US20120241336A1

US20120241336A1 - On-Demand Marination Package

Info

Publication number: US20120241336A1
Application number: US13/052,217
Authority: US
Inventors: David M. Finley; Andrew B. Carrouth, JR.; Terry O. Millwood; Hubert J. Cook; Matthew F. Ellis; Brian P. Rivers
Original assignee: Cryovac LLC
Current assignee: Cryovac LLC
Priority date: 2011-03-21
Filing date: 2011-03-21
Publication date: 2012-09-27
Also published as: BR112013022979A2; RU2013146596A; RU2549099C1; EP2688811A1; WO2012129269A1

Abstract

The presently disclosed subject matter is directed to a package comprising a lower film that contains at least first and second compartments separated by a partition. The first compartment can substantially contain a food product and the second compartment can substantially contain a pouch. Specifically, the pouch comprises at least one rupturable seal and houses one or more food additives. An upper film is sealed to the lower film about the perimeter of the package via outer perimeter seal. In addition, the package comprises at least one inner perimeter seal that cooperates with the pouch rupturable seals and functions to isolate the first and second compartments until it is desired to intermix the food additive and the food product.

Description

BACKGROUND

Of the several sensory characteristics of meat, tenderness is perhaps the trait most highly desired by consumers. Consequently, meat tenderness is a factor of major economic importance to the livestock and meat industries. Accordingly, consumer acceptance of meat, e.g., beef, pork, and poultry, depends to a large measure on the tenderness of the meat after cooking. When the meat is tough and fibrous, consumer acceptance is quite low. Meat prepared for home consumption and sold in local groceries and butcheries is normally of the more tender grades. For example, in the case of beef, lot feeding can be required to develop the desired amount of tenderness in the muscle tissue, including increases in fat content. However, such efforts can considerably increase the cost of the meat. For this reason, significant effort has been expended in the art to provide methods for tenderizing less tender grades of meat.
Commonly, food additives (such as, for example, marinades) can be used to improve the qualities of meats by providing enhanced visual appearance and tenderness from spices and flavorings. For example, some techniques utilize injection of flavorings into the muscle to impart flavor and juiciness prior to packaging the meat. Other techniques include a means of tumbling a meat product in a marinade prior to packaging. In the case of the injected or tumbled marinade techniques, the use of a tenderizer is often omitted because the proteolytic enzyme associated with tenderizing agents can overly soften the meat, resulting in an unsatisfactory texture. The over-tenderizing results from prolonged contact time between the meat and the tenderizing agent as a consequence of the poor ability to control the exposure time during distribution. Additionally, even without considering the role of a proteolytic enzyme, the quality of a pre-marinated package is necessarily inconsistent as the meat generally is exposed for too long to the flavorants.
Alternatively, restaurants or consumers can purchase a vacuum packaged meat package, cut open the package, and transfer the meat to a second bag where a marinade is added, or to a tray or vat that is loaded with a marinade. With the tray, vat, or second bag method, a consumer removes the meat from its shipment package and necessarily exposes the meat to outside conditions that can introduce contamination during marinating. In addition, the method can introduce the undesirable step of cleaning the tray or vat to prevent cross-contamination.

SUMMARY

In some embodiments, the presently disclosed subject matter is directed to a package for marinating a food product. In some embodiments, the package comprises a lower film comprising at least first and second compartments separated by a partition, such that the first compartment is adapted to substantially contain a food product and the second compartment is adapted to substantially contain a pouch. The package further comprises a pouch substantially contained within the second compartment and configured to contain a food additive. The pouch comprises at least one rupturable seal configured to rupture when exposed to a predetermined pressure. The rupturable seal is positioned at least partially overlapping the partition. The package also comprises an upper film peripherally sealed about the perimeter of the package to the lower film and to at least a portion of the partition of the lower film in the area overlapping the at least one rupturable seal to separate the first and second compartments, thereby forming a hermetically sealed package having an outer perimeter seal and an inner perimeter seal. In some embodiments, the pouch is in fluid communication with the first compartment upon rupture of the at least one rupturable seal to allow the food additive to mix with the food product. In some embodiments, the at least one rupturable seal has a lower rupture pressure compared to the outer perimeter seal and the inner perimeter seal. In some embodiments, the food item can be marinated directly in the package.
In some embodiments, the presently disclosed subject matter is directed to a package comprising a food product and a pouch comprising a food additive, wherein the pouch comprises at least one rupturable seal configured to rupture when exposed to a predetermined pressure. In some embodiments, the package comprises a lower film comprising at least first and second compartments separated by a partition, such that the first compartment is adapted to substantially contain the food product and the second compartment is adapted to substantially contain the pouch, and wherein the at least one rupturable seal is positioned at least partially overlapping the partition. The package further comprises an upper film peripherally sealed about the perimeter of the package to the lower film and at least partially to the partition of the lower film in the area overlapping the at least one rupturable seal to separate the first and second compartments, thereby forming a hermetically sealed package having an outer perimeter seal and an inner perimeter seal. In some embodiments, the pouch is in fluid communication with the first compartment upon rupturable of the at least one rupturable seal to allow the food additive to mix with the food product. In some embodiments, the at least one rupturable seal has a lower rupture pressure compared to the outer perimeter seal and the inner perimeter seal. In some embodiments, the food item can be marinated directly in the package.
In some embodiments, the presently disclosed subject matter is directed to a method of controlling a level of food additive imparted to a food product. Particularly, the method comprises forming a support member of a package that includes a first compartment configured to substantially contain a food product and a second compartment configured to substantially contain a pouch, wherein the first and second compartments are separated by a partition. The method further comprises forming the pouch configured to contain the food additive and loading food additive into the pouch. The method also comprises sealing food additive in the pouch with at least one rupturable seal configured to rupture and allow the food additive to escape the pouch. The method further comprises loading the food product into the first compartment of the support member and loading the pouch into the second compartment of the support member such that the at least one rupturable seal is positioned at least partially overlapping the partition, and such that the pouch is in fluid communication with the first compartment upon rupturing of the rupturable seal to allow the food additive to mix with the food product. The method further comprises sealing the support member with a film about the perimeter of the package with an outer perimeter seal and at least partially to said partition in the area overlapping the at least one rupturable seal with an inner perimeter seal to separate the first and second compartments, such that the first package is configured to withstand the predetermined pressure and prevent leaking of the food additive and food product from the first package during the mixing of the food additive and the food product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a perspective view of a package according to some embodiments of the presently disclosed subject matter.

FIG. 1 b is a sectional view taken along lines 1 b-1 b of FIG. 1 a.

FIG. 2 a is a perspective view of one embodiment of a package lower film in accordance with some embodiments of the presently disclosed subject matter.

FIG. 2 b is a sectional view taken along lines 2 b-2 b of FIG. 2 a.

FIG. 3 a is a top plan view of one embodiment of a pouch that can be used in accordance with the presently disclosed subject matter.

FIG. 3 b is a sectional view taken along lines 3 b-3 b in FIG. 3 a.

FIG. 4 is a top plan view of one embodiment of an upper film that can be used in accordance with some embodiments of the presently disclosed subject matter.

FIG. 5 a is a top plan view of one embodiment of a package that can be used in accordance with the presently disclosed subject matter.

FIG. 5 b is a fragmentary sectional view of the package of FIG. 5 a.

FIG. 5 c is a perspective view of one embodiment of a folded pouch that can be used in accordance with some embodiments of the presently disclosed subject matter.

FIG. 5 d is a top plan view of one embodiment of a package that can be used in accordance with the presently disclosed subject matter.

FIG. 5 e is a fragmentary sectional view of the package of FIG. 5 d.

FIGS. 6 a and 6 b are top plan views of packages that can be used in accordance with some embodiments of the presently disclosed subject matter.

FIG. 7 a is a top sectional view of a package that can be used in accordance with some embodiments of the presently disclosed subject matter.

FIG. 7 b is a top plan view of one embodiment of a pouch that can be used in accordance with some embodiments of the presently disclosed subject matter.

FIG. 7 c is a top sectional view of a package that can be used in accordance with some embodiments of the presently disclosed subject matter.

FIG. 8 is a top sectional view of a package that can be used in accordance with some embodiments of the presently disclosed subject matter.

DETAILED DESCRIPTION

I. General Considerations

FIGS. 1 a and 1 b illustrate one embodiment of package 5 in accordance with the presently disclosed subject matter. Particularly, package 5 comprises lower film 10 that contains at least first and second compartments 15 and 20 separated by partition 17. First compartment 15 can substantially contain food product 25 and second compartment 20 can substantially contain pouch 30. Specifically, pouch 30 comprises first and second rupturable seals 35, 36 and houses one or more additives 31. Upper film 40 is sealed to lower film 10 about the perimeter of the package via outer perimeter seal 45. In addition, as set forth in more detail herein below, package 5 comprises at least one inner perimeter seal 50 that cooperates with at least one of rupturable seals 35, 36 and functions to isolate first and second compartments 15, 20 until it is desired to intermix additive 31 and food product 25.
In use, applying pressure to at least second compartment 20 of package 5 can break at least one of the rupturable seals of pouch 30 to effectively distribute additive 31 to food product 25. As a result, the presently disclosed subject matter achieves, among other things, controlled application of a food additive to a food product within package 5, while also maintaining the separation of first and second compartments 15, 20 prior to mixing. After sufficient intermixing time, the marinated food product can be removed from package 5 and heated and/or cooked in an oven or microwave.
Although discussion of the presently disclosed package herein is limited to food applications, it should be understood that the disclosed subject matter is not limited and can be used with a wide variety of applications, including (but not limited to) medical applications.

II. Definitions

While the following terms are believed to be well understood by one of ordinary skill in the art, the following definitions are set forth to facilitate explanation of the presently disclosed subject matter.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are now described.
Following long-standing patent law convention, the terms “a”, “an”, and “the” refer to “one or more” when used in the subject specification, including the claims. Thus, for example, reference to “a package” (e.g., “a marinade package”) includes a plurality of such packages, and so forth.
Unless otherwise indicated, all numbers expressing quantities of components, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the instant specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the presently disclosed subject matter.
As used herein, the term “about”, when referring to a value or to an amount of mass, weight, time, volume, concentration, percentage, and the like can encompass variations of, in some embodiments ±20%, in some embodiments ±10%, in some embodiments ±5%, in some embodiments ±1%, in some embodiments ±0.5%, and in some embodiments ±0.1%, from the specified amount, as such variations are appropriate in the disclosed package and methods.
As used herein, the phrase “abuse layer” refers to an outer film layer and/or an inner film layer, so long as the film layer serves to resist abrasion, puncture, and other potential causes of reduction of package integrity, as well as potential causes of reduction of package appearance quality. Abuse layers can comprise any polymer, so long as the polymer contributes to achieving an integrity goal and/or an appearance goal. In some embodiments, an abuse layer can comprise polymers having a modulus of at least 10⁷Pascals, at room temperature. In some embodiments, an abuse layer can comprise, but is not limited to, polyamide and/or ethylene/propylene copolymer; in some embodiments, nylon 6, nylon 6/6, and/or amorphous nylon.
As used herein, the term “barrier”, and the phrase “barrier layer”, as applied to films and/or layers, can be used with reference to the ability of a film or layer to serve as a barrier to one or more gases. In the packaging art, oxygen (i.e., gaseous O₂) barrier layers have included, for example, ethylene/vinyl alcohol copolymer (polymerized ethylene vinyl alcohol), polyvinyl chloride, polyvinylidene chloride (PVDC), polyalkylene carbonate, polyamide, polyethylene naphthalate, polyester, polyacrylonitrile, and the like, as known to those of ordinary skill in the art. In some embodiments, the barrier layer can comprise ethylene/vinyl alcohol copolymer, polyvinyl chloride, polyvinylidene chloride, and/or polyamide.
The term “comprising” as used herein is used synonymously with the term “including” and is intended as an open, non-limiting term.
As used herein, the term “easy open sealant” refers to any suitable polymer or polymer blend that comprises at least a majority of the film layer in which the easy-open sealant is disposed. In some embodiments, the easy-open sealant exhibits a seal strength (in accordance with ASTM F88-05) that is less than the seal strength of the regular sealant as defined herein. Typical seal strengths can range in some embodiments from about 1 pound/inch to 20 pounds/inch; in some embodiments, from about 1 pound/inch to 10 pounds/inch; and in some embodiments, from about 1 pound/inch to 3 pounds/inch. However, the easy open sealant can have any seal strength so long as it is stronger than the tensil strength of the film near the seal area (i.e., the film will fail before the regular seal will). Examples of easy-open sealants that can be used in accordance with the presently disclosed subject matter include (without limitation) the following: (1) DuPont APPEEL™ resins; (2) polyethylene, such as low density polyethylene (LDPE) and/or EVA copolymers blended with polypropylene or other non-compatible resin; (3) polyolefin blended with polybutene-1; (4) polyolefin blended with polypropylene or other non-compatible resin; (5) Versify™ 5050 or Sealution™; (6) SPS-70 or SPS-33C-3; (7) Surlyn® or Surlyn® blend blended with incompatible resin, such as polypropylene or polybutylene. Suitable easy-open sealants for use in embodiments of the presently disclosed subject matter are disclosed in U.S. Patent/Publication Nos. 4,875,587; 5,023,121; 5,024,044; 6,395,321; 6,476,137; 7,055,683 and 2003/0152669, each of which is incorporated herein by reference in its entirety.
As used herein, the term “film” can be used in a generic sense to include plastic web, regardless of whether it is film or sheet.
As used herein, the term “food additive” refers to any liquid or solid material that results or can reasonably be expected to result, directly or indirectly, in its becoming a component or otherwise affecting the characteristics of any food product. In some embodiments, the food additive can, for example, be an agent having a distinct taste and/or flavor, such as a salt or any other taste or flavor potentiator or modifier. Examples of food additives include, but are not limited to, marinades and proteolytic enzymes. In addition, components that by themselves are not additives, such as vitamins, minerals, color additives, herbal additives (e.g., echinacea or St. John's Wort), antimicrobials, preservatives, and the like can be considered food additives.
As used herein, the term “food product” refers to any nourishing substance that is eaten or otherwise taken into the body to sustain life, provide energy, promote growth, and/or the like. For example, in some embodiments, food products can include, but are not limited to, meats, vegetables, fruits, starches, and combinations thereof. In some embodiments, food products can include individual food components or mixtures thereof.
As used herein, the term “heat seal” refers to any seal of a first region of a film surface to a second region of a film surface, wherein the seal is formed by heating the regions to at least their respective seal initiation temperatures. Heat-sealing is the process of joining two or more thermoplastic films or sheets by heating areas in contact with each other to the temperature at which fusion occurs, usually aided by pressure. In some embodiments, heat-sealing can be inclusive of thermal sealing, melt-bead sealing, impulse sealing, dielectric sealing, and/or ultrasonic sealing. The heating can be performed by any one or more of a wide variety of means, such as (but not limited to) a heated bar, hot wire, hot air, infrared radiation, ultrasonic sealing, and the like.
The term “hermetically sealed” as used herein refers to a package that is substantially sealed against, e.g., the escape or entry of air and/or liquid in accordance with standard usage.
As used herein, the term “lamination”, the term “laminate”, and the phrase “laminated film”, can refer to the process and resulting product made by bonding together two or more layers of film and/or other materials. Lamination can be accomplished by joining film layers with adhesives, joining with heat and pressure, spread coating, and/or extrusion coating. In some embodiments, the term “laminate” can be inclusive of coextruded multilayer films comprising one or more tie layers.
As used herein, the term “layer” refers to the thickness of material formed over a surface and extending generally parallel to the surface, with one side toward the surface and another side away from the surface.
As used herein, the term “marinade” refers to an edible substance that can impart one or more flavors and/or textures to a food item. In some embodiments, the marinade can comprise acidic ingredients, such as vinegar, lemon juice, and/or wine. In some embodiments, the marinade can comprise savory ingredients, such as soy sauce, brine, or other prepared sauces. In some embodiments, the marinade can comprise oils, herbs, and spices to further flavor a food item. In some embodiments, the marinade can comprise one or more proteolytic enzymes to flavor the food and/or to tenderize a food item.
As used herein, the term “meat” comprises both cooked and uncooked meat and includes, but is not limited to, beef, birds such as poultry (including chicken, duck, goose, turkey, and the like), buffalo, camel, crustacean (including shellfish, clams, scallops, mussels, oysters, lobster, crayfish, crab, shrimp, prawns, and the like), dog, fish (including salmon, trout, eel, cod, herring, plaice, whiting, halibut, turbot, ling, squid, tuna, sardines, swordfish, dogfish, shark, and the like), game (including deer, eland, antelope, and the like), game birds (such as pigeon, quail, doves, and the like), goat, hare, horse, kangaroo, lamb, marine mammals (including whales and the like), amphibians (including frogs and the like), monkey, pig, rabbit, reptiles (including turtles, snakes, alligators, and the like), and/or sheep.
“Medical product” and the like herein refers to any product that is used in health care, whether for medical, dental, or veterinary applications, such as those used during medical intervention. Such products can include (but are not limited to) needles, syringes, sutures, wound dressings such as bandages, general wound dressings, non-adherent dressings, burn dressings, surgical tools such as scalpels, gloves, drapes, and other disposal items, solutions, ointments, antibiotics, antiviral agents, blood components such as plasma, drugs, biological agents, intravenous solutions, saline solutions, surgical implants, surgical sutures, stents, catheters, vascular grafts, artificial organs, cannulas, wound care devices, dialysis shunts, wound drain tubes, skin sutures, vascular grafts, implantable meshes, intraocular devices, heart valves, biological graft materials, tape closures and dressings, head coverings, shoe coverings, sterilization wraps, and the like.
As used herein, the term “package” refers to packaging materials configured around a product being packaged, and can include (but are not limited to) bags, pouches, trays, and the like.
As used herein, the term “partition” refers to a structure that spatially separates or divides a whole into sections or parts. For example, in some embodiments, a partition can separate a support member into two compartments.
As used herein, the term “polymer” refers to the product of a polymerization reaction, and can be inclusive of homopolymers, copolymers, terpolymers, etc. In some embodiments, the layers of a film can consist essentially of a single polymer, or can have still additional polymers together therewith, i.e., blended therewith.
The term “pouch” as used herein refers to a hollow receptacle defining a volume. In some embodiments, the pouch can be deemed “closed” in the sense that the pouch contents are substantially retained within the pouch and the pouch volume is substantially sealed about its perimeter. The term pouch also includes bags, satchels, and the like.
As used herein, the term “proteolytic enzyme” refers to an enzyme that can be added to a marinade fluid to sever peptide bonds in proteins, and therefore tenderize a meat. Proteolytic enzymes suitable for use with the presently disclosed subject matter can include, but are not limited to, bromelain from pineapple and papain from papaya, achromopeptidase, aminopeptidase, ancrod, angiotensin converting enzyme, bromelain, calpain, calpain I, calpain II, carboxypeptidase A, carboxypeptidase B, carboxypeptidase G, carboxypeptidase P, carboxypeptidase W, carboxypeptidase Y, caspase, caspase 1, caspase 2, caspase 3, caspase 4, caspase 5, caspase 6, caspase 7, caspase 8, caspase 9, caspase 10, caspase 11, caspase 12, caspase 13, cathepsin B, cathepsin C, cathepsin D, cathepsin G, cathepsin H, cathepsin L, chymopapain, chymase, chymotrypsin a-, clostripain, collagenase, complement Clr, complement Cls, complement Factor D, complement Factor I, cucumisin, dipeptidyl peptidase IV, elastase (leukocyte), elastase (pancreatic), endoproteinase Arg-C, endoproteinase Asp-N, endoproteinase Glu-C, endoproteinase Lys-C, enterokinase, factor Xa, ficin, furin, granzyme A, granzyme B, HIV protease, IGase, kallikrein tissue, leucine aminopeptidase (general), leucine aminopeptidase (cytosol), leucine aminopeptidase (microsomal), matrix metalloprotease, methionine amiopeptidase, neutrase, papain, pepsin, plasmin, prolidase, pronase E, prostate specific antigen, protease (alkalophilic form), Streptomyces griseus, protease from Aspergillus, protease from Aspergillus saitoi, protease from Aspergillus sojae, protease (B. licheniformis) (Alkaline), protease (B. licheniformis) (Alcalase), protease from Bacillus polymyxa, protease from Bacillus sp, protease from Bacillus sp (Esperase), protease from Rhizopus sp., protease S, proteasomes, proteinase from Aspergillus oryzae, proteinase 3, proteinase A, proteinase K, protein C, pyroglutamate amiopeptidase, renin, rennin, streptokinase, subtilisin, thermolysin, thrombin, tissue plasminogen activator, trypsin, tryptase, urokinase, and combinations thereof.
As used herein, the term “regular sealant” refers to any suitable polymer or polymer blend that comprises at least a majority of the film layer in which the regular sealant is disposed. The regular sealant exhibits a seal strength (as measured by ASTM F 904-98) that is greater than the seal strength of the easy-open sealant of the same film. In some embodiments, the outer film layer in which the regular sealant is disposed exhibits a seal strength of at least 3.5 pounds per inch, such as at least 4.0, 4.5, 5.0, and at least 6 pounds per inch, or 3.5, 4.0, 4.5, 5.0, or 6 pounds per inch. In another embodiment, the film layer in which the regular sealant is disposed exhibits a seal strength of from 3.0 to 6.0 pounds per inch, such as 3.5 to 5.5, and 4.0 to 5.0 pounds per inch. The seal strength of the regular sealant can in some embodiments be greater than the seal strength of the easy-open sealant by a difference of at least about 75 pounds per inch, e.g. at least about 0.5, 1.0, 2.0, 3.0, 5, 10, 15, 20, or 25 pounds per inch, e.g. from 0.5 to 20 pounds, such as from 1 to 15, or 5 to 10 pounds per inch. Examples of regular sealants include without limitation the following: (1) Ziegler-Natta catalyzed linear low density polyethylene (LLDPE) such as DOWLEX™ 2045.03, DOWLEX™ 2045.04, and DOWLEX™ 2247G; (2) metallocene-catalyzed LLDPE (m-LLDPE), such as Exxon EXCEED™ 4518PA and Exxon EXCEED™ 3518CB; (3) polyolefin “plastomer” grade polyethylenes (VLDPE) with high comonomer incorporation, comonomers selected from octene or hexene and/or butene, such as Dow AFFINITY™ PL 1888G, Dow AFFINITY™ PL 1850G, Dow AFFINITY™ PL 1850, ExxonMobil EXACT™ 4151, and ExxonMobil EXACT™ 3024; (4) polyolefin “elastomer” grade polyethylenes such as Dow AFFINITY™ EG 8100 and DuPont-Dow ENGAGE™ resins; (5) propylene-ethylene copolymer, including “plastomer” grades; (6) other “enhanced” copolymer grades, such as Dow ELITE™ 5400G; (7) LDPE, such as Huntsman PE 1042cs15™ and ExxonMobil ESCORENE™ LD-200.48 0.915/7.5; (8) ionomer resin, such as SURLYN™ 1650 from DuPont; (9) ethylene/vinyl acetate copolymers (EVA); (10) ethylene/methyl (meth)acrylate (EMA) copolymers; and (11) ethylene/butyl acrylate (EBA) copolymers.
As used herein, the term “rupturable” with regard to a seal can indicate the susceptibility of being broken without implying weakness. Thus, in referring to a rupturable seal between the films of a package, it can be meant that when so sealed the films are united together in a fluid impervious manner, and when the seal is broken or severed by delamination of the films from one another in the area of the seal, the films are separated apart from one another severing the seal while still maintaining the integrity of the individual films themselves. Thus, the rupturable seal in an intact state serves to maintain the integrity of the product chamber reservoir for maintaining fluid, semi-fluid, and/or solid products therein but in a broken or severed state allows for passage of these products between the films along a delaminated seal area.
As used herein, the term “seal” refers to any seal of a first region of an outer film surface to a second region of an outer film surface, including heat or any type of adhesive material, thermal or otherwise. In some embodiments, the seal can be formed by heating the regions to at least their respective seal initiation temperatures. The sealing can be performed by any one or more of a wide variety of means, including, but not limited to, using a heat seal technique (e.g., melt-bead sealing, thermal sealing, impulse sealing, dielectric sealing, radio frequency sealing, ultrasonic sealing, hot air, hot wire, infrared radiation, etc.).
As used herein, the phrases “seal layer”, “sealing layer”, “heat seal layer”, and “sealant layer”, refer to an outer film layer, or layers, involved in the sealing of the film to itself, another film layer of the same or another film, and/or another article that is not a film. It should also be recognized that in general, up to the outer 3 mils of a film can be involved in the sealing of the film to itself or another layer. With respect to packages having only fin-type seals, as opposed to lap-type seals, the phrase “sealant layer” generally refers to the inside film layer of a package, as well as supporting layers adjacent this sealant layer often being sealed to itself, and frequently serving as a food contact layer in the packaging of foods. In general, a sealant layer sealed by heat-sealing layer comprises any thermoplastic polymer. In some embodiments, the heat-sealing layer can comprise, for example, thermoplastic polyolefin, thermoplastic polyamide, thermoplastic polyester, and thermoplastic polyvinyl chloride. In some embodiments, the heat-sealing layer can comprise thermoplastic polyolefin.
The term “substantially” as used herein is defined as largely (but not necessarily wholly) that which is specified. For example, in some embodiments, the term “substantially” can encompass a margin of +/−ten percent.
As used herein, the phrase “thermoforming layer” refers to a film layer that can be heated and drawn into a cavity while maintaining uniform thinning, as opposed to films or film layers that lose integrity during the thermoforming process (e.g., polyethylene homopolymers do not undergo thermoforming with uniform thinning). In some embodiments, thermoforming layers can comprise, but are not limited to, polyamide, ethylene/propylene copolymer, and/or propylene homopolymer; in some embodiments, nylon 6, nylon 6/6, amorphous nylon, ethylene/propylene copolymer, and/or propylene homopolymer.
As used herein, the term “thermoplastic” refers to uncrosslinked polymers of a thermally sensitive material that flow under the application of heat or pressure.
As used herein, the term “tie layer” refers to any internal layer having the primary purpose of adhering two layers to one another. In some embodiments, tie layers can comprise any nonpolar polymer having a polar group grafted thereon, such that the polymer is capable of covalent bonding to polar polymers such as polyamide and ethylene/vinyl alcohol copolymer. In some embodiments, tie layers can comprise at least one member selected from the group including, but not limited to, modified polyolefin, modified ethylene/vinyl acetate copolymer, and/or homogeneous ethylene/alpha-olefin copolymer. In some embodiments, tie layers can comprise at least one member selected from the group consisting of anhydride modified grafted linear low density polyethylene, anhydride grafted low density polyethylene, homogeneous ethylene/alpha-olefin copolymer, and/or anhydride grafted ethylene/vinyl acetate copolymer.
As used herein, terminology employing a “/” with respect to the chemical identity of a copolymer (e.g., “an ethylene/alpha-olefin copolymer”), identifies the comonomers that are copolymerized to produce the copolymer. Such phrases as “ethylene alpha-olefin copolymer” are the respective equivalent of “ethylene/alpha-olefin copolymer.”

III. Package 5

III.A. Generally
As discussed herein above in accordance with FIGS. 1 a and 1 b, package 5 comprises lower film 10 that comprises first and second compartments 15 and 20. First compartment 15 can house food product 25 and second compartment 20 can house pouch 30. Specifically, pouch 30 comprises first and second rupturable seals 35, 36 and contains one or more additives 31. Upper film 40 is sealed to lower film 10 about the perimeter of the package via outer perimeter seal 45. In addition, package 5 comprises at least one inner perimeter seal 50 that cooperates with rupturable seals 35, 36 of pouch 30 and functions to separate first and second compartments 15, 20 until it is desired to intermix additive 31 and food product 25.
III.B. Lower Film 10
FIGS. 2 a and 2 b are illustrative views of package lower film 10 in some embodiments. Particularly, lower film 10 can be formed through an extrusion molding and thermoforming process to produce first and second compartments 15 and 20 separated by partition 17. Although two compartments are illustrated in the Figures, one of ordinary skill in the art would recognize that the presently disclosed subject matter can include configurations wherein lower film 10 comprises more than two compartments.
Extrusion molding is a well known plastic shaping process in which thermoplastic materials are fed from a hopper or other device into an extruder configured to heat the thermoplastic material and force it through a die to form a particular profile, such as a plastic film or sheet. Thermoforming is also well known in the packaging art, and is the process whereby a thermoplastic web is heat softened and reshaped to conform to the shape of a cavity in a mold. Suitable thermoforming methods, for example, include a vacuum forming or plug-assist vacuum forming method. In a vacuum forming method, the first web is heated, for instance, by a contact heater, and a vacuum is applied beneath the web causing the web to be pushed by atmospheric pressure down into a preformed mold. In a plug-assist vacuum forming method, after the first or forming web has been heated and sealed across a mold cavity, a plug shape similar to the mold shape impinges on the forming web and, upon the application of vacuum, the forming web transfers to the mold surface.
The films used to form lower film 10 can be provided in sheet or film form and can be any of the films commonly used for the disclosed type of packaging. To this end, in some embodiments, lower film 10 can be a monolayer or multilayer structure produced by any suitable process, including coextrusion, lamination, extrusion coating, and combinations thereof. Typically, the films employed will have two or more layers to incorporate a variety of properties, such as sealability, gas impermeability and toughness, into a single film. For example, lower film 10 can comprise one or more barrier layers, abuse layers, tie layers, seal layers, and/or bulk layers, as would be known to those of ordinary skill in the art. The polymer components used to fabricate lower film 10 can also comprise appropriate amounts of other additives normally included in such compositions. For example, slip agents (such as talc), antioxidants, fillers, dyes, pigments, radiation stabilizers, antistatic agents, elastomers, and the like can be added.
Thus, various combinations of layers can be used in the formation of lower film 10 in accordance with the presently disclosed subject matter. The following are several non-limiting examples of combinations wherein letters are used to represent film layers: NB, A/B/A, A/B/C, A/B/D, A/B/E, A/B/C/D, A/B/C/E, A/B/E/E′, A/B/D/E, A/B/D/C, A/B/C/B/A, A/B/C/D/A, A/B/E/B/A, A/B/C/D/E, A/B/C/E/D, A/B/D/C/D, A/B/D/C/E, A/B/D/E/C, A/B/D/E/E′, A/B/E/C/E, A/B/E/C/D, A/B/E/D/D′, A/B/E/D/E, wherein A represents a sealant layer; B represents a bulk layer or a sealant layer (depending on whether it is present as an inner or outer layer of the film); C represents a barrier layer; D and D′ represent bulk and/or abuse layers (depending on whether they are present as an inner or outer layer of the film); and E and E′ represent abuse layers. Of course, one or more tie layers (“T”) can be used between any one or more layers of in any of the above multilayer film structures.
In some embodiments, lower film 10 comprises a total of from about 4 to about 20 layers; in some embodiments, from about 4 to about 12 layers; and in some embodiments, from about 5 to about 9 layers. Thus, in some embodiments, the disclosed film can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 layers. One of ordinary skill in the art would also recognize that the disclosed film can comprise more than 20 layers, such as in embodiments wherein the film components comprise microlayering technology.
Lower film 10 can have any total thickness desired, so long as it provides the desired properties for the particular packaging operation in which the film is used. Final web thicknesses can vary, depending on process, end use application, and the like. Typical thicknesses can range between about 0.1 to 20 mils; in some embodiments, between about 0.3 and 15 mils; in some embodiments, between about 0.5 to 10 mils; in some embodiments, between about 1 to 8 mils; in some embodiments, between about 3 to 6 mils; and in some embodiments, between about 4 to 5 mils.
It should be noted that lower film 10 can be considered a “bottom” web, e.g., in normal usage, package 5 can rest on the lower film. Likewise, in some embodiments, upper film 40 can be considered a “top” web, e.g., in normal usage, package 5 can be positioned such that the web of the upper film comprises the top of the package. Nevertheless, those skilled in the art will understand after a review of the presently disclosed subject matter that package 5 can be manufactured, stored, shipped, and/or displayed in any suitable orientation. For example, package 5 can be placed on a supporting surface such that lower film 10 functions as the top of the package and upper film 40 functions as the bottom of the package.
In some embodiments, lower film 10 can be transparent (at least in the non-printed regions) so that the packaged items are visible through the films. “Transparent” as used herein means that the material transmits incident light with negligible scattering and little absorption, enabling objects (e.g., packaged food or print) to be seen clearly through the material under typical unaided viewing conditions (i.e., the expected use conditions of the material). The transparency (i.e., clarity) of the film can be at least about any of the following values: 20%, 25%, 30%, 40%, 50%, 65%, 70%, 75%, 80%, 85%, and 95%, as measured in accordance with ASTM D1746.
III.C. Pouch 30
FIGS. 3 a and 3 b illustrate one embodiment of pouch 30 that can be used in accordance with the presently disclosed subject matter. Particularly, pouch 30 includes first and second walls 55, 60 each having an inner surface and an outer surface. Pouch 30 also includes first and second side edges 65, 66 and top and bottom edges 70, 71. In addition, the pouch comprises first and second rupturable seals 35, 36 and lap seal 37.
As would be apparent to those of ordinary skill in the art, pouch 30 can be constructed using a wide variety of polymeric materials. To this end, in some embodiments, pouch 30 is constructed from a polymeric film comprising an inside (innermost) easy open sealant layer and an outside (outermost) regular sealant layer. Alternatively, in some embodiments, the layer adjacent to the inside layer can comprise the easy open sealant, such as in embodiments wherein “easy open tear out” is employed. “Easy open tear out” refers to situations wherein an easy open sealant layer is positioned adjacent to a relatively thin inner or outer layer. When the resultant easy open seal is ruptured, it tears through the adjacent thin layer.
The disclosed film structure enables rupturable seals 35, 36 to be formed as a result of the inside layer-to-inside layer bond of the film (i.e., easy open sealant-to-easy open sealant bond). In addition, lap seal 37 can be formed as a result of an outer layer-to-inside layer bond of the film (i.e., regular sealant-to-easy open sealant bond). Thus, lap seal 37 is a regular (hard) seal as a result of the outside sealant being sealed to the inside sealant. The strength of lap seal 37 can also be increased by the pressures applied during opening. Specifically, during opening pressure is applied in a direction such that a shirring action is created, rather than pulling the seal directly apart at a right angle.
In addition to the inside and outside sealant layers described above, the film used to construct pouch 30 can optionally comprise one or more additional layers. Examples of such layers include (but are not limited to) barrier layers, abuse layers, core layers, tie layers, bulk layers, and the like. Those of ordinary skill in the art are aware of the plethora of polymers and polymer blends that can be included in each of the foregoing layers. Regardless of the particular structure of a given multilayer film, it can be used to form pouch 30 so long as the inside layer comprises an easy open sealant and the outside layer comprises a regular sealant. In addition, one or more conventional packaging film additives can be included in the film. Examples of additives that can be incorporated include (but are not limited to): antiblocking agents, antifogging agents, slip agents, colorants, flavorants, meat preservatives, stabilizers, antioxidants, UV absorbers, cross-linking enhancers, cross-linking inhibitors, and the like, as would be well understood to those of ordinary skill in the art.
Thus, various combinations of layers can be used in the formation of pouch 30 in accordance with the presently disclosed subject matter. The following are several non-limiting examples of combinations wherein letters are used to represent film layers: A/B, A/B/A, A/B/C, A/B/D, A/B/E, A/B/C/D, A/B/C/E, A/B/E/E′, A/B/D/E, A/B/D/C, A/B/C/B/A, A/B/C/D/A, A/B/E/B/A, A/B/C/D/E, A/B/C/E/D, A/B/D/C/D, A/B/D/C/E, A/B/D/E/C, A/B/D/E/E′, A/B/E/C/E, A/B/E/C/D, A/B/E/D/D′, A/B/E/D/E, wherein A represents a sealant layer; B represents a bulk layer or a sealant layer (depending on whether it is present as an inner or outer layer of the film); C represents a barrier layer; D and D′ represent bulk and/or abuse layers (depending on whether they are present as an inner or outer layer of the film); and E and E′ represent abuse layers. Of course, one or more tie layers (“T”) can be used between any one or more layers of in any of the above multilayer film structures.
The film used to construct pouch 30 can comprise 2 to 20 layers; in some embodiments, from 2 to 12 layers; in some embodiments, from 2 to 9 layers; and in some embodiments, from 3 to 8 layers. Thus, in some embodiments, the disclosed film can have 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 layers. One of ordinary skill in the art would also recognize that the disclosed film can comprise more than 20 layers, such as in embodiments wherein the film components comprise microlayering technology.
The film can have any total thickness as long as the film provides the desired properties for the particular packaging operation in which it is to be used. Nevertheless, in some embodiments the disclosed film has a total thickness ranging from about 0.1 mil to about 15 mils; in some embodiments, from about 0.2 mil to about 10 mils; and in some embodiments, from about 0.3 mils to about 5.0 mils.
The film used to construct pouch 30 can be manufactured by thermoplastic film-forming processes known in the art (e.g., tubular or blown-film extrusion, coextrusion, extrusion coating, flat or cast film extrusion, and the like). A combination of these processes can also be employed.
Although pouch 30 can be constructed using any of a variety of methods known to those of ordinary skill in the art, in some embodiments, the pouch can be constructed using vertical form/fill/seal (“VFFS”) technology. One example of such a system is the Onpack™ packaging system marketed by Cryovac/Sealed Air Corporation (Saddle Brook, N.J., United States of America). The VFFS process is known to those of ordinary skill in the art, and is described in U.S. Pat. No. 4,589,247 to Tsuruta et al., U.S. Pat. No. 4,656,818 to Shimovama et al., U.S. Pat. No. 4,768,411 to Su, and U.S. Pat. No. 4,808,010 to Vogan, inter alia, all incorporated herein in their entireties by reference thereto.
In such a VFFS process, lay-flat thermoplastic film is first advanced over a forming device to form a tube. Next, a longitudinal (vertical) fin or lap seal is made, and a bottom end seal is formed by transversely sealing across the tube with heated seal bars. A pumpable product (such as a marinade) is introduced through a central, vertical fill tube to the formed tubular film. The pouch is then completed by sealing the upper end of the tubular segment, and severing the pouch from the tubular film above it. The process can be a two-stage process wherein the creation of a transverse heat seal occurs at one stage of the process, and downstream of the first stage, a separate pair of cooling/clamping means contact the newly-formed transverse heat seal to cool and thus strengthen the seal. In some VFFS processes, an upper transverse seal of a first pouch and the lower transverse seal of a following pouch are made. The pouches are then cut and thereby separated between two portions of the transverse seals without the need for a separate step to clamp, cool, clamp, cool, and cut the seals.
In some embodiments, pouch 30 can be “slack filled” with additive. That is, the pouch contents can occupy less than the full volume of the pouch. In these embodiments, the pouch can be easily moved or shaped as desired, while still maintaining the integrity of the rupturable seals. In addition, such slack filling of the pouch reduces the number of rupturable seal failures during normal use conditions, such as shipping and the like. Accordingly, in some embodiments, the pouch contents can occupy less than about 95% of the total volume of the closed pouch; in some embodiments, from about 20% to about 80% of the total volume of the pouch; and in some embodiments, from about 30% to about 70% of the total volume of the pouch.
One of ordinary skill in the art would recognize that the presently disclosed subject matter is not limited to pouches formed using the VFFS technology disclosed above. Rather, pouch 30 can be constructed using any of a variety of methods known in the packaging art, including (but not limited to) horizontal form/fill/seal technology.
To this end, one of ordinary skill in the art would recognize that the formation of rupturable seals 35, 36 are not limited to the VFFS methods set forth above. Rather, the presently disclosed subject matter includes embodiments wherein the pouch rupturable seals are formed using any of a wide variety of methods known in the art. For example, rupturable seals 35, 36 can be constructed using one or more of the following: incompatible materials, zone patterning, adhesive, ultrasonic welding, thermal bonding, crimping, cohesives, compression, nipping, needle punching, sewing, hydro-entangling, and the like. A combination of these methods can also be used. In general, rupturable seals 35, 36 are configured to have a lower strength than outer perimeter seal 45 and/or inner perimeter seal 50.
III.D. Upper Film 40
FIG. 4 is an illustrative view of package upper film 40. Particularly, upper film 40 comprises first and second side edges 75, 76 and top and bottom edges 80, 81. Upper film 40 can be provided in sheet or film form and can be any of the films commonly used for the disclosed type of packaging.
To this end, in some embodiments, upper film 40 can be a monolayer or multilayer structure produced by any suitable process, including coextrusion, lamination, extrusion coating, and combinations thereof. However, the films employed will typically have two or more layers to incorporate a variety of properties, such as sealability, gas impermeability and toughness, into a single film. For example, upper film 40 can comprise one or more barrier layers, abuse layers, tie layers, seal layers, and/or bulk layers, as would be known to those of ordinary skill in the art. The polymer components used to fabricate upper film 40 can also comprise appropriate amounts of other additives normally included in such compositions. For example, slip agents (such as talc), antioxidants, fillers, dyes, pigments and dyes, radiation stabilizers, antistatic agents, elastomers, and the like can be added.
Accordingly, various combinations of layers can be used in the formation of upper film 40 in accordance with the presently disclosed subject matter. The following are several non-limiting examples of combinations wherein letters are used to represent film layers: A/B, A/B/A, A/B/C, A/B/D, A/B/E, A/B/C/D, A/B/C/E, A/B/E/E′, A/B/D/E, A/B/D/C, A/B/C/B/A, A/B/C/D/A, A/B/E/B/A, A/B/C/D/E, A/B/C/E/D, A/B/D/C/D, A/B/D/C/E, A/B/D/E/C, A/B/D/E/E′, A/B/E/C/E, A/B/E/C/D, A/B/E/D/D′, A/B/E/D/E, wherein A represents a sealant layer; B represents a bulk layer or a sealant layer (depending on whether it is present as an inner or outer layer of the film); C represents a barrier layer; D and D′ represent bulk and/or abuse layers (depending on whether they are present as an inner or outer layer of the film); and E and E′ represent abuse layers. Of course, one or more tie layers (“T”) can be used between any one or more layers of in any of the above multilayer film structures.
Thus, in some embodiments, upper film 40 comprises a total of from about 2 to about 20 layers; in some embodiments, from about 4 to about 12 layers; and in some embodiments, from about 5 to about 9 layers. Thus, in some embodiments, the disclosed film can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 layers. One of ordinary skill in the art would also recognize that the disclosed film can comprise more than 20 layers, such as in embodiments wherein the film components comprise microlayering technology.
To this end, upper film 40 can have any total thickness desired, so long as it provides the desired properties for the particular packaging operation in which the film is used. Final web thicknesses can vary, depending on process, end use application, and the like. Typical thicknesses can range between about 0.1 to 20 mils; in some embodiments, between about 0.3 and 15 mils; in some embodiments, between about 0.5 to 10 mils; in some embodiments, between about 1 to 8 mils; in some embodiments, between about 3 to 6 mils, and in some embodiments, between about 4 to 5 mils.
In some embodiments, upper film 40 can be transparent (at least in the non-printed regions) so that the packaged items are visible through the films. “Transparent” as used herein means that the material transmits incident light with negligible scattering and little absorption, enabling objects (e.g., packaged food or print) to be seen clearly through the material under typical unaided viewing conditions (i.e., the expected use conditions of the material). The transparency (i.e., clarity) of the film can be at least about any of the following values: 20%, 25%, 30%, 40%, 50%, 65%, 70%, 75%, 80%, 85%, and 95%, as measured in accordance with ASTM D1746.
III.E. Food Product 25
As set forth in detail herein above, in some embodiments first compartment 15 of package 5 can comprise a food product, such as a cut of meat. Examples of food products that are suitable for use with the presently disclosed subject matter can include, but are not limited to, beef, birds such as poultry (including chicken, duck, goose, turkey, and the like), buffalo, camel, crustacean (including shellfish, clams, scallops, mussels, oysters, lobster, crayfish, crab, shrimp, prawns, and the like), dog, fish (including salmon, trout, eel, cod, herring, plaice, whiting, halibut, turbot, ling, squid, tuna, sardines, swordfish, dogfish, shark, and the like), game (including deer, eland, antelope, and the like), game birds (such as pigeon, quail, doves, and the like), goat, hare, horse, kangaroo, lamb, marine mammals (including whales and the like), amphibians (including frogs and the like), monkey, pig, rabbit, reptiles (including turtles, snakes, alligators, and the like), and/or sheep. In some embodiments, the food product can be whole, diced, minced, shaved, cut into strips, and/or formed into meatballs.
In some embodiments, meat substitutes can be used and are included under the term “meat”. Such meat substitutes can approximate the aesthetic qualities and/or chemical characteristics of certain types of meat. The meat substitutes can include, but are not limited to, seitan, rice, mushrooms, legumes, tempeh, textured vegetable protein, soy concentrate, mycoprotein-based Quorn, modified defatted peanut flour, and/or pressed tofu to make the meat substitute look and/or taste like chicken, beef, lamb, ham, sausage, seafood, and the like.
In some embodiments, the food product can comprise one or more vegetables. Vegetables that are particularly suited for use with the presently disclosed subject matter can include, but are not limited to, artichokes, asparagus, beans, bean sprouts, beets, broccoli, cauliflower, cabbage, carrots, celery, corn, collards, eggplant, green peppers, kale, leeks, mushrooms, mustard greens, onions, peas, potatoes, radishes, red peppers, rhubarb, spinach, squash, sweet potatoes, turnips, water chestnuts, watercress, yams, yellow peppers, and/or zucchini. In some embodiments, the vegetable can be diced, minced, shaved, and/or cut into strips.
Accordingly, the food product suitable for use with the presently disclosed subject matter is not particularly limited. The presently disclosed methods and package can be applied to raw (i.e., uncooked) food products, partially cooked food products, and/or pre-cooked products, where the cooking process is intended to cook, completely cook, and/or re-heat the food product. Thus, the food product selected can be any type that is suitable for consumption. The food product can be non-rendered, non-dried, raw, and can comprise mixtures of whole muscle meat formulations. Whole meat pieces can be fresh, although frozen or semi-frozen forms can also be used. Since freezing affects the tenderness of meat by rupturing intrafibrillar tissue as a result of ice crystal formation, the increased tenderness resulting from freezing can be taken into account when using such products in the package and methods described herein.
III.F. Additive 31
As set forth in detail herein above, in some embodiments, second compartment 20 of package 5 can comprise an additive, such as a marinade. The amount of additive used in the presently disclosed subject matter depends on the type and added amount of food additive. The food additive can be in any form including, but not limited to, liquid, paste, powder, and/or combinations thereof. In some embodiments, the food additive can be in the form of liquid or powder from the standpoint of handleability, preservability, and the like. If the food additive of the presently disclosed subject matter is used in liquid form, it can be in the form of solution or dispersion in water or an aqueous liquid or in the form of solution or dispersion in fatty oil.
In some embodiments, the food additive can comprise one or more enzymatic tenderizers to form a tenderized meat product. Particularly, one or more proteolytic enzymes can be added to the food additive to sever peptide bonds in proteins, and therefore tenderize the meat. Proteolytic enzymes suitable for use with the presently disclosed subject matter can include, but are not limited to, bromelain from pineapple and papain from papaya, achromopeptidase, aminopeptidase, ancrod, angiotensin converting enzyme, bromelain, calpain, calpain I, calpain II, carboxypeptidase A, carboxypeptidase B, carboxypeptidase G, carboxypeptidase P, carboxypeptidase W, carboxypeptidase Y, caspase, caspase 1, caspase 2, caspase 3, caspase 4, caspase 5, caspase 6, caspase 7, caspase 8, caspase 9, caspase 10, caspase 11, caspase 12, caspase 13, cathepsin B, cathepsin C, cathepsin D, cathepsin G, cathepsin H, cathepsin L, chymopapain, chymase, chymotrypsin a-, clostripain, collagenase, complement Clr, complement Cls, complement Factor D, complement Factor I, cucumisin, dipeptidyl peptidase IV, elastase (leukocyte), elastase (pancreatic), endoproteinase Arg-C, endoproteinase Asp-N, endoproteinase Glu-C, endoproteinase Lys-C, enterokinase, factor Xa, ficin, furin, granzyme A, granzyme B, HIV protease, IGase, kallikrein tissue, leucine aminopeptidase (general), leucine aminopeptidase (cytosol), leucine aminopeptidase (microsomal), matrix metalloprotease, methionine amiopeptidase, neutrase, papain, pepsin, plasmin, prolidase, pronase E, prostate specific antigen, protease (alkalophilic form), Streptomyces griseus, protease from Aspergillus, protease from Aspergillus saitoi, protease from Aspergillus sojae, protease (B. licheniformis) (Alkaline), protease (B. licheniformis) (Alcalase), protease from Bacillus polymyxa, protease from Bacillus sp, protease from Bacillus sp (Esperase), protease from Rhizopus sp., protease S, proteasomes, proteinase from Aspergillus oryzae, proteinase 3, proteinase A, proteinase K, protein C, pyroglutamate amiopeptidase, renin, rennin, streptokinase, subtilisin, thermolysin, thrombin, tissue plasminogen activator, trypsin, tryptase, urokinase, and combinations thereof.
In some embodiments, the food additive can comprise additional components, including but not limited to, bactericides, fungicides or other preservatives, wetting agents (e.g., a Tween), antioxidants, viscosity control agents (e.g. gums), brine (e.g., sodium chloride, phosphates, dextrose), curing agents (e.g., nitrites, sugars, erythorbate), flavoring agents (e.g., herbs, spices, and liquid smoke), and the like.

IV. Methods of Constructing Package 5

FIGS. 1 a and 1 b illustrate that package 5 can be closed on all four edges. In some embodiments, one or more of the edges can comprise sealed edges. For example, if package 5 is originally formed from two separate sheets of plastic film material, the four edges can all be sealed edges. Thus, package 5 can be formed by heat sealing upper and lower films 40, 10 to form a package containing food product 25 and pouch 30 in first and second compartments 15 and 20, respectively. Particularly, upper film 40 can be positioned to contact lower film 10 along the perimeter of the package. A vacuum can then be applied to the compartments and upper film 40 sealed around the perimeter of the compartmented lower film to form outer perimeter seal 45.
In some embodiments, the heat sealing operation can occur at the food packaging plant using a heat sealing machine designed for high speed operation. Heat sealing can occur by any of a number of techniques well known in the art, such as but not limited to, thermal conductance heat sealing, impulse sealing, ultrasonic sealing, dielectric sealing, and/or combinations thereof.
In some embodiments, the heat sealing machine includes a heated seal bar that contacts and compresses upper and lower films 40, 10 together to form outer perimeter seal 45. Generally, three variables can be considered in forming a heat seal: the seal bar temperature, the dwell time, and the sealing pressure. The seal bar temperature can refer to the surface temperature of the seal bar. The dwell time can refer to the length of time that the heated seal bar contacts the film to transfer heat from the seal bar to soften at least a portion of the films (e.g., the sealing layers of the films) so that they can be melded together. The sealing pressure can refer to the amount of force that squeezes the films together during this heat transfer. All of these variables can be modified accordingly to prepare a package suitable for use with the presently disclosed subject matter.
The resulting perimeter seal can extend continuously around the outside edge of package 5 to hermetically seal or enclose the food product and pouch therein. In this manner, upper and lower films 40, 10 can form a substantially gas impermeable enclosure to protect the pouch and food product from contact with the surrounding environment, including atmospheric oxygen, dirt, dust, moisture, liquid, microbial contaminates, and the like. In some embodiments, food product 25 and additive 31 can be packaged in a modified atmosphere package to extend the shelf life or bloom-color life. An example of such a package is disclosed in, e.g., U.S. Pat. No. 5,686,126 to Noel et al., the entire disclosure of which is hereby incorporated by reference.
Although upper and lower films 40, 10 can be heat-sealed to form outer perimeter seal 45, the use of other adhesives or mechanical closures (e.g., clips) as desired or necessary is within the scope of the presently disclosed subject matter. Particularly, adhesives can be applied in a desired pattern, or sealed at a certain temperature (such as with a layer of ionomer) to define seal strength in a directly proportional fashion; i.e., more adhesive or higher temperature can create a stronger seal, while less adhesive or lower temperature can produce a weaker seal.
FIGS. 5 a-5 e depict several embodiments of package 5 comprising inner perimeter seal 50. Particularly, as illustrated in FIGS. 5 a and 5 b, an inner perimeter seal can be formed between upper film 40 and lower film 10 in an area bordering second compartment 20 on at least one side. Thus, in some embodiments, inner perimeter seal 50 can be formed at least partially in partition 17. In some embodiments, inner perimeter seal 50 can be formed with a heat sealing machine that includes a heated seal bar that contacts and compresses upper film 40 and lower film 10 to form the seal. Although upper and lower films 40, 10 can be heat-sealed to form inner perimeter seal 50, the use of other adhesives or mechanical closures (e.g., clips) as desired or necessary is also within the scope of the presently disclosed subject matter. Particularly, adhesives can be applied in a desired pattern, or sealed at a certain temperature to define seal strength in a directly proportional fashion. In some embodiments, the inner perimeter seal can be constructed using a total seal head if the ends of pouch 30 are extended into compartment 15 and covered by product.
Outer perimeter seal 45 and inner perimeter seal 50 can be sufficiently strong to withstand the expected use conditions. For example, the bond strength of seals 45, 50 can be at least about any of the following values: 7.0, 8.0, 9.0, and 10 pounds/inch or greater. The term “heat seal bond strength” as used herein can refer to the amount of force required to separate upper and lower films 40, 10, as measured in accordance with ASTM F88-94 where the Instron tensile tester crosshead speed is 5 inches per second, using five, 1-inch wide representative samples. In some embodiments, the strength of the perimeter seals can be equal to or greater than the strength of the films themselves or can otherwise be considered permanent or hard seals.
Inner perimeter seal 50 can be configured to overlap with at least one of rupturable seals 35, 36 of pouch 30. For example, FIG. 5 a illustrates one embodiment wherein one rupturable seal of pouch 30 is positioned adjacent to second compartment 20 such that it can be contacted during the preparation of inner perimeter seal 50. In such embodiments, the upper pouch wall in the area of at least one of the rupturable seals is sealed to upper film 40 and the lower pouch wall in the area of at least one of the rupturable seals is sealed to lower film 10, as illustrated in FIG. 5 b.
As illustrated in FIG. 5 c, in some embodiments, pouch 30 can be folded over on itself at crease 51 prior to insertion into package 5. FIGS. 5 d and 5 e illustrate the pouch of FIG. 5 c positioned in second compartment 20 such that both rupturable seals 35, 36 are adjacent to the second compartment. In these embodiments, both rupturable seals of the pouch can be contacted during the construction of inner perimeter seal 50. Accordingly, two portions of the upper pouch wall (as a result of the folding of the pouch) will be sealed to the upper film and lower film.
In the embodiments depicted in FIGS. 5 a-5 e, the position of inner perimeter seal 50 creates channel 85 through which additive can ultimately travel, as set forth in more detail herein below. In these embodiments, a large volume of additive can be incorporated into pouch 30. In addition, the additive can only travel in one direction (into channel 85) and exit pouch 30 at rupturable seal 35 and/or 36.
As would be appreciated by those having ordinary skill in the art, the L-shaped inner perimeter seal depicted in FIGS. 5 a-5 e is merely one example of a configuration that can be used. It should be appreciated that the inner perimeter seal can be in any of a wide variety of configurations so long as at least a portion of the inner perimeter seal overlaps with at least one pouch rupturable seal.
To this end, in some embodiments, inner perimeter seal 50 can extend the full length across the package (i.e., no channel is created). For example, as illustrated in FIG. 6 a, in some embodiments, one rupturable seal of pouch 30 is positioned adjacent to second compartment 20 such that it can be contacted during the preparation of inner perimeter seal 50. In such embodiments, the upper pouch wall in the area of at least one of the rupturable seals is sealed to upper film 40 and the lower pouch wall in the area of at least one of the rupturable seals is sealed to lower film 10. Similarly, as illustrated in FIG. 6 b, in some embodiments, pouch 30 can be folded over on itself and positioned in second compartment 20 such that both rupturable seals 35, 36 are adjacent to the second compartment. In these embodiments, both rupturable seals of the pouch are contacted during the construction of inner perimeter seal 50. Accordingly, two portions of the upper pouch wall (as a result of the folding of the pouch) will be sealed to the upper film and lower film.
One of ordinary skill in the art would understand that instead of folding pouch 30 on itself exactly as illustrated in FIGS. 5 c and 6 b, the pouch can be folded at an angle such that both rupturable seals are separately included in inner perimeter seal 50, as illustrated in FIG. 7 a. In these embodiments, the inner perimeter seal can take any shape (such as a v-shape) so long as it follows the line of at least one of the rupturable seals. It should also be appreciated that the converse is also true. That is, in some embodiments, pouch 30 can be constructed such that the rupturable seals are at an angle. In these embodiments, when the pouch is folded, a straight line is created, as illustrated in FIGS. 7 b and 7 c. In embodiments wherein pouch 30 is folded, the pouch can be tacked at the proper folding angle using adhesive or a heat seal, as would be known to those of ordinary skill in the packaging art.
As would also be appreciated by those of ordinary skill in the art, the presently disclosed subject matter can also include embodiments wherein more than one pouch is included within second compartment 20. For example, in some embodiments, it can be desired to use than one marinade to flavor a cut of meat.
FIG. 8 illustrates one such embodiment. It should be understood that all descriptions of packages that include a single pouch herein can equally be applied to packages comprising more than one pouch.

V. Methods of Using Package 5

As set forth in detail herein above, the presently disclosed subject matter is directed to a package for marinating and/or heating a food product. Particularly, package 5 comprises a lower film that contains at least two compartments. The first compartment can substantially contain a food product and the second compartment can substantially contain a pouch. Specifically, the pouch comprises first and second rupturable seals and houses one or more additives (such as a marinade). The upper film is sealed to the lower film about the perimeter of the package through an outer perimeter seal. In addition, the package comprises at least one inner perimeter seal that cooperates with at least one of the pouch rupturable seals and functions to isolate the first and second compartments until it is desired to intermix the additive and food product.
Thus, at a desired time, a user can grip package 5 and using his thumbs or a hard object, emit pressure on second compartment 20 and thus onto pouch 30 contained substantially therein. Upon the increased pressure, at least one of pouch rupturable seals 35, 36 will fail, allowing additive 31 contained within the pouch to flow into first compartment 15 freely mix with food product 25. In embodiments wherein inner perimeter seal 50 is configured with channel 85 (such as in the embodiment depicted in FIGS. 5 a-5 d), additive will flow from pouch 30 and follow channel 85 to first compartment 15 to contact food product 15. In embodiments wherein the inner perimeter seal is configured without channel 85 (such as those embodiments illustrated in FIGS. 6 a and 6 b), additive will flow directly from pouch 30 to first compartment 15 and contact food product 25.
Outer perimeter seal 45 is configured to be strong enough to minimize the likelihood that it will rupture or otherwise leak during the intermixing process. As a result, additive 31 and food product 25 are contained within package 5 even when the pressure is applied from the user. In some embodiments, to facilitate mixing, the user can shake or rotate package 5 to fully mix the food product and the additive.
Package 5 can then be marinated for a desired amount of time. In some embodiments, the package can be incubated for a sufficient time to allow food product 25 to tenderize to a desired amount. Thus, in some embodiments, the presently disclosed subject matter is directed to a method of controlling the level of additive imparted to a food product.

VI. Advantages of Package 5

In addition to the advantages that would be evident to one skilled in the art, the use of a pouch to contain additive 31 can have one or more advantages. For example, loading the food additive into pouch 30 prior to insertion into second compartment 20 can minimize the likelihood of premature cross-contamination between additive 31 and food product 25.
Moreover, prior art methods for loading an additive and a food product directly into package compartments at the same time can require that the food additive be frozen to allow the machinery to advance rapidly as well as to prevent flashing of a liquid as the vacuum is applied to the food product. Such freezing can prove costly and require time and the maintenance of an environment below 0° F. In addition, the thawing of the food additive after the packaging operations can create condensation on the surface of the package, resulting in aesthetic and functional issues. In the presently disclosed subject matter, the additive can be handled as a liquid, thereby allowing for more options for handling.
In addition, the use of a pouch to house the food additive allows for the lower film to be specifically configured to hold the food product and the pouch to be specifically configured to hold the additive. For example, in some embodiments, the materials of the lower film can be “breathable” which can be preferred for food products such as fish or chicken. Similarly, the materials of the pouch can include barrier layers that can be preferred for the additive.
In some embodiments, the pouch can be labeled or printed individually and then placed in a first package so a customer can change from one type to another type of additive without changing the top web of film used for the package, even if it is printed for a particular food product.
The use of a pouch also allows for the seals to be specifically configured for particular functions. For example and as discussed above, the outer perimeter seal of package 5 is a hard seal that reduces the likelihood of the package rupturing or otherwise leaking, even as the user applies pressure or shakes the package to mix the additive and food product. The rupturable seal of the pouch, however, is specifically configured to rupture and allow the additive and the food product to mix.
Continuing, as set forth herein above, package 5 comprises inner perimeter seal 50 that separates the components of the first and second compartments prior to intermixing. As a result, any purge seepage generated from food product 25 is confined to first compartment 15 and is prevented from flowing into the second compartment housing pouch 30. Thus, package 5 maintains an appealing look to customers and cross-contamination between the two package compartments is prevented.
In addition, the tooling required to construct package 5 can be fitted relatively inexpensively into existing horizontal form, fill, and seal machines. Particularly, forms that fit into existing forming and sealing boxes and trays can be simply constructed by those having ordinary skill in the art. Thus, package 5 requires less cost for tooling and less time to change the tooling sizes compared to other packages known in the art.
In embodiments wherein pouch 30 is folded prior to insertion into second compartment 20, a larger volume of marinade can be inserted into the pouch. In addition, shipping and handling between the marinade packager and the final package manufacturer is improved. Particularly, the rupturable seals in the flat marinade pouches are less susceptible to hydraulic forces created during shipping and/or handling.
Many modifications and other embodiments of package and methods set forth herein can be included within the scope of the presently disclosed subject matter. Therefore, it is to be understood that the disclosed subject matter is not to be limited to the specific embodiments and drawings disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A package for marinating a food product, said package comprising:

a. a lower film comprising at least first and second compartments separated by a partition, such that said first compartment is adapted to substantially contain a food product and said second compartment is adapted to substantially contain a pouch;

b. a pouch substantially contained within said second compartment and configured to contain a food additive, the pouch comprising at least one rupturable seal configured to rupture when exposed to a predetermined pressure, and wherein said at least one rupturable seal is positioned at least partially overlapping said partition;

c. an upper film peripherally sealed about the perimeter of the package to said lower film and to at least a portion of said partition of said lower film in the area overlapping said at least one rupturable seal to separate said first and second compartments, thereby forming a hermetically sealed package having an outer perimeter seal and an inner perimeter seal;

wherein said pouch is in fluid communication with the first compartment upon rupture of the at least one rupturable seal to allow the food additive to mix with the food product, and

wherein said at least one rupturable seal has a lower rupture pressure compared to said outer perimeter seal and said inner perimeter seal, and wherein said food item can be marinated directly in said package.

2. The package of claim 1, wherein said lower film is a thermoformed film formed into a compartmented support member having first and second compartments.

3. The package of claim 1, wherein said pouch is formed using a vertical form, fill, and seal machine.

4. The package of claim 3, wherein said pouch is constructed from a film comprising an innermost layer comprising an easy open sealant and an outermost layer comprising a regular sealant.

5. The package of claim 3, wherein said pouch is constructed from a film comprising an easy open sealant layer positioned adjacent to the innermost layer and an outermost layer comprising a regular sealant.

6. The package of claim 1, wherein said pouch is folded prior to insertion into said first compartment.

7. The package of claim 1, wherein said additive occupies from about 20% to about 80% of the total volume of the pouch.

8. The package of claim 1, wherein said inner perimeter seal forms a channel.

9. The package of claim 8, wherein said channel optionally has depth added during the forming process.

10. A package comprising:

a. a food product;

b. a pouch comprising a food additive, wherein said pouch comprises at least one rupturable seal configured to rupture when exposed to a predetermined pressure;

c. a lower film comprising at least first and second compartments separated by a partition, such that said first compartment is adapted to substantially contain said food product and said second compartment is adapted to substantially contain said pouch, and wherein said at least one rupturable seal is positioned at least partially overlapping said partition;

d. an upper film peripherally sealed about the perimeter of the package to said lower film and at least partially to said partition of said lower film in the area overlapping said at least one rupturable seal to separate said first and second compartments, thereby forming a hermetically sealed package having an outer perimeter seal and an inner perimeter seal;

wherein said pouch is in fluid communication with the first compartment upon rupturable of the at least one rupturable seal to allow the food additive to mix with the food product; and

11. The package of claim 10, wherein said lower film is a thermoformed film formed into a compartmented support member having first and second compartments.

12. The package of claim 10, wherein said pouch is formed using a vertical form, fill, and seal machine.

13. The package of claim 12, wherein said pouch is constructed from a film comprising an innermost layer comprising an easy open sealant and an outermost layer comprising a regular sealant.

14. The package of claim 12, wherein said pouch is constructed from a film comprising an easy open sealant layer positioned adjacent to the innermost layer and an outermost layer comprising a regular sealant.

15. The package of claim 10, wherein said pouch is folded prior to insertion into said first compartment.

16. The package of claim 10, wherein said additive occupies from about 20% to about 80% of the total volume of the pouch.

17. The package of claim 10, wherein said inner perimeter seal forms a channel.

18. A method of controlling a level of food additive imparted to a food product, said method comprising:

a. forming a support member of a package that includes a first compartment configured to substantially contain a food product and a second compartment configured to substantially contain a pouch, wherein the first and second compartments are separated by a partition;

b. forming said pouch configured to contain said food additive;

c. loading said food additive into said pouch;

d. sealing said food additive in said pouch with at least one rupturable seal configured to rupture and allow the food additive to escape said pouch;

e. loading said food product into said first compartment of the support member;

f. loading said pouch into the second compartment of said support member such that said at least one rupturable seal is positioned at least partially overlapping said partition, and such that the pouch is in fluid communication with the first compartment upon rupturing of the rupturable seal to allow the food additive to mix with the food product; and

g. sealing the support member with a film about the perimeter of the package with an outer perimeter seal and at least partially to said partition in the area overlapping said at least one rupturable seal with an inner perimeter seal to separate said first and second compartments, such that the first package is configured to withstand the predetermined pressure and prevent leaking of the food additive and food product from the first package during the mixing of the food additive and the food product.

19. The method of claim 18, wherein said lower film is a thermoformed film formed into a compartmented support member having first and second compartments.

20. The method of claim 18, wherein said pouch is constructed using a vertical form, fill, and seal machine.

21. The method of claim 20, wherein said pouch is constructed from a film comprising an innermost layer comprising an easy open sealant and an outermost layer comprising a regular sealant.

22. The method of claim 18, wherein said pouch is folded prior to insertion into said first compartment.

23. The method of claim 18, wherein said inner perimeter seal forms a channel.