US20060280844A1

US20060280844A1 - Flexible flavor gradient container and packaged liquid-based food item

Info

Publication number: US20060280844A1
Application number: US11/137,080
Authority: US
Inventors: Jorge Succar; Gail Tavill; James Bennett
Original assignee: Conagra Grocery Products Co LLC
Current assignee: Conagra Grocery Products Co LLC
Priority date: 2005-05-24
Filing date: 2005-05-24
Publication date: 2006-12-14

Abstract

A flexible package for a liquid-based food item and a packaged liquid-based food item, such as a soup. A flexible package or pouch includes an outer member or pouch and an inner dividing member or pouch that is disposed or positioned inside the outer member to define inner and outer cavities. A liquid, such as water or broth, and one or more seasonings are placed in the inner cavity. Particulates, such as meat and vegetable particulates and, if necessary, water, are placed in the outer cavity. Seasonings are separated from particulates, and the seasoning does not diffuse into the particulates. Thus, the tastes of the individual ingredients are maintained. A sealing member extends across a tops of the inner and outer members to close the package. When the sealing member is removed to open the package, the water or broth with the seasoning, and the particulates and any water can be poured from their respective cavities in a single motion. By reducing or eliminating diffusion of seasonings into particulates, reduced quantities of salt and other seasonings can be added to processed soup products and allows salt and other seasonings to be added just prior to cooking, providing more natural flavor. Separating broth and particulates within a container can also reduce sterilization times.

Description

FIELD OF THE INVENTION

The present invention relates generally to containers and packaging for food items. More specifically, the invention relates to containers and packages for liquid based food items that separate ingredients of the food item.

BACKGROUND

Traditionally, soup and other related liquid-based food items are either home made or processed and packaged by commercial preparers of such products. Home made soups may provide the most natural and appealing taste, particularly since they can include selected ingredients and seasonings to suit individual preferences. Preparing home made soups, however, can require a substantial amount of time. For example, particulates, such as vegetables and meat items, must be prepared, which may involve washing and cutting vegetables and meats. The vegetable and meat ingredients are added to water or a broth, which can include seasonings and flavorings, such as salt, pepper, sugar, garlic and onion, etc. These seasonings can also be added to water. The ingredients are then heated and served. Packaged, processed, ready-to-eat soups have become very popular since they are convenient and can be quickly and easily prepared compared to home made soups. A typical can of processed soup includes a mixture of various ingredients, including a broth or a liquid stock, particulates such as meats and vegetables in different combinations, and seasonings, including salt. In use, a consumer opens the can, empties the contents of the can into a pan or bowl, and heats the soup over a range or in a microwave oven.
The manner of making processed soups is well known. Typically, they are made by metering a predetermined quantity of an ingredient or mixture of selected ingredients, which are combined and mixed in a can. A lid is placed on the can and the lid and the can are sealed together. The sealed can is sterilized and pressurized and prepared for storage or distribution. Sterilization involves exposing the can of soup to temperatures from about 240° F. to about 265° F. for about 12-60 minutes depending on the container size, soup thickness and rate of agitation. Sterilization issues are of particular concern with the meat and vegetable ingredients within the mixture because they may contain pathogens, which must be rendered commercially sterile for shelf stability or pasteurized in the case of refrigerated distribution. The heat source must be applied for a sufficient amount of time so that the thermal center of the food in the container achieves commercial sterility or pasteurization.
Processed soups typically have relatively large quantities of salt (sodium chloride), which is the main source of sodium in foods. Large quantities of salt are typically used to provide a sufficient flavor impact to a consumer. Sodium is carried in the broth, and over time, the sodium diffuses or migrates from the broth into particulates, such as meats and vegetables. This “sodium diffusion” typically occurs during processing or distribution of the prepared soups (e.g., sterilization, pressurization, freezing, refrigeration, storage and distribution). Thus, a commercial preparer of soups must add enough salt to the can to compensate for sodium diffusion so that a desired flavor impact is achieved. Although a package soup delivers an adequate salt content, it contains salt levels that are typically higher than those considered healthy for consumers.
Home made soups and other liquid-based food items, such as stews, on the other hand, typically do not these high quantities of salt since the salt is mostly concentrated in the surrounding broth. Thus, home made soups and stews taste fresher and healthier and have lower salt contents compared to processed food items, while still providing desirable flavor impact.
High sodium contents may cause various health problems, particularly considering United States Department of Agriculture (USDA) recommendations and that it is generally accepted that high sodium diets can contribute to health problems, such as high blood pressure. For example, a single can of certain processed “Chunky” brand soups available from Campbell Soup Company has about 1,800 mg of sodium, or 900 mg per serving. The USDA recommends that the amount of salt consumed on a daily basis not exceed 2,400 mg. Thus, a single can of processed, ready-to-eat soup almost meets the recommended daily allowance of sodium.
Attempts have been made to reduce sodium content by reducing the quantity of salt that is added to a can of soup. While the objective is on the right track, the taste of the resulting processed soup may not be satisfactory since the reduced amount of salt is absorbed by the particulates and does not provide sufficient salt flavor.
Processed soups and other liquid-based food items, therefore, can be improved. Soups can be made to deliver a more natural, home-cooked taste by providing a naturally occurring flavor gradient so that sodium does not diffuse into particulates. In other words, it is desirable that salt remains in the surrounding broth and is added to the particulates when the soup is prepared. The amount of salt and sodium that is added to processed foods should also be reduced to provide a healthier food item, while not sacrificing taste. Reducing the amount of sodium in processed soups can contribute to healthier diets.
Further, processed soups can be prepared and processed more efficiently. Known sterilization steps must apply heat to a can of soup for a sufficient amount of time to ensure mass average sterilization and/or thermal center sterilization or pasteurization of the soup mixture, particularly the meat and vegetable particulates. The time required for the middle sections of the soup mixture to be heated can be reduced while still achieving the desired sterilization, thereby maximizing nutrient retention, color, flavor and other quality attributes, while processing soup products in a more efficient manner.
Accordingly, there exists a need for improved and healthier processed soup products and other liquid based food items that have reduced salt and sodium contents, have acceptable flavor impact, and that can be processed more efficiently than known processed soup products and liquid-based food items.

SUMMARY

According to one embodiment, a segmented pouch for a liquid-based food item includes a flexible outer pouch, a flexible inner pouch, and a seal. The flexible inner pouch is disposed within the flexible outer pouch so that an inner surface of the flexible inner pouch at least partially defines an inner cavity, and an outer surface of the flexible inner pouch and an inner surface of the flexible outer pouch define an outer cavity. The seal extends across tops of the flexible inner and outer pouches and closes the inner and outer cavities. The inner cavity can be filled with a liquid and a seasoning and the outer cavity can be filled with particulates so that the seasoning and the particulates are separated from each other. When the seal is removed or broken to open the segmented pouch, the liquid, the seasoning, and the particulates are pourable from their respective inner and outer cavities in a single motion.
According to another embodiment, a segmented pouch for a liquid-based food item includes a flexible plastic outer pouch, a flexible plastic inner pouch, and a seal. The flexible plastic outer pouch includes a gusseted bottom surface that enables the segmented pouch to stand upright. The flexible plastic inner pouch is disposed within the flexible outer pouch so that an inner surface of the flexible plastic inner pouch at least partially defines an inner cavity, and an outer surface of the flexible plastic inner pouch and an inner surface of the flexible plastic outer pouch define an outer cavity. The seal extends across tops of the flexible plastic inner and outer pouches and closes the inner and outer cavities. The inner cavity can be filled with a seasoning and a liquid and the outer cavity can be filled with particulates so that the seasoning and the particulates are separated from each other. When the seal is removed or broken to open the segmented pouch, the liquid, the seasoning, and the particulates are pourable from their respective inner and outer cavities in a single motion.
In accordance with a further alternative embodiment is a packaged liquid-based food item that includes a flexible outer pouch, a flexible inner pouch, a seal, a liquid, a seasoning and a plurality of particulates. The flexible inner pouch is disposed within the flexible outer pouch. An inner surface of the flexible inner pouch at least partially defines an inner cavity. An outer surface of the flexible inner pouch and an inner surface of the flexible outer pouch define an outer cavity. A seal extends across the tops of the flexible inner and outer pouches and closes the inner and outer cavities. The inner cavity is filled with a seasoning and liquid, and the outer cavity is filled with particulates. Thus, the seasoning and particulates are separated from each other. When seal is removed or broken to open the pouch, the liquid, the seasoning, and the particulates are pourable from their respective inner and outer cavities in a single motion.
In various embodiments, the height of the outer pouch and outer cavity can be greater than that of the inner pouch and inner cavity. The width of the outer pouch and outer cavity can be the same or greater than that of the inner pouch and inner cavity. The inner and outer pouches can have various shapes, e.g., rectangular and square shapes.
The inner and outer pouches can be transparent or translucent plastic material. Lateral support members can extend between outer sides of the inner pouch and inner sides of the outer pouch.
The pouch can be gusseted so that the pouch can stand upright. For example, the bottom surface of the outer pouch can be gusseted. The outer cavity can extend into areas defined by the gusseted bottom surface. A tear strip extends along the seal of the inner and outer pouches and can be tom or broken to access the contents in the outer and inner cavities, e.g., ingredients of a soup.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, in which like reference numbers represent corresponding parts throughout, and in which:
FIG. 1 is top view of a segmented container for a liquid-based food item according to one embodiment;
FIG. 2 is a side view of the container shown in FIG. 1;
FIG. 3 is an illustrative cross-sectional view of a liquid based food item having the container shown in FIGS. 1 and 2, illustrating separation of particulates and seasonings according to one embodiment;
FIG. 4 is bottom view of a lid having a sealing member or cushion according to one embodiment;
FIG. 5 is a cross-sectional view of the container shown in FIGS. 1 and 2 showing how sterilization is improved by separating particulates within a container according to one embodiment;
FIG. 6 further illustrates heat transfer characteristics of package embodiments shown in FIG. 5;
FIG. 7 is top view of a container for a liquid-based food item according to another embodiment that includes an offset inner dividing member;
FIG. 8 is a side view of the container shown in FIG. 7;
FIG. 9 is bottom view of a lid according to one embodiment that can be used with the container shown in FIG. 7;
FIG. 10 is top view of a container for a liquid-based food item according to a further embodiment that includes an inner dividing member that extends between inner surfaces of an outer member;
FIG. 11 is a side view of the container shown in FIG. 10;
FIG. 12 is bottom view of a lid according to one embodiment for use with the container shown in FIG. 10;
FIG. 13 is top view of a container for a liquid-based food item according to another alternative embodiment that includes a square- or rectangular-shaped inner dividing member;
FIG. 14 is a side view of the container shown in FIG. 13;
FIG. 15 is bottom view of a lid according to one embodiment for use with the container shown in FIG. 13;
FIG. 16 is top view of a container for a liquid-based food item according to yet a further alternative embodiment that includes an inner dividing member that is connected to an inner surface of an outer member;
FIG. 17 is a side view of the container shown in FIG. 16;
FIG. 18 is bottom view of a lid according to one embodiment for use with the container shown in FIG. 16;
FIG. 19 is top view of a container for a liquid-based food item according to another alternative embodiment that includes an inner dividing member that is connected to an inner surface of an outer member and that extends partially between the top and bottom of the outer member;
FIG. 20 is a side view of the container shown in FIG. 19;
FIG. 21 is bottom view of a lid according to one embodiment for use with the container shown in FIG. 19;
FIG. 22 is top view of a square- or rectangular-shaped container for a liquid-based food item according to another embodiment that includes an inner dividing member;
FIG. 23 is a side view of the container shown in FIG. 22;
FIG. 24 is bottom view of a lid according to one embodiment for use with the container shown in FIG. 22;
FIG. 25 is a front view of a flexible segmented pouch for a liquid-based food item according to one embodiment having a “pouch within a pouch” in which the widths of the inner and outer members are the same;
FIG. 26 is a side view of the flexible segmented pouch shown in FIG. 26;
FIG. 27 is a front view of a flexible segmented pouch for a liquid-based food item according to one embodiment having a “pouch within a pouch” in which the width of the inner member is less than the width of the outer member;
FIG. 28 is a side view of the flexible segmented pouch shown in FIG. 26;
FIG. 29 illustrates a flexible segmented pouch for a liquid based food item having a “pouch within a pouch” in which the width of the inner member is less than the width of the outer member; and
FIG. 30 is a flow chart illustrating preparation of a packaged liquid-based food item according to one embodiment.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS

Embodiments of segmented or flavor gradient package of container, a packaged liquid-based food item, and a method of manufacturing a packaged liquid-based food item are described. With various embodiments, soups and other liquid-based food items (generally “soup”) can be prepared so that flavorings and seasonings, such as salt, pepper, sugar, onion powder or flavoring, garlic powder or flavoring, and any necessary colorings (hereafter referred to as “seasonings”) in a broth do not diffuse or migrate into particulates, such as meats and vegetables. Rather, the broth and the seasonings are stored in one segment, and particulates and water (as necessary) are stored in another segment. In some applications, a portion of the seasonings (and colorants if necessary) can be added to the particulate containing segment to provide an improved flavor impact. In use, the package or container is tilted and the broth and seasonings are poured out with the particulates and water from the respective cavities in a single pouring motion. As a result, the soup product is more similar to home made soups since the seasoning is added just prior to cooking, thus providing a more natural tasting product compared to typical processed soups in which the salt and sodium diffuses into the particulates. Since salt is not fully absorbed by particulates, a similar salt or flavor impact can be provided with reduced amounts of salt, thereby providing a soup with more natural taste and a healthier soup with reduced sodium contents compared to known processed soup products.
Referring to FIGS. 1-2, one embodiment of a container or package 100 suitable for a liquid-based food item, such as a soup and a stew, includes an outer member 110 and an inner dividing member 120. The outer and inner members 110 and 120 may have various shapes.
In the illustrated embodiment, the outer and inner members 110 and 120 are cylindrical, 25 however, other shapes can be utilized.
The outer member 110 includes an inner surface 111 and an outer surface 112, which is typically handled by a consumer, a bottom surface 113 and a top edge or surface 114. The inner dividing member 120 is disposed or positioned inside of the outer member 110 and includes an inner surface 121, an outer surface 122, a top edge or surface 123 and a bottom 30 edge or surface 124. In the illustrated embodiment the inner surface 121 of the inner member 120 defines a vertical, inner cavity 125, e.g., a circular or cylindrical cavity. An outer cavity 115 is defined between the outer surface 122 of the inner member 120 and the inner surface 111 of the outer member 110. In the illustrated embodiment, the outer and inner members 110 and 120 are cylindrical and concentric, or share a common axis or center point. Thus, the corresponding outer cavity 115 is annular or ring-like, and the inner cavity 125 is cylindrical.
The outer and inner members 110 and 120 may be formed using various techniques and food-grade materials. For example, the inner and outer members 110 and 120 can be substantially rigid and made of a substantially rigid metal or plastic, e.g., aluminum and other materials that are used to make soup cans and packages. The outer and inner members 110 and 120 can be formed together as a unitary piece or, alternatively, connected together using, for example, adhesive or welding, depending on the materials that are selected. As a further alternative, the inner and outer members 110 and 120 can be plastic and made using, for example, injection molding. Thus, in these embodiments, the outer and inner cavities 115 and 125 have pre-defined shapes. Further, the inner member 120 can be hollow so that the bottom of the hollow inner member 120 is sealed against the bottom 113 of the outer member 110, or the inner member 120 can have its own bottom surface. Persons skilled in the art will appreciate that various segmented configurations can be made with various techniques and materials.
Referring to FIG. 3, the inner cavity 125 is filled with a liquid or broth 300 containing seasonings 302. The outer cavity 115 is filed with particulate ingredients 310. Water 311 or other liquids can be added to the outer cavity 115, as necessary, so that the particulates 310 can be poured out of the package 100 with the water. Exemplary particulates include meat particulates, such as chicken, beef, turkey and meat substitutes, and vegetable particulates, such as celery, carrots, corn, peas, beans and potatoes. Particulates 310 may also include noodles and rice. Thus, the seasonings 302, including salt, are separated from particulates 310 that would otherwise absorb the seasonings 302 if they were not separated.
Referring to FIGS. 3-5, a sealing member 320, such as a lid or cover as illustrated, is placed on top of the package, i.e., over top edges or surfaces 114 and 124 of the outer and inner members 110 and 120, to close the package 100. The inner cavity 125 extends between radius r=o and radius r₁The outer cavity 115 extends between radius r, and radius r₂.
In the embodiment shown in FIG. 3, the sealing member 320 includes a body or plate 322 and a sealing member or cushion 324. The cushion 324 can be, for example, Teflon®, rubber or another food-grade material. The sealing cushion 324 is shaped and positioned so that it overlays the top edge or surface 124 of the inner member 120 to ensure that the contents of the inner cavity 125 do not leak into the outer cavity 115 holding the particulates. Thus, the cushion 324 is preferably larger than radius r₁. The cushion can be shaped appropriately to mate with the to edge or surface 124.
For example, as shown in FIG. 1 and 2, the top surface 124 of the inner member 120 has a circular shape and is placed in the middle of the space defined by the outer member 110. The sealing cushion 324, as shown in FIG. 4 can be correspondingly shaped and sized to cover the top circular section of the inner member 120 when the lid 320 is placed over the inner and outer members 110 and 120 to seal or close the package 100. This can be accomplished with a circularly shaped cushion 324, as illustrated. However, the sealing cushion 324 may or may not have a similar shape as the top edge or surface 124 of the inner member 120 since a sealing cushion 324 having various shapes and sizes can adequately cover and seal the top of the inner member 120. For example, the cushion 324 may be a solid piece that occupies most of the bottom surface 322 of the sealing member, or as a ring, as shown in FIG. 3. Accordingly, sealing cushions 324 having various shapes and sizes can be used to cover and seal top edges or surfaces 124 of various shapes and sizes.
The sealing member 320 is placed on top of the container after the inner cavity 125 is filled with broth 300 and seasonings 302 and the outer cavity 115 is filled with particulates 310 and water or other liquids 311. Thus, all or the majority of the salt and other seasonings 320 remain contained in the inner cavity 125, advantageously separated from the particulates 310 in the outer cavity 115. This separation is maintained from the beginning of production, during storage, distribution, sales, and subsequent consumer storage, thereby maintaining a flavor gradient to prevent “sodium diffusion” or other flavorings into the particulates.
Referring to FIG. 5, separating particulates 310 and broth and seasoning components 302 provides the additional benefit of more efficient sterilization. In the illustrated embodiment, the particulates 310 are retained and concentrated in the outer cavity 115 and against the inner surface 111 of the outer member 110. As a result, heat 500 is more easily applied to the particulates 310 since they are concentrated in a particular area in the package and removed from the thermal geometrical center of the container, rather than being diffused and mixed together throughout the package as in conventional processed soups. Thus, embodiments provide for faster heat transfer and faster sterilization compared to traditional soup mixtures since the particulates 310 are separated from the faster heating thermolabile broth or fluid center 300 with salt, sugar and other seasonings 302. In other words, the fluid center is more readily sterilized by heat 500. Further, while heat is being applied to the particulates in the outer cavity 115, the particulates 310 are also heated by conductive heating from the convective heated fluid center. One can selectively control the heat transfer within the segmented container by selectively “insulating” the concentric material 120, 121 and 122 illustrated in FIG. 1.
As a result of the segmented configuration, shorter heating durations can be used to achieve the same sterilization results while optimizing flavor, color and nutrient retention. In contrast, traditional soups having mixtures of ingredients require longer heating durations since the particulates are mixed together with the broth and are not heated as easily, since thermal processes have to be assumed at the thermal center of the container which is typically along the axis of the container where heating lags are notable when compared to the outer layers of the container. Thus, the traditional soup or food containers require longer heating durations. Further, food items according to various embodiments are subjected to less heat 500. This reduced thermal stress, results in a higher quality food item that is not otherwise subjected to unnecessary heating and flavor and texture degradation.
The benefit of faster sterilization times and reduced thermal stress on the food item is further illustrated in FIG. 6. As shown in FIG. 6, the heat transfer 500 to the center or to a particular width of a concentric ring can be determined as follows:
Liquid or particulate: T=j _rl*(T ₁ −T ₀)*10^(−/fh)
This equation represents the heat transfer in the water, broth or puree after the curvilinear heating (Hayakawa, 1980) has been transposed. In some foods there are “broken” heating curves that require to solve the equation through specific mathematical algorithms for varying values of f_h. Numerical solutions can also be applied to solve heat transfer within containers. The governing differential equations vary and follow simple energy balances as shown in the following one dimensional equation
k*p*c _p * dT/dt=a*d ² t/dr ²

- for 0 <x <r1 in axi-symmetric heating
  Boundary conditions have to be defined according to heating medium characteristics where T=Temperature of food

j=heating lag factor in the liquid or solid particles
r=dimensional location within the container
Tl=Heating medium temperature
To=Initial food temperature
f=empirically measured heating rates
h=heat transfer coefficient
k=thermal conductivity of food
p (rho)=food density
Cp=food specific heat
This equation represents a simplified heat transfer system and one versed in the science of heat transfer would conclude that multiple complex conditions of heat transfer would apply. The solutions currently applied in the industry typically require numerical solutions to complex partial differential equations. Exemplary numerical methods include finite differences and finite elements.
Various other package designs can be utilized to provide a flavor gradient in liquid-based food items and/or provide more efficient sterilization by separating out particulates from thermolable broth having seasonings.
In one alternative embodiment, referring to FIGS. 7-9, the vertical inner dividing member 120 can be offset relative to the outer member 110 so that the inner and outer members 120 and 110 do not share a common center point or axis, as do the embodiments shown in FIG. 1-6.
In another alternative embodiment, referring to FIGS. 10-12, the vertical inner dividing member 110 may be connected to the inner surface 111 of the outer member 110. In this embodiment, the inner cavity 125 is defined by a combination of the inner surface 111 of the outer member 110, and an inner surface 121 of the inner member 120.
A further alternative embodiment is shown in FIGS. 13-15, In the illustrated embodiment, the inner dividing member 110 can have a square or rectangular shape, and the outer member 120 can have a cylindrical shape. The sealing cushion 324 can also have a corresponding square or rectangle shape, or be large enough to cover the square-shaped inner member 110. The inner member 110 can have other shapes besides cylindrical, square and rectangle shapes, as necessary.
FIGS. 16-18 illustrate yet a further alternative embodiment. The inner dividing member 120 can be side-mounted to an inner surface 111 of the outer member 110 using side mounting component 1600. As shown in the Figures, in this embodiment, the inner member 120 extends between the top 114 and the bottom 113 of the outer member 110. It may or may not be necessary to secure the bottom of the inner dividing member 120 to a bottom of the outer member 110. Alternatively, as shown in FIGS. 19-21, a similar side-mounting configuration can be used, and the inner member 120 can extend from the top 114 and partially down into the outer member 110. In other words, the bottom 123 of the inner member 120 may be suspended above the bottom 113 of the outer member 110. A smaller inner cavity 125 area may be useful if, for example, a higher concentration broth or brine is utilized, and less volume is needed to contain the broth. The particulates 310 and water 311 can also flow around the bottom of the suspended inner member 120 shown in FIGS. 19-21.
Further alternative embodiments are shown in FIGS. 22-24. In this embodiment, the outer member 110 and package design can be square or rectangular rather than cylindrical. Further, the shape of the inner dividing member 120 can be cylindrical (as illustrated) or square, such as shown in FIGS. 13-15.
FIGS. 25-27 illustrate an additional alternative embodiment of a segmented container or package that provides a flavor gradient. The package is a flexible pouch 2500 and, more particularly, a “pouch within a pouch” that includes an outer member or pouch 2510 and an inner dividing member or pouch 2520. The outer member 2510 includes two panels 2511 and 2512, and the inner member 2520 includes two panels 2521 and 2522. The outer member 2510 and the inner member 2520 are flexible, e.g., flexible plastic. The plastic can be transparent, translucent or colored.
A seal 2530 extends across the tops 2514 and 2524 of the outer and inner members 2510 and 2520. The seal 2530 can be, for example, heat seal. The sides of the outer and inner members 2510 and 2520 can be similarly sealed. A tear strip 2532 can be provided across a top portion of the package to allow a consumer to tear open the top of the sealed package and access the contents in the outer and inner pockets or cavities 2515 and 2525 and allow the contents to be poured out of the package in a single pouring motion.
The outer member 2510 includes an inner surface and an outer surface. The inner member 2520 includes an inner surface and an outer surface. The inner surface of the inner member 2520 at least partially defines an inner pocket or cavity 2525 for holding seasonings. An outer pocket or cavity 2515 is defined between the outer surface of the inner member 2520 and the inner surface of the outer member 2510. The outer pocket 2515 includes particulates, such as meat and vegetable particulates, and water, as necessary. The pouch 2500 shown in FIGS. 25-27 is shown having liquid for purposes of illustration, but the outer and inner cavities 2515 and 2525 can be filled with various ingredients as appropriate. In the illustrated embodiment, the inner member 2520 is shorter than the outer member 2510 so that the outer member 2510 and the outer cavity 2515 substantially envelope the inner member 2520, i.e., the side and bottom portions of the inner member 2520.
The flexible segmented pouch 2500 provides a flavor gradient by separating the salt and other seasonings from particulates, and allowing a consumer to empty the pouch contents in a single motion. The embodiment of a segmented pouch also decreases sterilization times since particulates are concentrated in one area or pocket and can be readily heated through a plastic material. Further, the outer and inner members are flexible, thus allowing the package to assume different shapes. The packages are also durable since they are made of plastic or other durable flexible materials.
In the embodiment shown in FIGS. 25-27, the pouch 2500 includes a gusseted bottom 2540 that is formed by bottom portions of the outer member 2510 being folded upwardly at 2542. The bottom of the pouch 2500 is flexible and flares outwardly, thereby forming a base or bottom 2540 upon which the pouch can stand. As shown in FIG. 25, the outer cavity 2515 can extend into an area defined by the gusseted bottom 2540. In alternative embodiments, the bottom can be non-gusseted.
FIGS. 28-30 illustrate an alternative embodiment of a flexible segmented package or pouch 2800. The embodiment shown in FIGS. 28-30 is similar to the embodiment shown in FIGS. 25-27 in that the pouch 2800 includes flexible outer and inner members 2810 and 2820 that form outer and inner cavities 2815 and 2825 and a gusseted bottom 2840 to form a base upon which the package 2800 can stand. The tops 2814 and 2824 are sealed. A tear strip, although not shown, can also be used to allow the tops of the pouch to be easily opened.
The package 2800 shown in FIGS. 28-30 includes an inner member or pouch 2810 having a width that is less than the width of the outer member or pouch 2820. In the illustrated embodiment, the inner member 2820 is disposed or positioned centrally within the outer member 2810. The width of the narrower inner member 2820 can vary as needed. The outer cavity 2825 can extend into an area defined by the gusseted bottom 2840. In alternative embodiments, the bottom of the package can be non-gusseted.
FIG. 31 illustrates a further alternative embodiment of a pouch 3100 that is similar to the embodiment shown in FIGS. 28-30, but includes a different bottom or base 3140. In the illustrated embodiment, the base 3140 extends outwardly from the front of the package to allow the package to stand upright.
FIG. 32 illustrates an alternative embodiment of a segmented pouch that is similar to the pouch shown in FIG. 28 and further illustrates lateral support members 3200 that extend between the sides of the inner member or pouch 2820 to the sides of the outer member or pouch 2810. Thus, when the tops of the outer and inner members 2810 and 2820 are broken or torn, the inner member 2820 is laterally supported by members 3200, and the contents can be poured from their respective outer and inner cavities 2815 and 2825. Alternatively, as shown in FIG. 33, the sides and the bottom of the inner member 2820 may be unattached to the outer member 2810.
Referring to FIG. 34, in a further alternative embodiments, the inner member or pouch 2820 and inner cavity 2825 can be displaced from the central portion of the outer member or pouch 2810. In the illustrated embodiment, the inner member 2820 is disposed along one side of the outer member 2810. This configuration may be beneficial when, for example, the pouch is tilted to one side to pour the contents from the respective cavities 2815 and 2825.
FIG. 35 illustrates a method of making a packaged liquid-based food item can be summarized as follows, although additional details have been previously discussed. In step 3500 a segmented package having an outer member and an inner dividing member is provided. In step 3510 the inner cavity is filled with a liquid and seasonings. In step 3520, the other cavity is filled with particulates and any necessary water or broth. The inner and outer cavities may be filled simultaneously or at different times depending on the configuration of the equipment. As a result, the broth and seasonings are separated from the particulates so that the seasonings do not diffuse into the particulates. The package is then sealed by placing a sealing member across over the inner and outer members in step 3530.
The tops of the outer and inner members can be different heights so that the tops can be engaged more easily by a filling machine. Additionally, a vacuum can be used to engage the outer faces of the outer member and to make the inner and outer cavities more accessible. A filling machine can a rotary machine that includes multiple heads, or multiple stage filling process can be used.
The embodiments shown and described are not intended to be limiting, but are provided for purposes of explanation and illustration. Various segmented package configurations, shapes, sizes and designs can be used to provide a flavor gradient. For example, the containers can have a size suitable for both individual consumption and for commercial or large scale use. Further, square-or rectangular-shaped outer members can be paired with inner members having cylindrical, square, rectangular or other shapes. Similarly, cylindrical-shaped outer members can be paired with inner members having cylindrical, square, rectangular or other shapes. Further, the inner members can be concentric or offset relative to the outer member, stand-alone or connected to the inner surface of the outer member. The inner members can extend between the top and bottom of an outer member or a portion thereof. The package can also be designed so that the package is easy to hold, e.g., the outer member can be contoured to fit a person's hand. Thus, persons skilled in the art will appreciate that various segmented designs that provide flavor gradients can be utilized depending on, for example, food item ingredients, concentrations and packaging considerations.

Claims

1. A segmented pouch for a liquid-based food item, comprising:

a flexible outer pouch;

a flexible inner pouch disposed within the flexible outer pouch, wherein an inner surface of the flexible inner pouch at least partially defines an inner cavity, and an outer surface of the flexible inner pouch and an inner surface of the flexible outer pouch define an outer cavity; and

a seal that extends across tops of the flexible inner and outer pouches and closes the inner and outer cavities,

whereby the inner cavity can be filled with a liquid and a seasoning and the outer cavity can be filled with particulates so that the seasoning and the particulates are separated from each other, and when the seal is removed or broken to open the segmented pouch, the liquid, the seasoning, and the particulates are pourable from their respective inner and outer cavities in a single motion.

2. The segmented pouch of claim 1, wherein a height of the outer pouch is greater than a height of the inner pouch.

3. The segmented pouch of claim 1, wherein a width of the outer pouch is the same as a width of the inner pouch.

4. The segmented pouch of claim 1, wherein a width of the outer pouch is greater than a width of the inner pouch.

5. The segmented pouch of claim 1, wherein a height of the outer cavity is greater than a height of the inner cavity.

6. The segmented pouch of claim 1, wherein a width of the outer cavity is the same as a width of the inner cavity.

7. The segmented pouch of claim 1, wherein a width of the outer cavity is greater than a width of the inner cavity.

8. The segmented pouch of claim 1, wherein the outer cavity substantially envelopes the inner cavity.

9. The segmented pouch of claim 1, wherein the inner and outer pouches are plastic.

10. The segmented pouch of claim 1, wherein the outer pouch is transparent or translucent.

11. The segmented pouch of claim 1, wherein the inner pouch is transparent or translucent.

12. The segmented pouch of claim 1, further comprising lateral support members that extend between outer sides of the inner pouch and inner sides of the outer pouch.

13. The segmented pouch of claim 1, wherein a bottom of the outer pouch is gusseted.

14. The segmented pouch of claim 13, wherein the gusseted bottom enables the segmented pouch to stand upright.

15. The segmented pouch of claim 13, wherein the outer cavity extends into areas defined by the gusseted bottom.

17. The segmented pouch of claim 1, further comprising a tear strip that extends along the seal of the inner and outer pouches, wherein the tear strip can be torn to break the seal and access the outer and inner cavities.

18. The segmented pouch of claim 1, wherein the inner and outer pouches have a rectangular or square shape.

19. The segmented pouch of claim 1, wherein both sides and the tops of the inner and outer pouches are sealed together, and the bottom of the outer pouch is gusseted.

20. A segmented pouch for a liquid-based food item, comprising:

a flexible plastic outer pouch having a gusseted bottom that enables the segmented pouch to stand upright;

a flexible plastic inner pouch disposed within the flexible outer pouch, wherein an inner surface of the flexible plastic inner pouch at least partially defines an inner cavity, and an outer surface of the flexible plastic inner pouch and an inner surface of the flexible plastic outer pouch define an outer cavity; and

a seal that extends across tops of the flexible plastic inner and outer pouches and closes the inner and outer cavities,

whereby the inner cavity can be filled with a seasoning and a liquid and the outer cavity can be filled with particulates so that the seasoning and the particulates are separated from each other, and when the seal is removed or broken to open the segmented pouch, the liquid, the seasoning, and the particulates are pourable from their respective inner and outer cavities in a single motion.

21. The segmented pouch of claim 20, wherein a height of the outer pouch is greater than a height of the inner pouch.

22. The segmented pouch of claim 20, wherein a width of the outer pouch is the same as a width of the inner pouch.

23. The segmented pouch of claim 20, wherein a width of the outer pouch is greater than a width of the inner pouch.

24. The segmented pouch of claim 20, wherein a height of the outer cavity is greater than a height of the inner cavity.

25. The segmented pouch of claim 20, wherein a width of the outer cavity is the same as a width of the inner cavity.

26. The segmented pouch of claim 20, wherein a width of the outer cavity is greater than a width of the inner cavity.

27. The segmented pouch of claim 20, wherein the outer cavity substantially envelopes the inner cavity.

28. The segmented pouch of claim 20, wherein the outer pouch is transparent or translucent.

29. The segmented pouch of claim 20, wherein the inner pouch is transparent or translucent.

30. The segmented pouch of claim 20, further comprising lateral support members that extend between outer sides of the inner pouch and inner sides of the outer pouch.

31. The segmented pouch of claim 20, wherein the outer cavity extends into areas defined by the gusseted bottom.

32. The segmented pouch of claim 20, further comprising a tear strip extending along the seal of the inner and outer pouches, wherein the tear strip can be torn to break the seal and access the outer and inner cavities.

33. The segmented pouch of claim 20, wherein the inner and outer pouches have a rectangular or square shape.

34. A packaged liquid-based food item, comprising

a flexible outer pouch;

a flexible inner pouch disposed within the flexible outer pouch, wherein an inner surface of the flexible inner pouch at least partially defines an inner cavity, and an outer surface of the flexible inner pouch and an inner surface of the flexible outer pouch define an outer cavity;

a seal that extends across tops of the flexible inner and outer pouches and closes the inner and outer cavities;

a liquid;

a seasoning; and

a plurality of particulates, wherein

the inner cavity is filled with the seasoning and the liquid and the outer cavity is filled with the plurality of particulates so that the seasoning and the particulates are separated from each other, and when the seal is removed or broken to open the segmented pouch, the liquid, the seasoning, and the particulates are pourable from their respective inner and outer cavities in a single motion.

35. The packaged liquid-based food item of claim 34, wherein the outer cavity includes the plurality of particulates and water.

36. The packaged liquid-based food item of claim 34, wherein a height of the outer pouch is greater than a height of the inner pouch.

37. The packaged liquid-based food item of claim 34, wherein a width of the outer pouch is the same as a width of the inner pouch.

38. The packaged liquid-based food item of claim 34, wherein a width of the outer pouch is greater than a width of the inner pouch.

39. The packaged liquid-based food item of claim 34, wherein a height of the outer cavity is greater than a height of the inner cavity.

40. The packaged liquid-based food item of claim 34, wherein a width of the outer cavity is the same as a width of the inner cavity.

41. The packaged liquid-based food item of claim 34, wherein a width of the outer cavity is greater than a width of the inner cavity.

42. The packaged liquid-based food item of claim 34, wherein the outer cavity substantially envelopes the inner cavity.

43. The packaged liquid-based food item of claim 34, further comprising lateral support members that extend between outer sides of the inner pouch and inner sides of the outer pouch.

44. The packaged liquid-based food item of claim 34, wherein a bottom of the outer pouch is gusseted and enables the segmented pouch to stand upright.

45. The package liquid-based food item of claim 34, wherein the seasoning, the liquid and the plurality of particulates are ingredients of a soup.

46. A packaged liquid-based food item, comprising

a flexible plastic inner pouch disposed within the flexible plastic outer pouch, wherein an inner surface of the flexible plastic inner pouch at least partially defines an inner cavity, and an outer surface of the flexible plastic inner pouch and an inner surface of the flexible plastic outer pouch define an outer cavity;

a seal that extends across tops of the flexible plastic inner and outer pouches and closes the inner and outer cavities;

a liquid;

a seasoning; and

a plurality of particulates, wherein

47. The packaged liquid-based food item of claim 46, wherein the outer cavity includes the plurality of particulates and water.

48. The packaged liquid-based food item of claim 46, wherein a height of the outer pouch is greater than a height of the inner pouch.

49. The packaged liquid-based food item of claim 46, wherein a width of the outer pouch is the same as a width of the inner pouch.

50. The packaged liquid-based food item of claim 46, wherein a width of the outer pouch is greater than a width of the inner pouch.

51. The packaged liquid-based food item of claim 46, wherein a height of the outer cavity is greater than a height of the inner cavity.

52. The packaged liquid-based food item of claim 46, wherein a width of the outer cavity is the same as a width of the inner cavity.

53. The packaged liquid-based food item of claim 46, wherein a width of the outer cavity is greater than a width of the inner cavity.

54. The packaged liquid-based food item of claim 46, wherein the outer cavity substantially envelopes the inner cavity.

55. The packaged liquid-based food item of claim 46, fuirther comprising lateral support members that extend between outer sides of the inner pouch and inner sides of the outer pouch.

56. The package liquid-based food item of claim 34, wherein the seasoning, the liquid and the plurality of particulates are ingredients of a soup.