US20060034979A1

US20060034979A1 - Packaged food products

Info

Publication number: US20060034979A1
Application number: US10/916,115
Authority: US
Inventors: Mark Stenbeck; Anthony Huot
Original assignee: EMERALD FOODS Inc
Current assignee: EMERALD FOODS Inc
Priority date: 2004-08-11
Filing date: 2004-08-11
Publication date: 2006-02-16

Abstract

The present invention is a packaged food product for placement in a refrigerated section of a retail store for sale to a retail customer and adapted to have a specific shelf life when generally maintained at a temperature between approximately 38° F. and approximately 48° F. In one embodiment, the product includes a container, an amount of cheese, an amount of meat, and an atmosphere. The container includes a sealed interior volume at least partially defined by a barrier with an oxygen permeability of less than 0.5 cubic centimeters of oxygen per 100 square inches of barrier area per 24 hours at 73° F., zero percent relative humidity and standard atmospheric pressure. The amount of cheese is located within the sealed volume. The cheese is a natural cheese (i.e., not a processed cheese) and is not frozen prior to being sold to the customer. The amount of meat is located within the sealed volume and is in physical contact with the amount of cheese. The atmosphere is located within the sealed volume and has an oxygen content of less than 0.5 percent.

Description

FIELD OF THE INVENTION

The present invention relates to packaged food products and methods for preparing packaged food products. More specifically, the present invention relates to packaged meat and cheese food products and methods of preparing such food products.

BACKGROUND OF THE INVENTION

Meat and cheese have complimentary tastes that consumers enjoy experiencing at the same time. For example, meat and cheese are often eaten together in sandwiches, pizza, and other foods. Meat and cheese are also enjoyed together as a snack with nothing else (e.g., a meat and cheese platter).
To capitalize on the consumer's desire to experience the flavors of meat and cheese together with nothing else, retail stores sell various meat and cheese products. For example, retail stores sell shelf-stable meat products and shelf-stable cheese products. Shelf-stable products are packaged within either shrink poly or polypropylene bag material and, while these products have a substantial shelf life and do not need to be refrigerated, they are difficult to open. Furthermore, USDA regulations prohibit shelf-stable meat and cheese from touching. As a result, shelf-stable meat and cheese products must be packaged separately. This hinders the consumer's ability to simultaneously enjoy meat and cheese because two packages must be opened and manipulated at the same time. Finally, shelf-stable products utilize processed cheese, which has a less preferable taste and texture as compared to natural cheese.
Retail stores sell meat and cheese products in their deli sections. These deli-type products typically have meat and cheese placed in a plastic tray. The plastic tray is then wrapped over with plastic film or poly material. This is a typical arrangement for a common meat and cheese platter. These deli-type products are either prepared daily by the deli department of the retail store or the products are frozen after manufacture and shipped to the retail store. In either case, the deli-type product's shelf life is quite limited, typically ranging from 5-14 days at best. Also, freezing adversely impacts the taste and texture of cheese.
Retail stores sell meat and cheese products in their refrigerated sections that are prepackaged by a manufacturer and shipped to the retail store. An example of such a prepackaged product would be a meat and cheese type platter sold by Oscar Mayer® (i.e., Kraft Foods) under the name of Lunchables®. With this prepackaged product, the meat and cheese are placed in separate sections of a tray. Each section has its own seal such that the meat and cheese are sealed separately from each other. Also, this prepackaged product utilizes processed cheese. The typical shelf life for such prepackaged products is approximately 45 to 90 days.
There is a need in the art for a packaged food product that allows convenient, simultaneous enjoyment of meat and natural cheese and has a substantial shelf life. There is also a need in the art for a method of producing such a package food product and providing it to a retail customer.

BRIEF SUMMARY OF THE INVENTION

The present invention, in one embodiment, is a packaged food product for placement in a refrigerated section of a retail store for sale to a retail customer and adapted to have a specific shelf life when generally maintained at a temperature between approximately 38° F. and approximately 48° F. In one embodiment, the product includes a container, an amount of cheese, an amount of meat, and an atmosphere. The container includes a sealed interior volume at least partially defined by a barrier with an oxygen permeability of less than 0.5 cubic centimeters of oxygen per 100 square inches of barrier area per 24 hours at 73° F., zero percent relative humidity, and standard atmospheric pressure (i.e., approximately 1 atmosphere). The amount of cheese is located within the sealed volume. The cheese is natural (i.e., not a processed cheese) and is not frozen prior to being sold to the customer. In one embodiment, the natural cheese is also a non-pasteurized cheese. The amount of meat is located within the sealed volume and is in physical contact with the amount of cheese. The atmosphere is located within the sealed volume and has an oxygen content of less than 0.5 percent.
In one embodiment, the product has a shelf life of at least approximately 90 days. In another embodiment, the product has a shelf life of approximately 90 days to approximately 180 days.
In one embodiment, the atmosphere is substantially nitrogen. In another embodiment, the atmosphere is substantially carbon dioxide. In yet another embodiment, the atmosphere is substantially comprised of nitrogen and carbon dioxide. In one embodiment, the amount of cheese is treated with an antimicrobiological agent, such as natamycin.
In one embodiment, the container is a clear cup with ultra violet protection and a removable top. In one embodiment, the removable top is a peal type top. In one embodiment, a lid, which includes a detachable eating utensil, is placed over the peal type top.
In one embodiment, the container is a clear flexible or semi-flexible bag, which has ultra violet protection and/or a substantial percentage of the bag surface is covered with printing. In one embodiment, an eating utensil is included with the bag. In one embodiment, the bag includes a grooved resealable opening.
The present invention, in another embodiment, is a method of producing a packaged food product and providing the product to a retail customer, wherein the product is adapted to have a specific shelf life when generally maintained at a temperature between approximately 38° F. and approximately 48° F. In one embodiment, the product includes providing a container with an interior volume, placing an amount of cheese into the volume, placing an amount of meat into the volume, injecting the volume with a gas, sealing the volume, marking the container with a self-life date, placing the container into a refrigerated area, and allowing the customer to access the product in a retail store.
In one embodiment, the interior volume of the container will be at least partially defined by a barrier with an oxygen permeability of less than 0.5 cubic centimeters of oxygen per 100 square inches of barrier area per 24 hours at 73° F., zero percent relative humidity and standard atmospheric pressure (i.e., approximately 1 atmosphere). The cheese is natural (i.e., not a processed cheese) and is not frozen prior to being provided to the customer, and the amount of meat is in physical contact with the amount of cheese. In one embodiment, the natural cheese is also not pasteurized. The gas is injected such that the volume ends up having an atmosphere with an oxygen content of less than 0.5 percent, and sealing the volume helps to maintain the atmosphere in this condition.
In one embodiment, the marked shelf life date is at least approximately 90 days subsequent to the date the volume was sealed. In another embodiment, the shelf life date is at least approximately 90 days subsequent to the date the volume was sealed, but not more than approximately 180 days subsequent to the date the volume was sealed.
In one embodiment, the refrigerated area is generally maintained at a temperature of between approximately 38° F. and approximately 48° F. In another embodiment, the refrigerated area is generally maintained at a temperature of between approximately 33° F. and approximately 49° F. or 50° F. In one embodiment, the volume is subjected to vacuum conditions prior to being injected with gas.
While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded isometric view of one embodiment of the packaged food product wherein an amount of meat and cheese is sealed within a cup container.
FIG. 2 is a section elevation of the cup taken along section line AA in FIG. 1.
FIG. 3 is an isometric view of the lid with the integral eating utensil removed.
FIG. 4 is an isometric view of the eating utensil in its folded configuration immediately after being separated from the lid, but prior to being assembled into its use configuration.
FIG. 5 is an isometric view of the eating utensil after being assembled into its use configuration.
FIG. 6 is a front elevation of another embodiment of the packaged food product wherein the amount of meat and cheese is sealed within a bag.
FIG. 7 is a plan view of a packaging line for producing the package food product of the subject invention.
FIG. 8 is a flow chart outlining the method of producing the packaged food product and providing it to a retail customer.

DETAILED DESCRIPTION

In one embodiment, the packaged food product of the subject invention includes an easily openable and conveniently sized container enclosing amounts of meat and natural cheese in physical contact. The packaged food product has features that allow it to have a significant shelf life without resorting to processed cheeses, freezing or making the meat and cheese shelf-stable, all of which adversely impact the taste and texture of cheese. Thus, the package food product offers a consumer the ability to conveniently enjoy a low carbohydrate snack having the palatable combination of meat and natural cheese.
For a detailed discussion of the packaged food product of the subject invention, reference is now made to FIG. 1, which is a partially exploded isometric view of one embodiment of the packaged food product 2. As shown in FIG. 1, the packaged food product 2 includes amounts 4 of meat and natural cheese enclosed within a cup 6 sealed by a peal seal 8 and having a lid 10 adapted to fit onto the top of the cup 6 and cover the peal seal 8. As indicated in FIG. 1, in one embodiment, the lid 10 includes an eating utensil 11 formed into the lid 10.
As illustrated in FIG. 1, in one embodiment, the cup 6 is clear (i.e., generally see-through) and has a label 12 encompassing at least a portion of the cup 6. As shown in FIG. 1, the label 12 has a window 14 through which the amounts 4 of meat and natural cheese may be viewed.
For a more detailed discussion of the sealed cup 6 and its contents, reference is made to FIG. 2, which is a section elevation of the cup 6 taken along section line AA in FIG. 1. As shown in FIG. 2, the cup 6 has walls 6 a that extend continuously between a base 6 b and a continuous lip 6 c. The peal seal 8 is removably affixed to the top surface of the cup's lip 6 c. The walls 6 a, base 6 b and peal seal 8 define a volume within the cup that contains, and completely encloses, the contents of the cup 6.
As indicated in FIG. 2, in one embodiment, the contents of the cup 6 are amounts 4 of meat and natural cheese and an atmosphere 16. The amounts 4 of meat and cheese are in physical contact. In one embodiment, the atmosphere 16 is substantially nitrogen and has an oxygen content of less than approximately 0.5 percent. In one embodiment, the atmosphere 16 is substantially carbon dioxide and has an oxygen content of less than approximately 0.5 percent. In one embodiment, the atmosphere 16 is substantially a combination of nitrogen and carbon dioxide and has an oxygen content of less than approximately 0.5 percent. In one embodiment, the atmosphere is substantially other types of inert gases or combinations of inert gases and has an oxygen content of less than approximately 0.5 percent.
In one embodiment, the cup's uppermost internal diameter is approximately 2.8″, the external diameter of the cup's lip 6 c is approximately 3.2″, and the cup's height from the bottom of the cup's base 6 b to the top of the cup's lip 6 c is approximately 3.4″. In one embodiment, the cup 6 is a clear barrier cup of approximately six-ounce size and holding approximately 1.4 ounces of meat and approximately 2.2 ounces of natural cheese.
In one embodiment, the cup 6 is made from thermoformed or pressure-formed polypropylene with approximately three percent to approximately eight percent EVOH. In one embodiment, the cup 6 weights between approximately six grams and approximately ten grams. In one embodiment, the cup 6 is configured such that it has thicknesses of approximately 60 mils for the cup's lip 6 c, approximately 12 mils for the cup's sidewall 6 a, and approximately 20 mils for the cup's base 6 b. Cups 6 having one or more of the aforementioned features may be obtained from CPT Coextruded Plastics Technologies, Inc. of 415 E. Fulton Street, Edgerton, Wis. 53534, Plasdecol, Avenida 37B, #44-31, Itaqui, Ant. Colombia; or Huhtamaki Instanbul Ambalaj Sanayi A.S., SAN-BIR Bulvan 3. Bolge 6, Cadde No: 46B, Cekmece, 34900 Instanbul, Turkey.
In one embodiment, the peal seal 8 is a multilayer configuration that is approximately 2.8 to approximately 3.2 mils thick. In one embodiment the multilayer configuration includes a PET layer that is approximately 48 ga., an ink layer; a PEL layer that is approximately 75 ga., and a Coex. EVOH single site LLDPE layer that is approximately 1.75 mils thick. Peal seals 8 having one or more of the aforementioned features may be obtained from Curwood Bemis Co., 2200 Badger Avenue, Oshkosh, Wis. 54904 or Plastopil, Kibbutz Hazorea 30060 Israel.
In one embodiment, the cup 6 and peal seal 8 provide a barrier with an oxygen permeability of less than 0.5 cubic centimeters of oxygen per 100 square inches of barrier area per 24 hours at 73° F., zero percent relative humidity and standard atmospheric pressure (i.e., approximately 1 atmosphere). In one embodiment, the cup 6 and peal seal 8 will have the aforementioned oxygen permeability when tested according to ASTM F1307-90. This oxygen barrier feature helps to maintain the atmosphere 16 within the sealed cup at an oxygen content of less than approximately 0.5 percent. Consequently, when the packaged food product 2 is generally maintained at a temperature between approximately 38° F. and approximately 48° F., the contents of the packaged food product 2 will have a shelf life of at least approximately 90 days. In one embodiment, the shelf life will be between approximately 90 days to approximately 180 days.
In another embodiment, where the packaged food product 2 is generally maintained at a temperature between approximately 33° F. and approximately 48° F., the contents of the packaged food product 2 will have a shelf life of at least approximately 90 days. In one embodiment, the shelf life will be between approximately 90 days to approximately 180 days. In one embodiment, the packaged food product 2 will have one of the aforementioned shelf lives if generally maintained at a temperature of between approximately 33° F. and approximately 49° F. or 50° F.
In one embodiment, the contents of the cup 6 are protected from ultra violet radiation. In one embodiment, as shown in FIG. 1, this is achieved by wrapping an ultra violet resistant label 12 about the cup 6. In one embodiment, the label 12 is provided with an ink layer that covers a substantial percentage of the label's surface. As indicated in FIG. 1, in one embodiment, the label 12 has an inkless area that forms a generally see-through window 14 that allows the contents of the cup 6 to be viewed.
In one embodiment, the cup 6 itself is made of material that is ultra violet resistant, but still allows the cup 6 to be generally see-through (e.g., the above-discussed thermoformed or pressure-formed polypropylene material having approximately three percent to approximately eight percent EVOH and being provided with an UV light inhibitor or stabilizer
Similarly, in one embodiment, the peal seal 8 is ultra violet resistant. In one embodiment, this is achieved via a layer of ink printing placed on the peal seal 8. In another embodiment, the peal seal 8 is made of a polymer or other material that is ultra violet resistant (e.g., the above-discussed peal seal 8 with its multilayered configuration).
In one embodiment, the cheese sealed within the cup 6 is a natural cheese. In other words, the cheese sealed within the cup 6 is not processed cheese. Processed cheese is a cheese product made by combining one or more cheese types with other non-cheese ingredients. For example, in making a processed cheese, one or more natural cheese varieties (e.g., varieties such as cheddar, colby, swiss, mozzarella, provolone, etc.) and/or one or more differently aged portions of the same cheese variety are combined. The cheese combination is then heated and mixed with emulsifiers, gums, stabilizers, colorings, flavorings, etc. As compared to natural cheeses, processed cheeses have longer shelf lives and are superior when melted because they remain homogeneous and flow smoothly. However, to achieve these benefits, processed cheeses have flavor and texture that is less desirable than those of natural cheeses.
In one embodiment, the cheese sealed within the cup 6 is natural cheese that has not been frozen prior to selling it to a retail customer. While freezing can significantly increase the shelf life of a natural cheese, freezing can adversely impact the taste and texture of a natural cheese.
In one embodiment, the cheese sealed within the cup 6 is a natural cheese made from non-pasteurized milk. Thus, the cheese within the cup 6 is a non-pasteurized natural cheese. While a pasteurized natural cheese is generally considered to be safer to eat than a non-pasteurized natural cheese (this is why the U.S. Food and Drug Administration bans the sale of all cheeses made with un-pasteurized milk that have not been aged for at least 60 days), the pasteurized cheese typically will have a flavor and texture that is less desirable than those of the non-pasteurized cheese.
In one embodiment, the pieces of natural cheese sealed within the cup 6 are treated with an antimicrobiological agent to protect the natural cheese from mold and yeast growth. In one embodiment, the antimicrobiological agent is natamycin.
For a more detailed discussion of the lid 10 and its integral eating utensil 11, reference is made to FIGS. 3, 4 and 5. FIG. 3 is an isometric view of the lid 10 with the integral eating utensil 11 removed. FIG. 4 is an isometric view of the eating utensil 11 in its folded configuration immediately after being separated from the lid 10, but prior to being assembled into its use configuration. FIG. 5 is an isometric view of the eating utensil 11 after being assembled into its use configuration.
As indicated in FIG. 1, the lid 10 is provided with an eating utensil 11 integrally formed into the lid 10. As shown in FIG. 1, the eating utensil 11 forms a center strip of the lid in. As can be understood from FIG. 3, when the eating utensil 11 is separated from the lid 10, the lid 10 will have a gap or void 18 where the eating utensil 11 used to be attached to the lid 10.
As shown in FIG. 4, when the eating utensil 11 is first removed from the lid 10, it exists in a folded configuration. Specifically, the head 20 of the eating utensil 11 is folded back onto the handle 22 of the eating utensil 11. The handle 22 has rearward side portions 22 a′ that exist on each side of a rearward center portion 22 b′ and forward side portions 22 a″ that exist on each side of a forward side portion 22 b″.
As illustrated in FIG. 5, when the eating utensil 11 is assembled into the use configuration, the side portions 22 a are folded up to join each other such that the two side portions 22 a and the center portion 22 b form three sides of a handle 22 having a triangular cross-section, and the head 20 of the eating utensil 11 is folded outwards. Depending on the embodiment, the head 20 of the eating utensil 11 is a fork, pitchfork or other type of stabbing instrument, a spoon, or a spork (i.e., a fork/spoon combination). In one embodiment, the lid 10 and eating utensil 11 are made of injection molded polypropylene, thermoplastic or other types of polymers.
For a detailed discussion of another embodiment of the packaged food product 2, reference is made to FIG. 6, which is a front elevation of the packaged food product 2 having an amount 4 of meat and cheese sealed within a bag 30. In one embodiment, the bag 30 is approximately 6.5-7.25 inches wide and approximately 9 inches tall. In one embodiment, the bag 30 holds approximately 2.5 ounces of meat and approximately 4.0 ounces of natural cheese.
As shown in FIG. 6, in one embodiment, the bag 30 has a pre-made opening 32 that is resealable via a tongue and groove arrangement as found on ziplock or zipper type polymer bags. In other embodiments, where the bag 30 has no pre-made opening 32, the consumer must tear or cut an opening.
In one embodiment, the bag 30 is employs a protective packaging film such as Cupolene® Grade 7170 as manufactured by Curwood Bemis Co. of 2200 Badger Avenue, Oshkosh, Wis. 54904. In one embodiment, such a bag 30 has 3.0 mil thick walls that are a sandwich comprising the following layers: a 48 ga. PET layer; an ink layer; a 75 ga. PEL layer; and a 1.75 mil Coex. EVOH single site LLDPE layer.
In one embodiment, the bag 32 provides a barrier with an oxygen permeability of less than 0.5 cubic centimeters of oxygen per 100 square inches of barrier area per 24 hours at 73° F., zero percent relative humidity and standard atmospheric pressure (i.e., approximately 1 atmosphere). In one embodiment, the bag 32 will have the aforementioned oxygen permeability when tested according to ASTM F1307-90. This oxygen barrier feature helps to maintain the atmosphere 16 within the sealed bag 30 at an oxygen content of less than approximately 0.5 percent. Consequently, when the packaged food product 2 is generally maintained at a temperature between approximately 38° F. and approximately 48° F., the contents of the packaged food product 2 will have a shelf life of at least approximately 90 days. In one embodiment, the shelf life will be between approximately 90 days to approximately 180 days.
In one embodiment, the contents of the bag 30 are protected from ultra violet radiation. In one embodiment, as shown in FIG. 6, this is achieved by providing an ink layer that covers a substantial percentage of the bag's surface. As indicated in FIG. 6, the bag 30 may have an inkless area that forms a generally see-through window 14 that allows the contents of the bag 30 to be viewed. In one embodiment, the bag 30 is made of material that is ultra violet resistant, but still allows the bag 30 to be generally see-through. Such materials are known in the art.
In one embodiment, the bag 30 is provided with an eating utensil, such as a fork, pitchfork, spoon or spork. Such eating utensil may be provided within the bag 30 or affixed to the exterior of the bag 30.
The packaged food product 2 may contain a variety of natural cheeses. For example, in one embodiment, the pieces of natural cheese in the package food product 2 may be all cheddar, colby, jack, swiss, mozzarella, provolone, or etc. In one embodiment, the pieces of natural cheese in the packaged food product 2 may be a variety of cheeses. For example, the packaged food product 2 may include pieces of cheddar and pieces of Swiss. Alternatively, the packaged food product 2 may include pieces of colby and pieces of mozzarella. As can be understood, a nearly infinite number of natural cheese combinations may be provided in the packaged food product 2. Also, the cheese could be formed in a nearly infinite number of shapes such as letters, numbers, stars, baseball bats, footballs, hockey pucks and smile faces.
The packaged food product 2 may contain a variety of USDA inspected meats. For example, in one embodiment, the pieces of meat in the packaged food product are all beef, chicken, turkey, lamb, pork, fish, spiced meats (e.g., peppered meat or jerky), or etc. In one embodiment, the pieces of meat in the packaged food product 2 may be a variety of meats. For example, the packaged food product 2 may include pieces of beef and pieces of chicken. Alternatively, the packaged food product 2 may include pieces of turkey and pork. As can be understood, a nearly infinite number of meat combinations may be provided in the packaged food product 2. Also, the meat could be formed in a nearly infinite number of shapes such as letters, numbers, stars, baseball bats, footballs, hockey pucks and smile faces.
For a discussion of the method of producing the packaged food product 2 and providing it to a retail customer, reference is now made to FIGS. 7 and 8. FIG. 7 is a plan view of a packaging line for producing the package food product 2 of the subject invention. FIG. 8 is a flow chart outlining the method of producing the packaged food product 2 and providing it to a retail customer.
As can be understood from FIGS. 7 and 8, multiple lots of USDA inspected/approved meat and natural cheese are shipped to a packaging facility 50 (block 100). Samples from each lot of meat and cheese are pulled for microbiological testing and the lots are placed in cold storage 52 (block 102). Amounts of meat and cheese are removed from the packaging of their respective lots in the stripping room 54 (block 104).
As indicated in FIGS. 7 and 8, amounts of meat are placed in the meat hopper 56, and amounts of cheese are placed in the cheese hopper 58 (block 106). Amounts of meat move up the meat conveyor 60 to the meat side of the split scale 62, and amounts of cheese move of the cheese conveyor 64 to the cheese side of the split scale 62 (block 108). The amounts of meat and cheese are weighed separately at the split scale 62 (block 110). The amounts of meat and cheese are combined, mixed and placed in the container (i.e., the cup 6 or bag 30 of the packaged food product 2) at the container-filling machine 66 such that the pieces of meat and cheese enter the container at generally the same instant (block 112).
As can be understood from FIGS. 7 and 8, the filled containers travel along a conveyor 68 to the container flushing/sealing machine 70 (e.g., the VGF R-20 Rotary Heat Seal Machine as manufactured by Orics Industries, Inc. of College Point, N.Y. 11356 or a Pack-Line Model PXG-2 machine manufactured by Pack Line Corp. of Pine Brook, N.J. 07058) where the volumes of the containers are subjected to a vacuum, flushed with an inert gas (e.g., nitrogen, carbon dioxide, a combination of nitrogen and carbon dioxide, or other inert gases or combinations thereof) and sealed (block 114). In one embodiment, the containers are simply flushed with an inert gas and sealed. In another embodiment, a liquid inert gas is placed into the container, the liquid inert gas vaporizes into an inert gas, and the container is then sealed.
In one embodiment, when the volumes of the containers are flushed with an inert gas, or at some point prior to the flushing the container volumes by an inert gas, an antimicrobiological agent is also injected into the volume to treat the amounts of cheese and meat. In the embodiment of the packaged food product 2 that has a cup 6 for its container, a lid 10 with an integral eating utensil 11 is attached over the top of the peel seal 8 of the cup 6.
Regardless of whether the packaged food product 2 employs the aforementioned cup 6 or bag 30, the packaged food product 2 of the subject invention now exists and the volume of the sealed container is filled with amounts of meat and cheese and an atmosphere that has less than approximately 0.5 percent oxygen. The packaged food products 2 travel along a conveyor 72 from the flushing/sealing machine 70 to a metal detector 74 (block 116).
As indicated in FIGS. 7 and 8, the packaged food products 2 continue along the conveyor 72 to a label machine 76 that places a label on the packaged food product 2 and a date coder 78 that places a shelf life indicating date on the label (block 118). In one embodiment, the shelf life indicating date is a date that is at least approximately 30 days subsequent to the date the volume was sealed. In one embodiment, the shelf life indicating date is a date that is at least approximately 60 days subsequent to the date the volume was sealed. In one embodiment, the shelf life indicating date is a date that is at least approximately 90 days subsequent to the date the volume was sealed. In anther embodiment, the shelf life indicating date is a date that is at least approximately 180 days subsequent to the date the volume was sealed.
As can be understood from FIGS. 7 and 8, sample packaged food products 2 are pulled for microbiological testing and the remaining packaged food products 2 are boxed 12 via a boxing machine 79 (block 120). The boxes of packaged food products 2 then pass through a corner labeler 80, are taped closed, placed on a pallet 82, and returned to cold storage 52 for shipping to a retail outlet (block 122). At the retail outlet, the packaged food products 2 are placed in a refrigerated section of the retail outlet (block 124).
In one embodiment, the natural cheese in the packaged food product 2 has not been frozen at any time prior to the retail customer's purchase of the packaged food product 2. Instead, the natural cheese contained in the packaged food product 2 is generally maintained at a temperature of between approximately 38° F. and approximately 48° F. at essentially all times prior to the packaged food product being purchased by a retail customer.
Packaged food products 2 having the aforementioned features, produced according to the aforementioned method, and maintained within the aforementioned temperature range provides retail customers with a conveniently sized and accessed packaged food product containing amounts of USDA meat and natural cheese that has a shelf life of between approximately 90 days and approximately 180 days. Although the present invention has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims

1. A packaged food product for placement in a refrigerated section of a retail store for sale to a retail customer and adapted to have a specific shelf life when generally maintained at a temperature between approximately 38° F. and approximately 48° F., the product comprising:

a container including a sealed interior volume at least partially defined by a barrier with an oxygen permeability of less than 0.5 cubic centimeters of oxygen per 100 square inches of barrier area per 24 hours at 73° F., zero percent relative humidity and standard atmospheric pressure;

an amount of cheese located within the sealed volume, wherein the cheese is a natural cheese, not a processed cheese, and is not frozen prior to being sold to the customer,

an amount of meat located within the sealed volume and in physical contact with the amount of cheese; and

an atmosphere located within the sealed volume, wherein the atmosphere has an oxygen content of less than 0.5 percent.

2. The product of claim 1, wherein the natural cheese is also a non-pasteurized cheese.

3. The product of claim 1, wherein the shelf life is at least approximately 90 days.

4. The product of claim 1, wherein the shelf life is approximately 90 days to approximately 180 days.

5. The product of claim 1, wherein the atmosphere is substantially nitrogen.

6. The product of claim 1, wherein the atmosphere is substantially carbon dioxide.

7. The product of claim 1, wherein the atmosphere is substantially comprised of nitrogen and carbon dioxide.

8. The product of claim 1, the amount of cheese is treated with an antimicrobiological agent.

9. The product of claim 8, wherein the antimicrobiological agent is natamycin.

10. The product of claim 1, wherein the container is a clear cup with ultra violet protection and a removable top.

11. The product of claim 10, wherein the ultra violet protection is provided via an ultra violet resistant label about the cup.

12. The product of claim 10, wherein the removable top is a peal type top with ultra violet protection.

13. The product of claim 12, wherein the container further comprises a lid for placement over the peal type top and including a detachable eating utensil.

14. The product of claim 1, wherein the container is a clear flexible or semi-flexible bag.

15. The product of claim 14, wherein the bag has ultra violet protection and/or a substantial percentage of the bag surface is covered with printing.

16. The product of claim 14, wherein an eating utensil is included with the bag.

17. The product of claim 14, wherein the bag includes a grooved resealable opening.

18. A method of producing a packaged food product and providing the product to a retail customer, wherein the product is adapted to have a specific shelf life when generally maintained at a temperature between approximately 38° F. and approximately 48° F., the product comprising:

providing a container including an interior volume at least partially defined by a barrier with an oxygen permeability of less than 0.5 cubic centimeters of oxygen per 100 square inches of barrier area per 24 hours at 73° F., zero percent relative humidity and standard atmospheric pressure;

placing an amount of cheese into the volume, wherein the cheese is a natural cheese, not a processed cheese, and is not frozen prior to being provided to the customer,

placing an amount of meat into the volume and in physical contact with the amount of cheese;

injecting the volume with a gas such that the volume ends up having an atmosphere with an oxygen content of less than 0.5 percent;

sealing the volume to maintain said atmosphere;

marking the container with a shelf life date that is at least approximately 90 days subsequent to the date the volume was sealed;

placing the container into a refrigerated area that is generally maintained at a temperature of between approximately 33° F. and approximately 49° F.; and

allowing the customer to access the product in a retail store.

19. The method of claim 18, wherein the natural cheese is also a non-pasteurized cheese.

20. The method of claim 18, wherein the volume is subjected to vacuum conditions prior to being injected with gas.

21. The method of claim 18, wherein the shelf life date is at least approximately 90 days subsequent to the date the volume was sealed, but no more than approximately 180 days subsequent to the date the volume was sealed.

22. The method of claim 18, wherein the gas injected into the volume is substantially nitrogen.

23. The method of claim 18, wherein the gas injected into the volume is substantially carbon dioxide.

24. The method of claim 18, wherein the gas injected into the volume is substantially comprised of nitrogen and carbon dioxide.

25. The method of claim 18, further comprising treating the cheese with an antimicrobiological agent.

26. The method of claim 25, wherein the antimicrobiological agent is natamycin.

27. The method of claim 18, wherein the container is a clear cup with ultra violet protection.

28. The method of claim 27, wherein the cup is sealed with a peal type top.

29. The method of claim 28, further comprising providing a lid over the peal type top and including a detachable eating utensil.

30. The method of claim 27, further comprising placing a sleeve label on the cup.

31. The method of claim 18, wherein the container is a clear flexible or semi-flexible bag.

32. The method of claim 31, wherein the bag has ultra violet protection and/or a substantial percentage of the bag surface is covered with printing.

33. The method of claim 31, wherein an eating utensil is included with the bag.

34. The method of claim 31, wherein the bag includes a grooved resealable opening.

35. The method of claim 18, further comprising providing the meat and cheese to split scales.

36. The method of claim 35, further comprising mixing together the amounts of meat and cheese prior to placing them into the volume, wherein the amounts of meat and cheese are placed into the volume at generally the same instant.