appreciated these are merely examples and the invention is not restricted to these embodiments. intellectual Pt*operty 1, Ift'i v \s 7 1 9 FEB 2007 In the first embodiment the pad structure includes a top layer 60 providing a meat contact surface of non woven fabric such as a non-woven mass/mat of plastic fibres such as polyethylene (PE) or polyester (PET). This top layer 60 allows or facilitates both gas flow and blood to flow there through into the structure beneath. It also provides the advantage of allowing gas flow providing the benefits as desired with reference to the wrap.

The pad, beneath the layer 60, is of an air-laid structure 66. The air-laid structure 66 includes materials which are preferably cellulose in nature and delineated.

Wood fibre of which bleached wood pulp is most preferred. These materials and structure can define an absorbent pad. The pad may also optionally incorporate "SAP" 50 (super absorbent powder/polymer) and/or super absorbent fibres ("SAF").

The SAP is an extruded polymer which is ground to a powder. SAF is an extrude polymer extruded as a fibre and cut to length.

The cellulose pad with the SAP or SAF may be pre-manufactured and then laminated to the PE film. This cellulose pad helps to absorb the fluids from the meat or meat primals either directly or via the fibres of the wrap material (if used) as described above. The air-laid fibre 52 mat is preferably embossed with such as wilt a diamond pattern which assists in wicking the blood/ fluid away from the meat or fat surface. The SAP 50 absorbs and contain the exudates reducing wet back onto the meat or meat primals and consequently fat staining to the underside of the primals.

The final component of this embodiment of the pad is a base layer 62 of tough material designed to stop bone puncture. The base layer 62 is provided outwardly from the meat contact or proximate more layers of the pad. Base layer 62 could be either a woven fabric as is commonly used for boneguard in the meat industry or an ultra tough biaxially oriented polymer of polyethylene (PE) to make thermal bonding of the base and top layers (62, 60) at the perimeter 64 of the pad easy thereby giving the pad the structural integrity required. Other desirable but optional properties of the base layer 62 could include the addition of an anti microbial coating to reduce microbial growth in the pad and/or adhesive strips on its outer surface of the pad to ensure that the pad does not move in the barrier pouch or master pack during transit.

Intellectual propertv t Jttlfyi £ 19 FEB 2007 RFPCl\/r One further adaptation or addition to the pad could be to affix another layer of base material (62 or 80) over the top layer being the meat proximate most layer of the pad. This would be adhered to the pad's perimeter on three sides leaving one side open to effectively form a boneguard pouch with an absorbent underside. See for Example figure 8. This structure would completely protect the barrier pouch and/or master pack in extreme circumstances. Hence, a pouch within a pouch can act as a additional protection. Layer 62 may be perforated to allow the blood to pass through it to the absorbent material.

A second embodiment of the pad is shown in Figure 4. Here, a top layer 42 (either a woven fabric or an ultra tough biaxially oriented polymer preferably of PE), is provided to another layer 46 of air laid absorbent fibre 52. SAP 50 may again be contained in the absorbent layer. In this configuration, the top layer 42 is perforated by inserting small holes 44, there through to allow blood flow to the SAP.

Optionally there may also be a base layer. The base layer may include an anti microbial coating to reduce microbial growth. The pad may also include an adhesive strips on the outer surface of the pad to ensure the pad does not move in the barrier pouch or master pack during transit. Similarly the pad structure of this configuration can also incorporate any further adaptation as mentioned above.

Use of the Wrap and the Pad of the Invention.

The wrap and pad may be utilised in a process that is automated. The wrap may be applied about the primal by machine. The pad may be placed in the base of the barrier pouch or master pack by hand or machine prior to the loading of the wrapped primal.

After the wrapped meat primal is placed in a barrier pouch or thermoformed master pack with a pad at the base of the pouch or master pack, the ambient atmosphere is withdrawn and a preservative gas or gas mixture is passed into the barrier pouch or master pack before it is sealed to ensure no egress of the preservative gas or gas mixture and no ingress of ambient gases. The juices from the meat can be absorbed by the pad at the bottom of the master pack. The pad also includes bone puncture resistant film to prevent or reduce the incidence of bone puncture through the Intellectual Pr0penv I 9 FEB 200? bottom of the master pack due to the pad being interposed the bottom of the master pack and the primal or stack of primals. The wrap allows breathing and in the preferred form, where the wrap consist solely of the non woven roving ply, the incidence of trapped air is negligible. The wrap can encompass the entire primal and prevent meat touching each other and the master pack thereby also reducing the incidence of trapped air. The wrap, not carrying a bone puncture resistance ply is cheaper to make that if it had a bone puncture resistant ply, is or a thinned gauge allowing more metres of stock to be carried on a roll of a given diameter. Of thinner gauge, the wrap also more conveniently or efficiently also lends itself to heat sealing. With the wrap encompassing the entire primal there is also no need to provide additional barrier to avoid contact of the cellulosic material of the pad with the meat. The wrap provides sufficient barrier for such purposes. Hence the pad does not need additional plies to capture the cellulosic material within the pad. The cellulosic material may be exposed to one side of said pad.

Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth.

Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and/or improvements may be made without departing from the scope or spirit of the invention.

In addition, where features or aspects of the invention are described in terms of Markush groups, those skilled in the art will recognise that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.

Intellectual Property { iftlr v -V 7 19 FEB 2007 r e c e i v e t

Claims (9)

1. A modified atmosphere pack that contains at least (a) a meat cut that is at least in part enveloped by a flexible sheet that includes a breather layer of a gas permeable configuration, and (b) a pad provided in a location to be capable of being in fluid connection with said at least one meat cut, said pad including an absorbent material and a ply of plastic film, said pad located intermediate of (i) said at least one meat cut and said flexible sheet and (ii) part of said pack.

2. A modified atmosphere pack as claimed in claim 1 wherein said breather layer comprises of non woven roving of at least one material selected from (a) polyethylene and (b) polyester.

3. A modified atmosphere pack as claimed in claim 1 wherein said breather layer comprises of at least one material selected from at least one of (a) fibres of polyethylene and (b) fibres of polyester.

4. A modified atmosphere pack as claimed in any one of claims 1 to 3 wherein said breather layer is captured between a sealing layer and a meat contact layer, said meat contact layer contiguous the meat proximate more to be disposed major surface of said breather layer, wherein said meat contact layer is gas permeable.

5. A modified atmosphere pack as claimed in claim 4 wherein said meat contact layer is liquid permeable.

6. A modified atmosphere pack as claimed in claim 4 or 5 wherein said meat contact layer is perforated.

7. A method of packaging meat cuts, said method being a precursor to modified atmosphere sealing of the meat cuts in a modified atmosphere environment, said method comprising: a. placing a meat cut within and adjacent the leading edge of a tube of a flexible and gas permeable configuration, b. sealing the leading edge of said tube to close the tube thereat, c. sealing said tube to itself a pouch length inwardly from said leading edge in the longitudinal direction of said tube, to enclose said meat cut within a pouch so formed, and severing said pouch from said tube, and Intellectual Proper i .iff'* -i- v M 7 19 FEB 2007 - 13 - d. placing said meat cut containing pouch in barrier pouch that has a pad provided at the bottom of the barrier pouch and in a location to be capable of being in fluid connection with said meat cut, said pad including an absorbent material and a ply of plastic film.

8. As part of a modified atmosphere packaging system for packaging meat cuts in a modified atmosphere, (i) a master pack to contain a plurality meat cuts each at least in part enveloped by a flexible sheet that includes a breather layer of a gas permeable configuration, and (ii) a pad provided in a location to be capable of being in fluid connection with said at least one meat cut, said pad including an absorbent material and a ply of plastic film, said pad located at the bottom of the master pack to offer a puncture resistant lining at the bottom of the master pack.

9. As part of a system of claim 8, the flexible sheet material that includes a breather layer. Intellectual Property Qfth v Vl 7 19 FEB 2007 received