US3094420A - Novel table spread package and process of preparing same - Google Patents

Novel table spread package and process of preparing same Download PDF

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US3094420A
US3094420A US70609A US7060960A US3094420A US 3094420 A US3094420 A US 3094420A US 70609 A US70609 A US 70609A US 7060960 A US7060960 A US 7060960A US 3094420 A US3094420 A US 3094420A
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heat
prints
wrapper
coating
foil
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US70609A
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Edmund L Josefowicz
Melnick Daniel
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Unilever Bestfoods North America
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Unilever Bestfoods North America
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    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01JMANUFACTURE OF DAIRY PRODUCTS
    • A01J21/00Machines for forming slabs of butter, or the like
    • A01J21/02Machines for forming slabs of butter, or the like with extruding arrangements and cutting devices, with or without packing devices

Definitions

  • This invention relates :to a novel wrapper for table spreads such as yellow margarine and butter and to processes for producing the same. More particularly this invention relates to a novel foil laminated paper wrapper for table spreads such as yellow margarine and butter and to processes for producing the same.
  • one-quarter pound prints are usually packaged by packaging machinery in an aluminum foilpaper laminated wrapper.
  • the wrapped prints are then automatically overwrapped in cartons and then placed in cases which are glue-sealed.
  • the finished cases are shipped in refrigerated carriers to distribution points.
  • the product undergoes various types of storage such as warehouse or super market cold rooms, refrigerated display cases and household refrigerators. All of these vary in temperature and humidity. Storage at relatively low humidity has deleteriou effects on products such as butter and yellow margarine since storage for even a short time under these conditions, causes certain areas of the prints to exhibit surface darkening.
  • Much margarine in print form is also stored at room temperature and here humidity of the atmosphere is also variable. At room temperature storage, localized surface darkening may be greater or less than that noted with prints stored in the refrigerator. Thus when the print is unwrapped by the consumer, the appearance due to the areas of increased color intensity is unattractive and objectionable and gives the product an old appearance. Although the objectionable appear ance does not in any way affect the flavor or nutritional value of the product, appetite appeal is lost and consequently the consumer changes brands in the hope of obtaining What appears to him to be a fresher product, with consequent loss of prestige and sales to the manufacturer.
  • the areas of increased color intensity in the case of yellow margarine are generally found on the longitudinal surface beneath and adjacent to the final overlap of the Wrapper and at the ends beneath the end folds (tucks) of the wrapper.
  • the longitudinal discoloration varies from a thin line to a hand up to A2 in width.
  • Margarine and butter manufacturers are most sensitive to the longitudinal discoloration since it is most frequently and most readily detected by the consumer because on stripping the wrapper from the print, the area under the longitu- -inal overlap is the first area of the print seen by the consumer.
  • the discoloration assumes the shape of the tucks viz, triangles.
  • Prints of table spreads such as margarine are usually wrapped in rectangular aluminum-paper laminated sheets.
  • the total thickness of each sheet is about 0.002 inch; the foil thickness averages about 0.0003 inch.
  • a coating of lacquer is sometimes applied to the foil surface.
  • the paper layer which is in contact with the product is laminated to the foil.
  • the foil wrapper is supplied :to the wrapper machine in roll form and the desired lengths are out just prior to the wrapping operation. Due to the inherent stiffness of the wrapper, the folds do not remain in positive contact with each other.
  • the overlapping outer portions of the wrappers lift away from the prints causing exposure to external air of the products, beneath and adjacent to these overlaps. Dehydration and increased color subsequently develop in these areas.
  • the packaging of the Wrapped margarines in cartons, with flaps tucked in, with flaps sealed, or with a paper or foil overwrap does not prevent the localized surface darkening of prints packaged in a foil inner-wrap.
  • the surface dehydration is of a generalized nature and not restricted to specific areas of the table spread.
  • foil laminated paper wrapper for conventional table spreads such as margarine and butter, said Wrapper being coated on at least a portion of one side with a heat-scalable coating of about 0.0000 15 inch to about 0.0015 inch in thickness With an edible grade sealing material having a melting point in the range of -180 F., said coated portion of said wrapper adapted to contact overlapping areas of the Wrapper. Thus a heat-seal bond is made between two dissimilar surfaces of the wrapper by means of the coating that was applied.
  • the coating materials which we have found suitable for use in our process include food grade materials such as paraffin wax having a melting point of about 133 F., soft polyethylene having about 300 500 ethylene units per molecule and having a melting point of about 125 F., vinyl chloride acetate having a melting point of about 160 F., mixtures of these substances such as a 40% wax, 60% polyethylene mixture which heat seals at under 200 F.
  • food grade materials such as paraffin wax having a melting point of about 133 F., soft polyethylene having about 300 500 ethylene units per molecule and having a melting point of about 125 F., vinyl chloride acetate having a melting point of about 160 F.
  • mixtures of these substances such as a 40% wax, 60% polyethylene mixture which heat seals at under 200 F.
  • the coating materials which are suitable for use in the process may have a melting point in the range of about 1l5180 F. as indicated above, we prefer to use those materials that have melting points in the range of about 120165' F. This is due to the facts that (a) since the coating is to be heat-sealed, the melting point differential between the sealing material and the table spread should be as low as possible in order to avoid as much heat abuse of the product as possible and (b) the melting point of the heat-scalable coating should be high enough to preclude blocking of the wrapper in roll form.
  • the table spreads, margarine and butter have an average melting point of about 95 (range of 92 F. to 100 F).
  • the coating material will be applied to the foil laminated paper wrapper in a coating of about 0.000015 inch (0.015 mil) to about 0.00 inch (1.5 mil) in thickness, we find that the best results are obtained when the coating is maintained in the range of about 0.00005 inch (0.05 mil) to about 0.0085 inch (0.5 mil).
  • the thickness of the coating is of course dependent upon the particular coating material employed and upon the temperature required to heat seal the coating but the coating should be sufficiently small so that the transparency and sheen of the foil surface will not be adversely affected.
  • the coating may be applied to the outer foil surface of the wrapper, to the inner paper surface, or to both surfaces of the wrapper.
  • the heat-scalable materials should have the following characteristics. They should have a specific melting point, i.e. in the order of 1 15180 F. but must also be quick setting.
  • the coating should be non-blocking; that is little or no adhesion between dissimilar surfaces of the wrapper in roll form, as it is supplied to the packaging machine.
  • the coating material must be of a food grade and must be odorless and tasteless.
  • the heat-seal must be sufficiently fragile to permit the wrapper around the print to peel apart without tearing the paper fibers, and the wrapper must be dry to the touch and not tacky when handled.
  • the coating must be nonflammable during the heat-sealing operation which takes place at about 135 200 F. and which will be described in greater detail hereinafter.
  • the heat-scalable food grade coating may be applied to the foil laminated paper by any suitable means, such as by passing the wrapper through a well containing the melted coating or a solution 'of the coating in a volatile solvent, or by spraying or painting the foil laminated paper with the material in the melted state or in solution, with subsequent volatilization of the solvent.
  • the heatsealable coating may be applied to either the foil side or the paper side of the wrapping material or to both surfaces. We prefer to coat the foil surface when the coating has no nutritive value, because upon Wrapping the table spread, the food does not some in contact with this coating at any point. If the laminated paper wrapper is coated on the paper side, we prefer to employ the edible hydrogenated fats as the sealing material because these fats are related to the fat components in the table spreads being wra ped.
  • the table spread is processed by conventional means and is formed into prints using conventional packaging equipment which wraps the prints in the coated foil laminated paper.
  • the sides of the prints bearing the overlaps, that is the longitudinal overlap and the end folds, are then gently pressed against the surface of a heating means, such as the heated pusher bar of a margarine wrapping machine for a small period of time, preferably for about 0.1 second to about 3.0 seconds.
  • the temperature of the heating means may vary from about P.-200 F.
  • the time must be carefully controlled so that the table spread which melts at least about 20 below the melting point of the sealing material, is not adversely aflected. Heat abuse of the product results in immediate and objectionable surface discoloration clue to melting of the fat component of the table spread.
  • the heating element such as the pusher bar
  • the period for heat-sealing at this area may be from about 0.1 second to about 1.0 second.
  • the end tuck (flaps) on the print are sealed by heating elements located at the guide rails which keep the prints travelling in a horizontal plane.
  • the period of heating is usuaily from about 0.3 to about 3 seconds.
  • the coating immediately seals the wrapped table spread prints without adversely affecting the product. Since the extensive discoloration under the longitudinal overlap is by far the more serious offender in causing consumer dissatisfaction with the table spread, sealing the wrapper only at the lo ngitudinal overlap contributes substantially to improvement in the appearance of the stored table spread.
  • the less preferred wrapped products of the present invention are those where the heat-sealing is made only at the longitudinal overlap.
  • the preferred wrapped products are those where all the overlaps are heat-sealed.
  • FIG. 1 is a perspective view of a margarine print wrapped in a conventional foil laminated paper wrapper.
  • PEG. 2 shows 'a perspective side view of a margarine print wrapped in inated aluminum wrapper causes the wrapper to lift away from the innerfold and end tucks spring apart thereby" exposing the print to air and allowing moisture lossi
  • FIG. 3 a margarine print wrapped in the heat-scalable foil laminated paper. of this invention is seen.
  • the foil wrapper has a paper underside 3, joined by laminant 4 to an aluminum foil 5, upon which may be printed advertising material with or without a protective lacquer layer.
  • the heat-scalable coating 6 is applied preferably as the outer coating, although it may be applied to the paper underside or to both sides of the wrapper.
  • a heating means '7 is applied to the areas of wrapper overlap, the longitudinal side fold and the end tucks. During the heat-sealing operation, the heat passes from the outer foil through the paper laminate layer onto the overlapped part of the inner foil surface and is then reflected back, thereby allowing heat to be dissipated in the coating without damage to the product.
  • FIG. 2 shows the margarine print 8 of this invention satisfactorily sealed at the areas of overlap 9 and 10.
  • Example 1 Rolls of conventional aluminum foil laminated paper wrappers received from the manufacturer were unrolled and placed on a table with the aluminum side up. Paraflin wax commonly used in the preparation of preserved foods by the housewife and having a melting point of 133 -134 F. was placed in a container of a paint spray gun and melted. The molten wax was then sprayed uniformly on the surface of the aluminum foil to provide about 0.0001 inch in thickness. The appearance of the foil remained unchanged. The foil was then cut into lengths used to package one-quarter pound prints of margarine. Prints of a conventional margarine at 50-55 F. and just ofi the packaging line were then wrapped in the sheets.
  • the sides of the prints bearing the folds were then gently pressed against the surface of a hot plate for about 0.25 second for the longitudinal seal and for about 0.75 second for heat-sealing each end.
  • the surface temperature of the hot plate was varied between 150-175 F. and averaged about 160 F.
  • Each fold Was thus heat-sealed one to the other due to the paraffin film.
  • the wrapped prints were then placed in cartons and cases by conventional packaging machinery and stored at 45 50 F. and about 45% relative humidity in simulation of storage conditions generally regarded as good by the trade.
  • the print surfaces of the margarine in the heat-sealed aluminum wrappers were uniform in light yellow color. There was no evidence of surface darkening at the longitudinal overlap or at the end folds. The prints were attractive and fresh in appearance.
  • the print surfaces beneath the longitudinal overlap and at the end folds of the margarine wrapped in conventional alumuinum foil wrappers bore distinct dark yellow lines and bands of increased color intensity. The lines varied in width when different prints were examined. All were unattractive in appearance and suggested that the prints were old, although satisfactory in flavor.
  • the heat sealed wrappers were easily peeled apart and were as readily removed from the prints as the Wrappers that were not heat-sealed.
  • Example 2 Rolls of foil wrappers bearing a parafiin wax coating on the foil surface of 4 pounds per ream (about 0.0003 inch in thickness) were used to machine-wrap prints of margarine at 5055 F. and just cast molded.
  • the paraffin coating had a melting point of 148 157 F.
  • the wrapped prints were then heat-sealed using a heating element with a flat surface and surface temperature of about 160-165 F. and a contact time of about 0.5 second for the longituudinal overlap and about 1.0 second for each end.
  • the prints were then cartoned and cased :by machine and stored at 45-50 F. and about 45% relative humidity with cases of margarines wrapped in non-heat-sealed foil wraps made on the same day and on the same packaging machine.
  • the same set of margarines were also stored at room temperature (75 F.) and at about 50 relative humidity.
  • Example 3 Rolls of conventional aluminum foil laminated paper wrappers as received from the manufacturer were unrolled and placed on a table with the paper side up. Edible hydrogenated cottonseed fat having a melting point of 139-140 F. was placed in a container of a paint spray gun and melted. The molten fat was then sprayed uniformly on the surface of the paper to a thickness of about 0.0005 inch. The foil-paper laminate was then cut into the lengths used to package one-quarter pound prints of margarine. Prints of a conventional margarine at 50- 55 F. and just off the packaging line were then wrapped in the sheets.
  • the sides of the prints bearing the folds were then gently pressed by the fiat surface of a heating element at about F. surface temperature for a period of about 0.5 second and about 1.0 second for the respec tive seals. Each fold was thus heat-sealed one to the other due to the melting and resetting of the fat film.
  • the Wrapped prints were then placed in cartons and cases by conventional packaging machinery and stored at 45-50 F. and at about 45% relative humidity.
  • the print surfaces of the margarine wrapped with the heat-sealed aluminum wrappers were uniform in light yellow color. There was no evidence of surface darkening at the longitudinal overlap or at the end. folds. The prints were attractive and fresh in appearance.
  • the print surfaces beneath the longitudinal overlap and the end folds of margarine wrapped in conventional aluminum foil wrappers bore distinct dark yellow lines and bands of increased color intensity. The lines varied in width when different prints were examined. All were unattractive in appearance and suggested that the prints were old.
  • the heat-sealed wrappers were as readily removed from the prints as the wrappers that were not heat-sealed.
  • Example 4 Rolls of foil wrappers bearing a paraffin wax coating on the paper surface of 1 pound per ream (about 0.000075 inch in thickness) were used to machine-wrap prints of margarine at 5055 F. and just east molded.
  • the paraffin coating had a melting point of 148157 F.
  • the wrapped prints were then heat-sealed using a heating element with a fiat surface and surface temperature of about F. and a contact time of about 0.125 second for the longitudinal overlap and about 0.33 second for the end tucks.
  • the prints were then cartoned and cased by machine and stored at 45 -50 F. and about 45% relative humidity with cases of margarine wrapped in non-heat-sealed foil wraps made on the same day and on the same packaging machine.
  • Example Four rolls bearing a heat-scalable polyamide coating (melting point of 190 F.) were employed in a different series of .tests.
  • the coating had been applied in two thicknesses (1 lb. and 2 lb. per ream or 0.000075 inch and 0.00015 inch in thickness) to two types of foil surfaces (embossed and unembossed).
  • the .rolls were used to -machine-wrap prints of a conventional margarine.
  • the Wrapped prints were then heat-sealed. A higher surface temperature was required (215225 F.) and longer contact times (0.75 second and 1.5 seconds) were required than with the acceptable heat-scalable coatings of the present invention.
  • the wrapped products of our invention not only fail to show on storage the objectionable areas of high color intensity so commonly associated with products wrapped in prior art aluminum foils, but also cannot be detected by the consumer as being differently processed; the coatings on the wrappers escape visual detection, and, in readily peeling apart the wrapper without mutilation of the package, the consumer is unaware that the wrapper has been heatsealed. As an extra bonus, the heat-sealed prints are less likely to oil stain cartons when the table spread is stored at roomtemperatures.
  • a table spread selected from the group consisting of margarine and butters in the form of a print, heat sealed in a foil laminated paper wrapper, wherein the inner paper layer faces said table spread and is in intimate contact with substantially the entire surface of the print and wherein a portion of the inner paper layer overlaps a portion of the outer foil thereof, and a sealant coating at least between the said portions, said coating being an edible food grade heat-scalable material selected from the group consisting of waxes, hydrogenated fats, polyethylene having about 300500 ethylene units per molecule, vinyl chloride acetate and mixtures of these substances, said material having a melting point in the range of 180 F., and said portions being heat sealed and bonded together by said coating whereby the wrapper is sealed about the print.
  • a process for heat sealing a heat sensitive table spread selected from the group consisting of yellow margarines and butters which comprises forming a print of the spread, wrapping said print in a foil laminated-paper wrapper so that the inner paper layer of the wrapper lies in intimate surface contact with substantially the entire surface of the print which is completely enveloped there by and 'a portion of the inner paper layer then overlaps a portion of the outer foil of the wrapper, applying a sealant coating at least between said lapped portions of said wrapper, said coating having a melting point at least 20 F.
  • said table spread being an edible food grade material selected from the group consisting of waxes, hydrogenated fats, polyethylene having about 300-500 ethylene units per molecule, vinyl chloride acetate and mixtures of those substances, said coating having a thickness of about 0.000015 inch to about 0.0015 inch in thickness, and then applying heat at a temperature of about -200" F. for a period of time of about 0.1 to 3.0 seconds to said lapped portions of the wrapper and the coating between them to effect a heat sealed bond by the coating of said lapped portions of said wrapper whereby the latter forms a sealed container for the print.
  • an edible food grade material selected from the group consisting of waxes, hydrogenated fats, polyethylene having about 300-500 ethylene units per molecule, vinyl chloride acetate and mixtures of those substances, said coating having a thickness of about 0.000015 inch to about 0.0015 inch in thickness, and then applying heat at a temperature of about -200" F. for a period of time of about 0.1 to 3.0 seconds to said
  • a process for heat sealing a heat sensitive table spread selected from the group consisting of margarines and butters which comprises forming a print of the spread, wrapping said print in a foil laminated-paper wrapper so that the inner paper layer of the wrapper lies in intimate surface contact with substantially the entire surface of the print which is completely enveloped thereby, and a portion of the inner paper layer then overlaps a portion of the outer foil of the wrapper, applying a sealant coating at least between said lapped portions of said wrapper, said coating having a melting point at least 20 F.

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  • Life Sciences & Earth Sciences (AREA)
  • Animal Husbandry (AREA)
  • Environmental Sciences (AREA)
  • Packging For Living Organisms, Food Or Medicinal Products That Are Sensitive To Environmental Conditiond (AREA)
  • Wrappers (AREA)

Description

June 18, 1963 E. JOSEFOWICZ ETAL 3, ,420
NOVEL TABLE SPREAD PACKAGE AND PROCESS OF PREPARING SAME Filed NOV- 21, 1960 Hil INVENTORS EDMUND L. dasc-Fowzcz BY DAN/6L MELN/CK 3 094,420 NOVEL TABLE SPREA D PAQKAGE AND PlRtECESS F PREPARING SAME Edmund L. .l'osefowicz, Bayonne, and Daniel Melnick, Teaneclr, Ni, assignors to Corn lroducts (Icmpany, New York, NRC, a corporation of Belaware Filed Nov. 21, 1960, Ser. No. 70,609 3 Claims. (Cl. 99-179) This invention relates :to a novel wrapper for table spreads such as yellow margarine and butter and to processes for producing the same. More particularly this invention relates to a novel foil laminated paper wrapper for table spreads such as yellow margarine and butter and to processes for producing the same.
In the manufacture of conventional table spreads such as yellow margarine, one-quarter pound prints are usually packaged by packaging machinery in an aluminum foilpaper laminated wrapper. The wrapped prints are then automatically overwrapped in cartons and then placed in cases which are glue-sealed. The finished cases are shipped in refrigerated carriers to distribution points. During the time between manufacture and final use by the consumer, which may be several months, the product undergoes various types of storage such as warehouse or super market cold rooms, refrigerated display cases and household refrigerators. All of these vary in temperature and humidity. Storage at relatively low humidity has deleteriou effects on products such as butter and yellow margarine since storage for even a short time under these conditions, causes certain areas of the prints to exhibit surface darkening. Much margarine in print form is also stored at room temperature and here humidity of the atmosphere is also variable. At room temperature storage, localized surface darkening may be greater or less than that noted with prints stored in the refrigerator. Thus when the print is unwrapped by the consumer, the appearance due to the areas of increased color intensity is unattractive and objectionable and gives the product an old appearance. Although the objectionable appear ance does not in any way affect the flavor or nutritional value of the product, appetite appeal is lost and consequently the consumer changes brands in the hope of obtaining What appears to him to be a fresher product, with consequent loss of prestige and sales to the manufacturer.
The areas of increased color intensity in the case of yellow margarine are generally found on the longitudinal surface beneath and adjacent to the final overlap of the Wrapper and at the ends beneath the end folds (tucks) of the wrapper. The longitudinal discoloration varies from a thin line to a hand up to A2 in width. Margarine and butter manufacturers are most sensitive to the longitudinal discoloration since it is most frequently and most readily detected by the consumer because on stripping the wrapper from the print, the area under the longitu- -inal overlap is the first area of the print seen by the consumer. At the end folds, the discoloration assumes the shape of the tucks viz, triangles.
It is therefore an object of this invention to prevent surface darkening of yellow margarine and butter wrapped in foil laminated paper wrappers. It is a further object of this invention to increase the shelf-life of margarine and butter despite variations in storage conditions prior to use by the consumer. A still further object of this invention is the prevention of oil leakage through the folds of the wrapper with subsequent staining of the carton under adverse storage conditions. A still further object of this invention is to provide a process for producing novel table spread wrappers which will overcome the problems discussed above. These and other objects 3,094,420 Patented June 18, 1963 "ice of the invention will become apparent from the following detailed description.
We have discovered that the localized surface darkening is due to moisture loss from the table spread prints only at the areas of wrapper overlap. These products contain from 14.5 to 19.5% moisture. The surface of the product, however, dehydnates only at specific areas since the foil laminated paper wrapper does not provide a hermetic seal around the print and this conditions of moisture loss results in the formation of dark yellow lines or hands on the surface of the product. When the moisture in the product leaves the surface, a more concentrated oil phase remains which is darker in color than the original light yellow color of the product. It is this dark color that gives the product its old appearance and which is responsible for objections by the consumer.
Prints of table spreads such as margarine are usually wrapped in rectangular aluminum-paper laminated sheets. The total thickness of each sheet is about 0.002 inch; the foil thickness averages about 0.0003 inch. To protect the ink of the printed matter, a coating of lacquer is sometimes applied to the foil surface. The paper layer which is in contact with the product is laminated to the foil. The foil wrapper is supplied :to the wrapper machine in roll form and the desired lengths are out just prior to the wrapping operation. Due to the inherent stiffness of the wrapper, the folds do not remain in positive contact with each other. The overlapping outer portions of the wrappers lift away from the prints causing exposure to external air of the products, beneath and adjacent to these overlaps. Dehydration and increased color subsequently develop in these areas.
Our discovery that the surface discoloration of the prints is due to moisture loss is indeed remarkable in View of the fact that parchment-Wrapped prints decrease in weight from 1.0 to 2.0% because of moisture loss after two weeks at F. in contrast to 0.25% in the case of foil Wrapped prints; and yet, surface darkening is far more apparent in the foil Wrapped prints. Likewise in the refrigerator with weight losses due to dehydration of 0.3 for the parchment-wrapped prints and with negligible weight loss for the foil Wrapped prints, only the foil Wrapped prints show areas of high color intensity. Furthermore, the packaging of the Wrapped margarines in cartons, with flaps tucked in, with flaps sealed, or with a paper or foil overwrap, does not prevent the localized surface darkening of prints packaged in a foil inner-wrap. In the case of parchment-Wrapped prints, exhibiting greater Weight loss due to surface dehydration but less obvious surface discoloration, the surface dehydration is of a generalized nature and not restricted to specific areas of the table spread. The discovery that the objectionable surface discoloration, noted above with foil-wrapped prints, is due to localized surface dehydration was made only after it Was observed that the areas of surface darkening fail to appear in foil-Wrapped prints of margarine stored at either refrigeration or room temperature but now in an atmosphere of high relative humidity, viz about According to this invention, we provide a foil laminated paper wrapper for conventional table spreads such as margarine and butter, said Wrapper being coated on at least a portion of one side with a heat-scalable coating of about 0.0000 15 inch to about 0.0015 inch in thickness With an edible grade sealing material having a melting point in the range of -180 F., said coated portion of said wrapper adapted to contact overlapping areas of the Wrapper. Thus a heat-seal bond is made between two dissimilar surfaces of the wrapper by means of the coating that was applied.
The coating materials which we have found suitable for use in our process include food grade materials such as paraffin wax having a melting point of about 133 F., soft polyethylene having about 300 500 ethylene units per molecule and having a melting point of about 125 F., vinyl chloride acetate having a melting point of about 160 F., mixtures of these substances such as a 40% wax, 60% polyethylene mixture which heat seals at under 200 F. and hydrogenated vegetable oils which are substantially saturated such as cottonseed oil having a melting point of about 135440 F., soybean oil having a melting point of about l55-160 F., and corn oil having a melting point of about 155l60 F.; partially hydrogenated vegetable oils may also be used such as hydrogenated peanut oil of 46 iodinevalue and having a melting point of about 118 F. Additives such as anti-oxidants, plasticizers, etc, may be added to the above mentioned coating materials to impart greater stability or utility to these materials when applied to wrappers, provided they do not interfere with the heat-sealing operation or are not organoleptically undesirable.
While the coating materials which are suitable for use in the process may have a melting point in the range of about 1l5180 F. as indicated above, we prefer to use those materials that have melting points in the range of about 120165' F. This is due to the facts that (a) since the coating is to be heat-sealed, the melting point differential between the sealing material and the table spread should be as low as possible in order to avoid as much heat abuse of the product as possible and (b) the melting point of the heat-scalable coating should be high enough to preclude blocking of the wrapper in roll form. The table spreads, margarine and butter, have an average melting point of about 95 (range of 92 F. to 100 F). The fact that a wrapper for a product of such low melting point may be heat-sealed by melting the sealant on the wrapper at a temperature of 20 to 85 F. above the melting point of the fat in the table spread without heat damaging the table spread in juxtaposition is the major discovery in the course of our investigations.
While generally the coating material will be applied to the foil laminated paper wrapper in a coating of about 0.000015 inch (0.015 mil) to about 0.00 inch (1.5 mil) in thickness, we find that the best results are obtained when the coating is maintained in the range of about 0.00005 inch (0.05 mil) to about 0.0085 inch (0.5 mil). The thickness of the coating is of course dependent upon the particular coating material employed and upon the temperature required to heat seal the coating but the coating should be sufficiently small so that the transparency and sheen of the foil surface will not be adversely affected. The coating may be applied to the outer foil surface of the wrapper, to the inner paper surface, or to both surfaces of the wrapper.
The heat-scalable materials should have the following characteristics. They should have a specific melting point, i.e. in the order of 1 15180 F. but must also be quick setting. The coating should be non-blocking; that is little or no adhesion between dissimilar surfaces of the wrapper in roll form, as it is supplied to the packaging machine. The coating material must be of a food grade and must be odorless and tasteless. Furthermore, the heat-seal must be sufficiently fragile to permit the wrapper around the print to peel apart without tearing the paper fibers, and the wrapper must be dry to the touch and not tacky when handled. Finally the coating must be nonflammable during the heat-sealing operation which takes place at about 135 200 F. and which will be described in greater detail hereinafter.
The heat-scalable food grade coating may be applied to the foil laminated paper by any suitable means, such as by passing the wrapper through a well containing the melted coating or a solution 'of the coating in a volatile solvent, or by spraying or painting the foil laminated paper with the material in the melted state or in solution, with subsequent volatilization of the solvent. The heatsealable coating may be applied to either the foil side or the paper side of the wrapping material or to both surfaces. We prefer to coat the foil surface when the coating has no nutritive value, because upon Wrapping the table spread, the food does not some in contact with this coating at any point. If the laminated paper wrapper is coated on the paper side, we prefer to employ the edible hydrogenated fats as the sealing material because these fats are related to the fat components in the table spreads being wra ped.
The table spread is processed by conventional means and is formed into prints using conventional packaging equipment which wraps the prints in the coated foil laminated paper. The sides of the prints bearing the overlaps, that is the longitudinal overlap and the end folds, are then gently pressed against the surface of a heating means, such as the heated pusher bar of a margarine wrapping machine for a small period of time, preferably for about 0.1 second to about 3.0 seconds. The temperature of the heating means may vary from about P.-200 F. The time must be carefully controlled so that the table spread which melts at least about 20 below the melting point of the sealing material, is not adversely aflected. Heat abuse of the product results in immediate and objectionable surface discoloration clue to melting of the fat component of the table spread.
During the sealing operation, the heating element, such as the pusher bar, only comes in contact with the longitudinal overlap and so the period for heat-sealing at this area may be from about 0.1 second to about 1.0 second. The end tuck (flaps) on the print are sealed by heating elements located at the guide rails which keep the prints travelling in a horizontal plane. Here, the period of heating is usuaily from about 0.3 to about 3 seconds.
f course, variations in heating period-temperature relationships are possible; the above serve as illustrations of successful applications. Thereupon the coating immediately seals the wrapped table spread prints without adversely affecting the product. Since the extensive discoloration under the longitudinal overlap is by far the more serious offender in causing consumer dissatisfaction with the table spread, sealing the wrapper only at the lo ngitudinal overlap contributes substantially to improvement in the appearance of the stored table spread. Hence the less preferred wrapped products of the present invention are those where the heat-sealing is made only at the longitudinal overlap. The preferred wrapped products are those where all the overlaps are heat-sealed.
The process of this invention may be illustrated by reference to the following drawing in which FIG. 1 is a perspective view of a margarine print wrapped in a conventional foil laminated paper wrapper. PEG. 2 shows 'a perspective side view of a margarine print wrapped in inated aluminum wrapper causes the wrapper to lift away from the innerfold and end tucks spring apart thereby" exposing the print to air and allowing moisture lossi In FIG. 3, a margarine print wrapped in the heat-scalable foil laminated paper. of this invention is seen. The foil wrapper has a paper underside 3, joined by laminant 4 to an aluminum foil 5, upon which may be printed advertising material with or without a protective lacquer layer. The heat-scalable coating 6 is applied preferably as the outer coating, although it may be applied to the paper underside or to both sides of the wrapper. A heating means '7 is applied to the areas of wrapper overlap, the longitudinal side fold and the end tucks. During the heat-sealing operation, the heat passes from the outer foil through the paper laminate layer onto the overlapped part of the inner foil surface and is then reflected back, thereby allowing heat to be dissipated in the coating without damage to the product. FIG. 2 shows the margarine print 8 of this invention satisfactorily sealed at the areas of overlap 9 and 10.
The following examples are illustrative of the invenrtion and applicants intend to be bound only by the spirit and scope of the appended claims.
Example 1 Rolls of conventional aluminum foil laminated paper wrappers received from the manufacturer were unrolled and placed on a table with the aluminum side up. Paraflin wax commonly used in the preparation of preserved foods by the housewife and having a melting point of 133 -134 F. was placed in a container of a paint spray gun and melted. The molten wax was then sprayed uniformly on the surface of the aluminum foil to provide about 0.0001 inch in thickness. The appearance of the foil remained unchanged. The foil was then cut into lengths used to package one-quarter pound prints of margarine. Prints of a conventional margarine at 50-55 F. and just ofi the packaging line were then wrapped in the sheets. The sides of the prints bearing the folds (the longitudinal overlap and the tucks at both ends) were then gently pressed against the surface of a hot plate for about 0.25 second for the longitudinal seal and for about 0.75 second for heat-sealing each end. The surface temperature of the hot plate was varied between 150-175 F. and averaged about 160 F. Each fold Was thus heat-sealed one to the other due to the paraffin film. The wrapped prints were then placed in cartons and cases by conventional packaging machinery and stored at 45 50 F. and about 45% relative humidity in simulation of storage conditions generally regarded as good by the trade.
Prints of the same margarine were packaged in the same aluminum foil paper wrappers but this time the wrappers did not bear any heat-scalable coating, i.e. conventionally wrapped. These prints were also stored in the same cases with he heat-sealed margarine prints. After two, four and eight weeks storage, prints of each type were unwrapped and the surfaces were examined.
The print surfaces of the margarine in the heat-sealed aluminum wrappers were uniform in light yellow color. There was no evidence of surface darkening at the longitudinal overlap or at the end folds. The prints were attractive and fresh in appearance. The print surfaces beneath the longitudinal overlap and at the end folds of the margarine wrapped in conventional alumuinum foil wrappers bore distinct dark yellow lines and bands of increased color intensity. The lines varied in width when different prints were examined. All were unattractive in appearance and suggested that the prints were old, although satisfactory in flavor.
The heat sealed wrappers were easily peeled apart and were as readily removed from the prints as the Wrappers that were not heat-sealed.
Example 2 Rolls of foil wrappers bearing a parafiin wax coating on the foil surface of 4 pounds per ream (about 0.0003 inch in thickness) were used to machine-wrap prints of margarine at 5055 F. and just cast molded. The paraffin coating had a melting point of 148 157 F. The wrapped prints were then heat-sealed using a heating element with a flat surface and surface temperature of about 160-165 F. and a contact time of about 0.5 second for the longituudinal overlap and about 1.0 second for each end. The prints were then cartoned and cased :by machine and stored at 45-50 F. and about 45% relative humidity with cases of margarines wrapped in non-heat-sealed foil wraps made on the same day and on the same packaging machine. The same set of margarines were also stored at room temperature (75 F.) and at about 50 relative humidity.
After two, four and eight weeks storage, the prints were unwrapped and examined. The heat-sealed samples showed no discoloration and no heat damage. The appearance was attractive and the color was uniform. The conventionally wrapped prints showed severe yellow darkening at the side fold and at the end folds. The darkening became progressively worse with time. Samples stored at room temperature and returned to the refrigerator for just 24 hours, for easy removal of the wrappers, exhibited the same degrees of surface discoloration; the heat-sealed prints were excellent in appearance in contrast to the noticeable surface discolorations noted with the conventionally wrapped margarines. In addition, oil staining of the cartons was far less in the case of the prints packed in the heat-sealed wrappers.
Example 3 Rolls of conventional aluminum foil laminated paper wrappers as received from the manufacturer were unrolled and placed on a table with the paper side up. Edible hydrogenated cottonseed fat having a melting point of 139-140 F. was placed in a container of a paint spray gun and melted. The molten fat was then sprayed uniformly on the surface of the paper to a thickness of about 0.0005 inch. The foil-paper laminate was then cut into the lengths used to package one-quarter pound prints of margarine. Prints of a conventional margarine at 50- 55 F. and just off the packaging line were then wrapped in the sheets. The sides of the prints bearing the folds (the longitudinal overlap and the tucks at both end) were then gently pressed by the fiat surface of a heating element at about F. surface temperature for a period of about 0.5 second and about 1.0 second for the respec tive seals. Each fold was thus heat-sealed one to the other due to the melting and resetting of the fat film. The Wrapped prints were then placed in cartons and cases by conventional packaging machinery and stored at 45-50 F. and at about 45% relative humidity.
Prints of conventional margarine were packaged in the same aluminum foil-paper wrappers which did not bear any heat-sealable coating. These prints were also stored in the same cases with the heat-sealed margarines. After two, four and eight weeks storage, prints of each type were unwrapped and the surfaces were examined.
The print surfaces of the margarine wrapped with the heat-sealed aluminum wrappers were uniform in light yellow color. There was no evidence of surface darkening at the longitudinal overlap or at the end. folds. The prints were attractive and fresh in appearance. The print surfaces beneath the longitudinal overlap and the end folds of margarine wrapped in conventional aluminum foil wrappers bore distinct dark yellow lines and bands of increased color intensity. The lines varied in width when different prints were examined. All were unattractive in appearance and suggested that the prints were old.
The heat-sealed wrappers were as readily removed from the prints as the wrappers that were not heat-sealed.
Example 4 Rolls of foil wrappers bearing a paraffin wax coating on the paper surface of 1 pound per ream (about 0.000075 inch in thickness) were used to machine-wrap prints of margarine at 5055 F. and just east molded. The paraffin coating had a melting point of 148157 F. The wrapped prints were then heat-sealed using a heating element with a fiat surface and surface temperature of about F. and a contact time of about 0.125 second for the longitudinal overlap and about 0.33 second for the end tucks. The prints were then cartoned and cased by machine and stored at 45 -50 F. and about 45% relative humidity with cases of margarine wrapped in non-heat-sealed foil wraps made on the same day and on the same packaging machine.
After two weeks and after four weeks storage the prints were unwrapped and examined. The heat-sealed samples showed only slight discoloration and no heat damage. The appearance was still attractive and the color was far more uniform than the control prints. The conventionally wrapped prints showed severe yellow darkening at the longitudinal overlap and at the end folds. The darkening became progressively Worse with time.
Example Four rolls bearing a heat-scalable polyamide coating (melting point of 190 F.) were employed in a different series of .tests. The coating had been applied in two thicknesses (1 lb. and 2 lb. per ream or 0.000075 inch and 0.00015 inch in thickness) to two types of foil surfaces (embossed and unembossed). The .rolls were used to -machine-wrap prints of a conventional margarine. The Wrapped prints were then heat-sealed. A higher surface temperature was required (215225 F.) and longer contact times (0.75 second and 1.5 seconds) were required than with the acceptable heat-scalable coatings of the present invention.
After cartoning and easing by machine, the samples were stored in the 45-50 F. refrigerator for two days. When examined, it was found that heat damage resulted due to the high temperature and longer contact time required to effect a heat-seal. (At lower temperatures of heat-sealing or after shorter periods of heat-sealing at 215 -2-25 F. the heat seals of the wrappers around the prints were totally ineffective in preventing subsequent moisture loss from the prints in the vulnerable areas.) It was also found that the unembossed foils had sealed more effectively than the embossed foils due to the smooth surface of the unembossed wrap providing greater surface area for intimate contact. This example demonstrates the criticality in employing a heat-sealing material of the proper melting point in order that the processing conditions will provide a good seal without adversely affecting the appearance of the packaged print.
Thus, following our realization that the localized surface darkening of conventionally wrapped table spreads is due to moisture loss from the prints at the areas of wrapper overlap, we have discovered ways to eliminate the surface darkening. This has been accomplished by (a) coating the areas of wrapper overlap with a heatsealable film, not visually detectable and melting at a temperature very much higher than the melting point of the table spread itself and (b) heat-sealing two dissimilar surfaces of the wrapper by the instantaneous application of heat without melting or heat abusing the table spread packed therein. We have further discovered that the wrapped products of our invention not only fail to show on storage the objectionable areas of high color intensity so commonly associated with products wrapped in prior art aluminum foils, but also cannot be detected by the consumer as being differently processed; the coatings on the wrappers escape visual detection, and, in readily peeling apart the wrapper without mutilation of the package, the consumer is unaware that the wrapper has been heatsealed. As an extra bonus, the heat-sealed prints are less likely to oil stain cartons when the table spread is stored at roomtemperatures.
Having thus provided a written description of the present invention and provided specific examples thereof, it should be understood that no undue restrictions or limitations are to be imposed by reason thereof but that the present invention is defined by the appended claims.
We claim:
1. A table spread selected from the group consisting of margarine and butters in the form of a print, heat sealed in a foil laminated paper wrapper, wherein the inner paper layer faces said table spread and is in intimate contact with substantially the entire surface of the print and wherein a portion of the inner paper layer overlaps a portion of the outer foil thereof, and a sealant coating at least between the said portions, said coating being an edible food grade heat-scalable material selected from the group consisting of waxes, hydrogenated fats, polyethylene having about 300500 ethylene units per molecule, vinyl chloride acetate and mixtures of these substances, said material having a melting point in the range of 180 F., and said portions being heat sealed and bonded together by said coating whereby the wrapper is sealed about the print.
2. A process for heat sealing :a heat sensitive table spread selected from the group consisting of yellow margarines and butters which comprises forming a print of the spread, wrapping said print in a foil laminated-paper wrapper so that the inner paper layer of the wrapper lies in intimate surface contact with substantially the entire surface of the print which is completely enveloped there by and 'a portion of the inner paper layer then overlaps a portion of the outer foil of the wrapper, applying a sealant coating at least between said lapped portions of said wrapper, said coating having a melting point at least 20 F. higher than the melting point of said table spread and being an edible food grade material selected from the group consisting of waxes, hydrogenated fats, polyethylene having about 300-500 ethylene units per molecule, vinyl chloride acetate and mixtures of those substances, said coating having a thickness of about 0.000015 inch to about 0.0015 inch in thickness, and then applying heat at a temperature of about -200" F. for a period of time of about 0.1 to 3.0 seconds to said lapped portions of the wrapper and the coating between them to effect a heat sealed bond by the coating of said lapped portions of said wrapper whereby the latter forms a sealed container for the print.
3. A process for heat sealing a heat sensitive table spread selected from the group consisting of margarines and butters which comprises forming a print of the spread, wrapping said print in a foil laminated-paper wrapper so that the inner paper layer of the wrapper lies in intimate surface contact with substantially the entire surface of the print which is completely enveloped thereby, and a portion of the inner paper layer then overlaps a portion of the outer foil of the wrapper, applying a sealant coating at least between said lapped portions of said wrapper, said coating having a melting point at least 20 F. higher than the melting point of said table spread and being an edible food grade material selected from the group consisting of waxes, hydrogenated fats, polyethylene having about 300-500 ethylene units per molecule, vinyl chloride acetate and mixtures of these substances, and then applying heat at a temperature of about 135-200 F. for a period of time of about 0.1 to 3.0 seconds to said lapped portions of the wrapper and the coating between them to effect a heat sealed bond by the coating of said lapped portions of said wrapper whereby the latter forms a sealed container for the print.
References Cited in the file of this patent UNITED STATES PATENTS 2,778,760 Hurst Jan. 22, 1957 FOREIGN PATENTS 635,268 Great Britain Apr. 5, 1950 817,778 Great Britain Aug. 6. 1959

Claims (1)

1. A TABLE SPREAD SELECTED FROM THE GROUP CONSISTING OF MARGARINE AND BUTTERS IN THE FORM OF A PRINT, HEAT SEALED IN A FOIL LAMINATED PAPER WRAPPER, WHEREIN THE INNER PAPER LAYER FACES SAID TABLE SPREAD AND IS IN INTIMATE CONTACT WITH SUBSTANTIALLY THE ENTIRE SURFACE OF THE PRINT AND WHEREIN A PROTION OF THE INNER PAPER LAYER OVERLAPS A PORTION OF THE OUTER FOIL THEREOF, AND A SEALANT COATING AT LEAST BETWEEN THE SAID PORTIONS, SAID COATING BEING AN EDIBLE FOOD GRADED HEAT-SEALABLE MATERIAL SELECTED FROM THE GROUP CONSISTING OF WAXES, HYDROGENATED FATS, POLYETHYLENE HAVING ABOUT 300-500 ETHYLENE UNITS PER MOLECULE, VINYL CHLORIDE ACETATE AND MIXTURE OF THESE SUBSTANCES, SAID MATERIAL HAVING A MELTING POINT IN THE RANGE OF 115*-180*F., AND SAID PORTIONS BEING HEAT SEALED AND BONDED TOGETHER BY SAID COATING WHEREBY THE WRAPPER IS SEALED ABOUT THE PRINT.
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3148993A (en) * 1962-12-31 1964-09-15 Corn Products Co Process for wrapping margarine and butter
EP0216408A2 (en) * 1985-08-28 1987-04-01 Unilever N.V. Packaged foodstuff

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB635268A (en) * 1944-06-13 1950-04-05 Carl Srensen Improvements in or relating to methods of wrapping blocks of butter, margarine, edible fat, and similar fatty substances, and wrapping material therefor
US2778760A (en) * 1954-07-08 1957-01-22 Kalamazoo Vegets Le Parchment Moisture proof heat sealable wrapping material
GB817778A (en) * 1957-01-23 1959-08-06 Beaverman Brothers Ltd Improvements in or relating to wrapping material for butter and other nutrient fats or products from the foodstuff and chemotechnical industries

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB635268A (en) * 1944-06-13 1950-04-05 Carl Srensen Improvements in or relating to methods of wrapping blocks of butter, margarine, edible fat, and similar fatty substances, and wrapping material therefor
US2778760A (en) * 1954-07-08 1957-01-22 Kalamazoo Vegets Le Parchment Moisture proof heat sealable wrapping material
GB817778A (en) * 1957-01-23 1959-08-06 Beaverman Brothers Ltd Improvements in or relating to wrapping material for butter and other nutrient fats or products from the foodstuff and chemotechnical industries

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3148993A (en) * 1962-12-31 1964-09-15 Corn Products Co Process for wrapping margarine and butter
EP0216408A2 (en) * 1985-08-28 1987-04-01 Unilever N.V. Packaged foodstuff
EP0216408A3 (en) * 1985-08-28 1988-04-06 Unilever Nv Packaged foodstuff

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