WO1998056680A2 - Unitized, stable stacking system and method for packaging, storing, transferring and readying produce for retail use - Google Patents
Unitized, stable stacking system and method for packaging, storing, transferring and readying produce for retail use Download PDFInfo
- Publication number
- WO1998056680A2 WO1998056680A2 PCT/US1998/009935 US9809935W WO9856680A2 WO 1998056680 A2 WO1998056680 A2 WO 1998056680A2 US 9809935 W US9809935 W US 9809935W WO 9856680 A2 WO9856680 A2 WO 9856680A2
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- WO
- WIPO (PCT)
- Prior art keywords
- tier sheet
- tier
- bananas
- containers
- sheet
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D71/00—Bundles of articles held together by packaging elements for convenience of storage or transport, e.g. portable segregating carrier for plural receptacles such as beer cans or pop bottles; Bales of material
- B65D71/70—Trays provided with projections or recesses in order to assemble multiple articles, e.g. intermediate elements for stacking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
- B65D85/30—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
- B65D85/34—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for fruit, e.g. apples, oranges or tomatoes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/80—Packaging reuse or recycling, e.g. of multilayer packaging
Definitions
- the present invention relates to an improved system and method for providing a stable, unitized, multi-tiered palletized stack of product containers, particularly perishable products such as produce, and a method of packing, shipping, and readying produce, particularly bananas, for retail use. More particularly, the present invention provides a system incorporating a stabilizing tier-sheet for placement between layers of containers, such as those used in the shipment of produce. In addition, a new method of readying bananas and other produce for retail consumption is provided.
- bananas are typically packed in the form of banana clusters (or hands) into corrugated containers or boxes at the plantation where they are harvested in a very green, unripened state. These cardboard boxes are then placed within large shipping containers, which are in turn placed in refrigerated ships.
- the pulp temperature of the bananas is kept at a temperature between 56° and 59° Fahrenheit. Once the ship has docked, the bananas are transferred to refrigerated tracks or rail cars, and transported to a warehouse. Once again, the pulp temperature is maintained between 56° and 59° Fahrenheit in order to retard the ripening of the bananas, thereby prolonging their shelf life. In order to maintain this temperature range, it is necessary to provide ventilation means within the cardboard or corrugated boxes, as well as within any inner containers such as plastic bags or tunnel pads. Ventilation is typically achieved by providing a plurality of ventilation openings about the surfaces of the boxes. These openings allow for cooled air to be circulated within the boxes, thereby maintaining the proper pulp temperature.
- the boxes are placed in ripening rooms where the pulp temperature is permitted to rise to about 60° to 62° Fahrenheit.
- Ethylene gas is also circulated about and within the containers by means of the ventilation openings. A combination of increased temperature and ethylene gas will hasten the ripening process, thereby reducing the time necessary for the bananas to fully ripen. Once this process has been completed, however, it is desirable to remove ethylene gas and decrease the temperature of the bananas in order to decelerate ripening.
- the containers and packaging employed for bananas must be able to account for the varying ventilation and temperature control needs during the shipping and storing steps. Nonetheless, when cardboard containers are used to form a palletized load of bananas, temperature pull down rates are not as efficient as is desired. Because cardboard containers are good insulators, even when they are provided with ventilation apertures, rapid, predictable, and efficient temperature pull down of palletized boxes of bananas is difficult if not impossible to achieve. As a result, palletized cardboard containers of bananas often yield unevenly ripened fruit. Further, while many of the containers and methods employed have generally met the needs of producers and retailers, many containers, such as cardboard boxes, usually require a considerable amount of extra handling.
- an improved tier sheet for stabilizing a plurality of containers of product comprises a top surface that includes an outer perimeter and a support area for supporting a plurality of containers.
- the top surface of the tier sheet also includes a plurality of upwardly projecting protuberances that are located so as to define a plurality of upper product cells. These protuberances further engage the containers aligned thereon so as to stabilize them and to prevent substantial movement relative to one other.
- the tier sheet also includes a bottom surface that comprises a plurality of underlying product cells. The underlying product cells are disposed substantially underneath the upper product cells of the top surface of the tier sheet.
- the tier sheet also includes a plurality of ventilation apertures. Preferably, each upper product cell includes one or more of these ventilation apertures.
- the tier sheet may also include one or more longitudinally or transversely disposed stiffening ribs.
- at least one of the stiffening ribs comprises one or more of the upstanding protuberances.
- each upper product cell includes a substantially convex support area of substantially uniform inverted-U- shaped lateral cross-section along its length.
- the tier sheet may also include a peripheral retaining lip depending downwardly from its perimeter.
- the tier sheet may include a plurality of elongated slits for holding one or more removable support walls.
- a portion of these slits is disposed near the outer perimeter of the tier sheet and a portion of the slits is disposed adjacent a centerline that divides the tier sheet into two halves of approximately equivalent area.
- One or more center support walls may be disposed in the slits, each of the center support walls comprising first and second end portions separated by and hingedly connected with a middle portion.
- each of the first and second end portions include one or more downwardly depending tabs capable of being disposed in corresponding slits disposed near the outer perimeter of the tier sheet.
- each middle portion of the center support walls include one or more downwardly depending tabs capable of being disposed in corresponding slits disposed substantially adjacent the centerline so that each of the first and second end portions are substantially parallel with a first pair of opposing tier sheet sides and so that the middle portion is substantially parallel with a second opposing pair of tier sheet sides and the centerline.
- one or more end support walls may be disposed in the slits, each of the end support walls comprising first and second end portions separated by and hingedly connected with a middle portion.
- each of the first and second end portions and middle portion include one or more downwardly depending tabs capable of being disposed in corresponding slits disposed near the outer perimeter of the tier sheet so that each of the first and second end portions are substantially parallel with a first pair of opposing tier sheet sides and so that the middle portion is substantially parallel with a second opposing pair of tier sheet sides.
- each of the center support walls and each of the side support walls include a plurality of ventilation holes.
- the center portion of each support wall may include first and second domed surfaces that are substantially convex on a first side of the center portion and substantially concave on a second side of the center portion.
- the flexible containers may each comprise a plastic bag that have a top portion and a sealed bottom portion.
- each of the bags further include a perforation connecting the top and bottom portions.
- the produce in the bags is preferably a plurality of banana clusters, each of which comprise a plurality of bananas.
- Each banana cluster further has a tip portion and a crown and the bananas of each cluster are connected to one another at the crown.
- the bananas may be positioned in each bag in three rows in a "crowns down" configuration.
- a reusable, stackable shipping receptacle for transporting produce is provided.
- the shipping receptacle is of a substantially rigid, rectangular construction and has a bottom wall and four side walls.
- each side wall is hingedly connected at a bottom edge with the bottom wall.
- the bottom wall comprises one or more upper product cells defined by two or more of the side walls.
- Each upper product cell further comprises a substantially convex produce support area of substantially uniform inverted-U-shaped lateral cross-section along substantially its entire length.
- the bottom wall of the shipping receptacle further comprises one or more underlying product cells, each of which further includes a substantially concave produce support area.
- Each substantially concave produce support area is preferably of substantially uniform inverted-U-shaped lateral cross-section along its length.
- each receptacle comprises 2 upper product cells and 2 underlying product cells that are substantially rectangular and of approximately equivalent size.
- Step (c) in the above method may be repeated in order to provide additional tiers of receptacles, as desired.
- each tier of stackable receptacles preferably comprises four receptacles.
- each banana cluster has a tip portion and a crown and the bananas of each cluster are connected to one another at the crown.
- Each bag has a neck portion, a top portion, a sealed bottom portion, an interior bottom and an opening adjacent the neck portion.
- Each bag is manufactured from a plastic having sufficient strength to permit one to grasp the sealed neck and lift the bag containing all of the bananas for transfer.
- Each of the bags further includes at least one perforation connecting the top and bottom portions of each bag and one or more ventilation apertures;
- Steps (e) - (h) may be repeated in order to unload, ship, and position for retail itional bags of bananas, as desired.
- the step of loading a plurality ible bags with a plurality of banana clusters comprises the following steps:
- the step of arranging the plurality of flexible bags in a unitized, stable multi- tiered arrangement may comprise the above-described method of stacking a plurality of loaded flexible containers of produce in a unitized, stable multi-tiered arrangement using the tier sheet constructed in accordance with the present invention as discussed in detail hereinabove. Further, the step of arranging the plurality of flexible bags in a unitized, stable multi-tiered arrangement may comprise the above-described method of stacking a plurality of reusable, stackable shipping receptacles for transporting produce using the stackable shipping receptacle constructed in accordance with the present invention as discussed in detail hereinabove.
- the tunnel pad includes one or more perforations across either its width or length.
- the first and second rows of bananas are preferably positioned in a "crowns down" configuration within the bag. More preferably, the crowns of the third row of bananas are positioned substantially adjacent the tip portion of the second row of bananas. The tip portions of the third row of bananas are preferably positioned substantially adjacent the tip portions of the first row of bananas.
- Figure 1 is a perspective view of the tier sheet according to the present invention.
- Figure 2 is a top plan view of the tier sheet of Figure 1 ;
- Figure 3 is a perspective view of the removable product support wall used with the tier sheet of the present invention;
- Figure 4 is a cross-sectional view of a tier sheet according to the present invention taken along line 4-4 of Figure 2;
- Figure 5 is a rear plan view showing the center portion of the product support wall of Figure 3;
- Figure 6 is a cross-sectional view of the product support wall of the present invention taken along line 6-6 of Figure 5;
- Figure 7 is a cross-sectional view of the product support wall of the present invention taken along line 7-7 of Figure 5;
- Figure 8 is a cross-sectional view of the product support wall of the present invention taken along line 8-8 of Figure 5;
- Figure 9 is a cross-sectional view of the product support wall of the present
- Figure 10 is a perspective view of a partial palletized load showing 4 layers of product in place;
- Figure 11 is a perspective view showing two center support walls installed on a tier sheet layer;
- Figure 12 is a perspective view of a pallet partially loaded with containers and showing containers disposed on the various product cells of the top tier sheet;
- Figure 13 is a perspective view of a partial palletized load of containers showing the top tier of containers, and top support walls in place;
- Figure 14 is a perspective view of a partial palletized load showing 5 layers of product in place
- Figure 15 is a perspective view of a pallet loaded with containers incorporating the tier sheet and support walls of the present invention.
- Figure 16 is a perspective view showing a worker loading a container of produce onto a product cell of a tier sheet of the present invention
- Figure 17 is a side plan view of the flexible bag of the present invention.
- Figure 18 is atop plan view of the tunnel pad of the present invention.
- Figure 19 is a cut-away view of the packing procedure of the present invention
- Figure 20 is a cut-away view of the packing procedure of the present invention
- Figure 21 is a cut-away view of the packing procedure of the present invention.
- Figure 22 is a perspective view of the stackable dome-bottomed shipping receptacle of the present invention.
- Figure 23 is a top plan view of the stackable dome-bottomed shipping receptacle of the present invention in a collapsed state
- Figure 24 is a side plan view of 2 layers of stacked dome-bottomed shipping receptacles of the present invention showing the contour of the product support area dashed lines;
- Figure 25 is a perspective view of a partially loaded pallet of stackable dome- bottomed shipping receptacles of the present invention.
- Figure 26 is a perspective view of a partially loaded pallet of stackable dome bottomed shipping receptacles showing 4 containers of bananas in position in
- Figure 27 is a perspective view of a pallet loaded with stackable dome- bottomed shipping receptacles of the present invention
- Figure 28 is a perspective view of the transfer procedure of the present invention showing a load of bananas being transferred from a partially loaded pallet incorporating the tier sheet system of the present invention
- Figure 29 is a perspective view of the transfer procedure of the present invention showing a load of bananas being transferred from a partially loaded pallet incorporating the dome-bottomed stackable shipping receptacles of the present invention.
- Figure 30 is a perspective view of a reusable box showing a load of bananas ready for retail use after the perforations of the flexible bag and tunnel pad have been torn and pulled away.
- Figures 1 and 2 show the preferred embodiment of the improved tier sheet for stabilizing a plurality of containers of product of the present invention, generally designated by the numeral 10.
- a flexible container such as a plastic bag
- the tier sheet 10 is generally rectangular in shape, since the vast majority of pallets and resultant palletized loads of stacked shipping containers are of a similar shape.
- tier sheet 10 is approximately 48 inches by approximately 41 inches. Obviously, other shapes could be employed for tier sheet
- the tier sheet 10 of the present invention comprises a top surface 14 that includes an outer perimeter and a support area upon which a layer of containers may rest.
- the top surface 14 of the tier sheet 10 also comprises a plurality of upwardly projecting protuberances 20 that are located so as to define a plurality of upper product cells 22.
- the spacing between the projecting protuberances 20 obviously may be varied depending upon the specific dimensions of the containers to be disposed on the upper product cells 22.
- each product cell 22 is approximately 9 inches by approximately 19 inches.
- the protuberances 20 advantageously engage the containers aligned thereon so as to stabilize them and to prevent substantial movement relative to one other. Protuberances 20 do not have to completely surround each product cell 22 in order to effectively engage the containers disposed within each cell.
- each side of each product cell 22 is provided with at least one such protuberance 20 in order to effect adequate container stability.
- each of the protuberances 20 is substantially elongated and of a length of between about 3 inches and about 36 inches.
- the upstanding protuberances may be substantially hollow which advantageously allows the tier sheet 10 to be injection molded which will be described in greater detail hereinafter. In order to facilitate ease of loading the tier sheet 10 with containers, it is preferred that the protuberances
- each of the protuberances are of a height between about 0.5 inch and about 6 inches.
- the tier sheet also includes a bottom surface that comprises a plurality of underlying product cells disposed substantially underneath the upper product cells 22 of the top surface 14 of the tier sheet 10.
- each underlying product cell of a tier sheet 10 may engage or contact a top portion of a corresponding container disposed on an upper product cell 22 of a lower tier sheet.
- each tier sheet 10 also includes a plurality of ventilation apertures 32 so that adequate ventilation is insured for each such cell 22. This slot shaped ventilation means allows for adequate ventilation without requiring significant removal of material from the top surface 14.
- each upper product cell 22 includes from about 1 to about 12 ventilation apertures 32.
- Each of the ventilation apertures may comprise a substantially elongated slot that is preferably substantially parallel with one or more of the upstanding protuberances 20.
- each upper product cell 22 includes one or more of these ventilation apertures 32.
- the tier sheet of the present invention may be manufactured of any materials using a number of different methods. It is preferred, however, that the tier sheet be singularly molded and that, for considerations of weight and strength, the tier sheet of the present invention be manufactured of an engineering thermoplastic, and preferably thermo ormed. Preferably, the tier sheet is made from high density polyethylene. This results not only in a strong and light weight tier sheet, but also one that is relatively inexpensive to manufacture and is durable and reusable.
- the tier sheet 10 may also include one or more longitudinally disposed stiffening ribs 34 or transversely disposed stiffening ribs 36.
- These ribs 34, 36 especially when disposed in a direction perpendicular to that of the grain structure, provide additional stiffening and strength for the tier sheet. This in turn results in a more stable load of containers when the tier sheet is fully loaded.
- at least one of the stiffening ribs 34, 36 comprises one or more of the upstanding protuberances 20. This configuration simultaneously provides additional strengthening of the tier sheet while providing advantageous definition of product cells 22.
- each upper product cell 22 includes a substantially convex support area 38 of substantially uniform inverted-U-shaped lateral cross-section along its length.
- this convex support area is especially advantageous for supporting contoured product loads.
- a flexible container i.e. , a plastic bag
- the curvature of the rows of bananas may snugly engage the convex support area.
- Such a configuration not only provides additional product support as is especially desired when transporting easily damaged and perishable goods such as bananas, but it also allows for stacking contoured products such as bananas in a more compact and efficient manner.
- the tier sheet 10 may include from about 2 to about 16 upper product cells 22 and from about 2 to about 16 underlying product cells.
- the tier sheet includes 8 upper product cells and 8 underlying product cells, both arranged in two rows of four cells.
- Each upper product cell 22 and each underlying cell are preferably rectangular and of approximately equivalent size.
- the tier sheet 10 may include means for holding one or more removable support walls 50.
- the means for holding one or more support walls comprises a plurality of elongated slits 48. A portion of these slits 48 is disposed near the outer perimeter of the tier sheet 10 and a portion of the slits 48 is disposed adjacent a centerline that divides the tier sheet into two halves of approximately equivalent area. Preferably, none of the slits 48 are disposed within any of the product cells 22.
- each of the support walls 50 may be disposed in the slits 48.
- each of the support walls 50 comprise first and second end portions 52a, 52b separated by and hingedly connected with a middle portion 54.
- each of the first and second end portions 52a, 52b include one or more downwardly depending tabs 58 capable of being disposed in corresponding slits 48 disposed near the outer perimeter of the tier sheet 10.
- each middle portion 54 of the support walls 50 include one or more downwardly depending tabs 58 capable of being disposed in corresponding slits 48 disposed either near the outer perimeter of the tier sheet or substantially adjacent a centerline that divides the tier sheet 10 into two halves of approximately equivalent area.
- each of the first and second end portions 52a, 52b are substantially parallel with a first pair of opposing tier sheet sides and the middle portion 54 is substantially parallel with a second opposing pair of tier sheet sides and the centerline.
- each tier sheet and as will be described in greater detail in the method descriptions of the present invention, it is preferred that two centrally disposed support walls and two side support walls be employed. In this manner, with all four walls disposed on the tier sheet 10, a substantially continuous support structure is formed about the periphery of the tier sheet. Similarly, when all four walls are in position, and as shown in Figure 13, the two middle portions 54 of the centrally disposed walls provide a double-walled transverse support structure adding additional stability to the tier sheet structure.
- utilizing the tier sheet 10 with support walls 50 of the present invention results in several notable advantages over commonly used stacking systems.
- the inclusion of walls 50 in the system of the present invention eliminates the need for product containers disposed on the tier sheet to be sufficiently rigid to support above-disposed layers of product.
- support walls 50 include tabs 58 that are disposed in the tier sheet, additional stability is achieved as compared with boxes that are merely set on a standard sheet.
- support walls 50 provide the necessary support for above-disposed layers of product, non-rigid containers incorporating less material than traditional corrugated boxes, such as plastic bags, may be used to containerize the product being palletized.
- the elimination of excess packing materials advantageously reduces the amount of waste material that must be discarded or recycled when the product arrives at its destination.
- the walls 50 are preferably injection molded and made from a sufficiently durable material, such as an engineering thermoplastic, so that like the tier sheet 10 of the present invention, they may be reused.
- the walls 50 are made of high density polyethylene.
- the walls are preferably removable and hinged, they may be collapsed and returned in a compact space-efficient fashion for later use to ship additional goods.
- the support walls be removable from the tier sheet, it will be understood that they may be formed as an integral part of the tier sheet itself.
- each of the support walls 50 includes a plurality of ventilation holes 62 in order to facilitate ventilation of product disposed within the walls. More preferably, each of the first and second end portions 52a, 52b and each center portion 54 of the support walls 50 include four ventilation holes 62. Further, each side support wall and each center support wall may include a plurality of detents 74 located substantially above the tabs 58 depending from the lower edge of the support wall 50.
- each detent 74 of a wall 50 of a lower tier sheet may receive a corresponding tab 58 of an above-disposed wall 50 of an adjacent tier sheet.
- the tier sheet may also include a peripheral retaining lip 42 depending downwardly from its perimeter.
- Each lip 42 is capable of fitting about the support walls 50 of the adjacent lower tier of product. This arrangement adds additional stability to the palletized load.
- each support wall 50 may include one or more domed surfaces 76 that are substantially convex on a first side 78 of the center portion 54 and substantially concave on a second side 80 of the center portion.
- the second substantially concave side 80 of each center portion is adjacent with one or more of the upper product cells 22 when walls 50 are installed on the tier sheet 10.
- This "bowed-out" arrangement effectively increases the volume enclosed by the support walls 50 on a tier layer. Accordingly, more product may be disposed within each cell 22 than if the walls 50 were planar.
- curved containers may be fitted snugly against each concave side 80 so as to provide additional support and to prevent sliding.
- a method of stacking a plurality of loaded flexible containers of produce in a unitized, stable multi-tiered arrangement that utilizes the tier sheet 10 and support walls 50 of the present invention, as described previously, is provided.
- a standard pallet 64 may be provided. While pallet 64 may be of any design and of any of a variety of materials, it is preferred that pallet 64 be of a plastic construction such as the type now often employed for shipping purposes.
- FIG. 10 shows a partial palletized load having 4 layers of product in place.
- each layer is formed by first providing a tier sheet 10 of the present invention. Retaining lip 42 of the tier sheet may be placed around the support walls 50 of the adjacent lower tier of containers in order to provide additional support to the palletized load.
- each of the support walls 50 comprise first and second end portions 52a, 52b separated by and hingedly connected with a middle portion 54.
- Each of the first and second end portions 52a, 52b and the middle portions 54 include a bottom edge having one or more tabs 58 depending downwardly therefrom.
- the tabs 58 of each middle portion of the two centrally disposed support walls 50 are disposed in corresponding slits 48 substantially adjacent a centerline that divides the tier sheet 10 into two halves of approximately equivalent area.
- the middle portions 54 of the two centrally disposed support walls are sufficiently spaced apart to accommodate the aforementioned domed surfaces 78 of the middle portions 54.
- the convex sides 78 of the middle portions 54 of the two centrally disposed support walls are facing each other so that product storage area is maximized.
- each first and second end portions 52a, 52b of the centrally disposed support walls 50 are disposed in one or more of the slits 48 disposed near the outer perimeter of the top surface 14 of the tier sheet so that each of the first and second end portions of the centrally disposed support walls 50 are substantially parallel with a first pair of opposing tier sheet sides and so that the middle portions
- each of the first and second end portions 52a, 52b of each centrally disposed support wall 50 substantially perpendicular to the middle portions 54.
- each loaded flexible container comprises a gussetted plastic bag 82 having a top portion and a sealed bottom portion 86.
- each bag 82 further includes one or more ventilation openings 88 and an open end 90 adjacent the top portion.
- each of the bags 82 further includes a perforation 100 connecting the top and bottom portions.
- the perforation 100 extends down the length of bag 82 from a first side of open end 90, across the sealed bottom portion 86, and up the length of bag 82 to a second side of open end 90.
- this preferred arrangement of perforation 100 divides the bag 82 into two halves.
- the produce in the bags 82 is preferably a plurality of banana clusters, each of which comprises a plurality of bananas. More preferably, the banana clusters are arranged within the bags 82 in accordance with the preferred packing method of the present invention to be described in detail hereinafter.
- the containers of produce may be loaded manually by one or more workers without any additional equipment other than the various components of the tier sheet system, it is preferred that hydraulic packing stations be used to load the containers.
- the palletized load may be built on a hydraulic platform that can be raised or lowered as the palletized load is assembled in order to keep the layer being assembled in an ergonomically efficient position for the workers loading the produce.
- two peripherally disposed, or side, support walls 50 are positioned in the holding means of the tier sheet.
- the tabs 58 of each middle portion 54 and each end portion 52a, 52b of the two peripherally disposed, or side, support walls 50 are disposed in corresponding slits 48 substantially adjacent the outer perimeter of the tier sheet.
- each of the first and second end portions 52a, 52b of the side support walls 50 are substantially parallel with a first pair of opposing tier sheet sides.
- Each middle portion of the side support walls is substantially parallel with a second opposing pair of tier sheet sides in such a manner so that each of the first and second end portions 52a, 52b of each side support wall 50 further is substantially perpendicular to the middle portions 54.
- an additional tier sheet 10 is placed on top of the exposed layer thus completing the fifth tier layer.
- the retaining lip 42 of the tier sheet may be placed around the support walls 50 of the adjacent lower tier of containers in order to provide additional support to the palletized load.
- Multiple tiers may be built according to the present method in order to provide additional tiers of containers as desired.
- from about 3 to about 12 layers of produce are produced with the present system. More preferably, nine tiers or layers of produce are included with the tier sheet system, as shown in Figure 15.
- a rigid top cap 66 may be provided and may be disposed about the periphery of the top most support walls of a palletized load.
- cap 66 is comprised of rigid plastic similar to the other components of the tier sheet system.
- additional securing means such as strapping tape may be used in order to provide additional security to the palletized load.
- the tier sheet 10, the support walls 50, the top cap 66 and the pallets 64 are durable and designed for a repeat return and reuse.
- support walls 50 are preferably hinged, they are collapsible into a substantially flat state and may be compactly stored when being returned for later use.
- the volume occupied by the various components of the tier sheet system, when compacted and stacked for return, is only roughly 25% of the volume of a complete nine-layered erected palletized load incorporating the components of the present invention.
- the additional cost and environmental impact associated with disposing of and/or recycling currently used corrugated packaging is substantially eliminated.
- the tier sheet system of the present invention when used to build a palletized layer of produce, replaces the need of using heavy and expensive disposable corrugated boxes, normally using about 3.2 lbs. of paper each.
- the tier sheet system of the present invention when used to transport flexible containers of bananas, additional fruit may be stored in a given volume.
- the contoured tier sheet is capable of approximating the curvature of the rows of bananas, and because the tier sheet system of the present invention utilizes relatively less packing material than conventional shipping systems, there is less wasted space within a palletized load.
- the surfaces of the tier sheet approximate the curvature of bananas, there are fewer pressure points in discreet areas of the banana rows. Accordingly, there is less resultant bruising and damage to the fruit during shipping. This is especially important for bananas which are susceptible to bruising, neck damage and latex seepage if mishandled.
- the tier sheet system of the present invention allows for more effective ventilation and more predictable temperature control as compared with standard palletized loads incorporating cardboard or corrugated containers. Because cardboard is a good insulator and frequently absorbs water, it is often difficult to increase or decrease the temperature in a controlled, uniform fashion throughout a palletized load using corrugated containers. In contrast, the plastic components of the tier sheet system of the present invention are not water absorbent, and they do not have corrugation channels that could trap insulating air. Accordingly, greater control of temperature pull down can be achieved thus resulting in more uniform fruit quality. This ability to more readily control and adjust temperature results in better customer control of preparing and ripening the frait for retail use and greater stability while the frait is in retail display. This results in less spoilage and higher yields of fruit and
- a reusable, stackable shipping receptacle may be used for stabilizing a plurality of containers of produce.
- the stackable shipping receptacle 114 is of a substantially rigid, rectangular construction and has a bottom wall 116 and four side walls 118a-d.
- stackable shipping receptacle 114 is molded from an engineering thermoplastic.
- each side wall 118 is preferably hingedly connected at a bottom edge with
- this hinged arrangement allows for the shipping receptacle 114 to be selectively erected and collapsed.
- the bottom wall 116 comprises one or more upper product cells 120 defined by two or more of the side walls 118. Similar to the convex support area 38 of the previously described tier sheet of the present invention, each upper product cell 120 of the receptacle 114 further also comprises a substantially convex produce support area 122 of substantially uniform inverted-U-shaped lateral cross-section along substantially its entire length. More preferably, each side wall 118 is provided with one or more engaging tabs 127 capable of securely engaging an adjacent sidewall 118 in order to selectively maintain the stackable receptacle 114 in an assembled state. Preferably, each side wall 118 includes one or more ventilation apertures 119.
- each convex support portion 122 includes from about 1 to about 12 ventilation holes 123.
- each of the ventilation holes comprises a substantially elongated slot that is preferably substantially parallel with one or more of the side walls 118.
- the bottom wall of the shipping receptacle further comprises one or more underlying product cells 124, each of which further includes a substantially concave produce support area.
- Each substantially concave produce support area is preferably of substantially uniform inverted-U-shaped lateral cross-section along its length.
- Each convex produce support area is further preferably disposed substantially above a corresponding concave produce support area.
- each receptacle 114 comprises 2 upper product cells and 2 underlying product cells that are substantially rectangular and of approximately equivalent size.
- each stackable receptacle 114 may include a downwardly depending retainer 117 disposed near an edge of the bottom perimeter of the box 114.
- the retainers 117 provide an extra measure of stability when receptacles 114 are stacked in multiple layers. Similar to the tier sheet 10 of the present invention, the stackable receptacle 114 exhibits improvement over prior art container systems. Specifically, the convex support portions 122 of the receptacles allow for additional product to be stored in a given volume, especially when a product such as bananas is being shipped because the convex portions 122 are capable of approximating the curvature of banana rows.
- stackable receptacle 114 of the present invention exhibit all of the improved temperature pull down and ventilation advantages associated with the tier sheet of the present invention over standard corragated shipping containers. Further, because stackable receptacles 114 are collapsible, they similarly might be returned for subsequent use and in a space efficient manner.
- a method of stacking a plurality of reusable, stackable shipping receptacles of produce in a unitized, stable multi-tiered arrangement that utilizes the stackable receptacles 114 of the present invention as described previously, is disclosed.
- a standard pallet 64 may be provided. While pallet 64 may be of any design and of any of a variety of materials, it is preferred that pallet 64 be of a plastic construction such as the type now often employed for shipping purposes.
- each layer of product comprise four stackable receptacles arranged in a substantially rectangular configuration in such a manner so that each receptacle 114 is adjacent with at least two other stackable receptacles. More preferably, and as discussed in greater detail previously, each receptacle 114 comprises two convex support surfaces 122.
- Figure 25 shows the top tier of receptacles empty, it is preferred that each receptacle 114 is packed prior to being placed on the pallet layer.
- flexible containers of produce are packed and assembled within the stackable
- each stackable receptacle 114 preferably includes two convex support areas 122, two flexible containers of product are preferably placed and packed in each stackable receptacle before being palletized.
- One or more removable separators may be employed while packing the first flexible container of product in the stackable receptacle 114 in order to provide additional product support while packing the flexible containers.
- each flexible container preferably comprises a gussetted plastic bag 82 having a top portion and a sealed bottom portion 86.
- each bag 82 further includes one or more ventilation openings 88 and an open end 90 adjacent the top portion.
- each of the bags 82 further includes a perforation 100 connecting the top and bottom portions. The produce in the bags
- banana clusters are arranged within the bags 82 in accordance with the preferred packing method of the present invention to be described in detail hereinafter.
- a rigid top cap 126 may be provided to cover the top layer of stacked receptacles of a palletized load. Although it is preferred that the cap 126 cover the entire top layer, individual caps may be provided for each stackable receptacle 114 of the top layer.
- cap 126 is comprised of rigid plastic similar to the components of the tier sheet system and the stackable receptacles 114. Further, additional securing means, such as strapping tape may be used in order to provide additional security to the palletized load.
- the stackable receptacles 114, caps 126 and the pallets 64 are durable and designed for a repeat return and reuse.
- stackable receptacles 114 are preferably hinged, they are collapsible into a substantially flat state and may be compactly stored when being returned for later use.
- the additional cost and environmental impact associated with disposing of and/or recycling currently used corragated packaging is substantially eliminated with the present stackable receptacle method.
- the stackable receptacles 114 when used to build a palletized layer of produce, replace the need of using heavy and expensive disposable corragated boxes, normally using about 3.2 lbs. of paper each.
- the stackable receptacle system of the present invention when used to transport flexible containers of bananas, additional frait may be stored in a given volume. Specifically, because the contoured surfaces of the stackable receptacles are capable of approximating the curvature of the rows of bananas, there is less wasted space within a palletized load. Additionally, because the surfaces of the stackable receptacles approximate the curvature of bananas, there are a fewer number of pressure points in discreet areas of the banana rows.
- the stackable receptacle system allows for more effective ventilation and more predictable temperature control as compared with standard palletized loads incorporating cardboard or corrugated containers. Because cardboard is a good insulator and frequently absorbs water, it is often difficult to increase or decrease the temperature in a controlled, uniform fashion throughout a palletized load using corragated containers. In contrast, the plastic components of the stackable receptacle system of the present invention are not water absorbent, and do not have corragation channels that could trap insulating air. Accordingly, greater control of temperature pull down is achieved thus resulting in more uniform fruit quality. This ability to more readily control and adjust temperature results in better customer control of preparing and ripening the frait for retail use and greater stability while the frait is in retail display.
- a new method for packing, shipping, and transferring a load of bananas and readying the bananas for retail display and sale has been developed.
- this method is preferably used with the tier sheet system or the stackable receptacle system of the present invention
- the present method may also be used with most any standard prior art shipping system.
- the present method substantially reduces the amount of handling of the bananas from the time they are packed at the plantation right up to the time they are delivered and readied for retail use, display or sale.
- the first step of the present method comprises loading a plurality of flexible bags 82 with a plurality of banana clusters.
- each banana cluster can be defined as comprising a crown portion 98 and a tip portion 96 as shown in Figure 19.
- the flexible bags 82 are first preferably disposed in a reusable packing box 99.
- the packing box 99 may be manufactured of any suitable and sufficiently strong material.
- the bag 82 is opened in any typical manner used to open a plastic bag (i.e., by forcing air into open end 90). Bag 82 is then inserted into packing box 99 with open end 90 of the bag 82 extending out of the top of packing box 99.
- Open end 90 is then draped about the outside of the side walls of box 99, thereby completely exposing the interior of the bag which is now in place in the packing box 99.
- at least a portion of perforation 100 of bag 82 is oriented and disposed on or near the bottom of the bag 82 and packing box 99.
- an optional tunnel pad 104 may then be inserted into and placed on the interior bottom of the bag as shown in Figure 19.
- a first row of banana clusters 132 may be positioned atop the tunnel pad 98, preferably in a "crowns down" configuration.
- a portion of tunnel pad 104 is folded over the first row of banana clusters 132.
- the second row 134 of banana clusters is then inserted in a crowns down configuration so that a portion of each of these banana clusters is positioned atop a portion of banana clusters of the first row 132.
- the first and second rows of banana clusters are separated by a portion of the tunnel pad 104 so as to minimize contact and friction between the banana rows, reducing the amount of scarring on the bananas.
- a portion of the tunnel pad 104 is folded up and over the tip portions of the first and second rows of banana clusters 132, 134.
- a third row of banana clusters 136 is placed within the bag 82 in such a manner so that the tip portions 96 of the third row of bananas 136 are substantially adjacent the tip portions 96 of the first row of bananas
- the third row of bananas 136 is positioned such that the crown portions
- each row will typically comprise between about 3 and about 4 banana clusters.
- the total weight of the three rows of bananas is approximately 31 lbs. of bananas.
- the ability of the present packaging method to reduce the amount of moisture lost is significant for the shipment of bananas, because significant moisture losses usually take place when conventional packaging systems are used. Accordingly, by incorporating the present packaging method, the weight of the bananas packaged according to the present method may be reduced as compared with conventional packing systems because less water weight is lost prior to delivery to retail.
- the cinched top portion of the bag is then sealed in any conventional manner such as securing the cinched end with strapping tape, a length of cord, or any other appropriate fashion.
- each flexible container comprises a gussetted plastic bag 82 having a top portion and a sealed bottom portion 86.
- each bag 82 further includes one or more ventilation openings 88 and an open end 90 adjacent to the top portion.
- each of the bags 82 further includes a perforation 100 connecting the top and bottom portions. More preferably, the perforation 100 extends down the length of bag 82 from a first side of open end 90, across the sealed bottom portion 86, and up the length of bag 82 to a second side of open end 90.
- the bag 82 can be constracted of any of a number of materials, and is preferably made of a substantially clear, flexible plastic such as that typically used for
- bag 82 can also be manufactured of opaque material.
- the presently preferred material for the bag is linear low density polyethylene, having small amounts of additional additives to insure that bag 82 may be easily opened and be of adequate strength, while maintaining its inexpensiveness.
- perforation 100 can be replaced by any type of area of weakness which would permit the bag to be opened easily.
- bag 82 could be scored at the location where perforation 100 is now positioned.
- bag 82 could even be molded so that the area of weakness corresponds to a thin area in bag 82.
- the ventilation apertures 88 of the bag are arranged in a series of rows in order to provide ventilation for the bananas therein.
- bag 82 has about 20 round ventilation apertures 88 located adjacent each of the lower corners of the bag, or a total of about 80 such apertures. The preferred positioning of ventilation apertures 88, as shown in Figure 17, will help insure that the apertures provide proper ventilation of the bananas therein.
- apertures 88 are of a size that would not permit substantially any portion of the bananas to extend therethrough.
- the tunnel pad 104 comprises a sheet of flexible plastic.
- the tunnel pad 104 is preferably made from polyethylene, the tunnel pad may comprise any suitable material that similarly advantageously reduces friction and resultant scarring between the banana clusters as they settle and shift during shipment.
- the tunnel pad 104 is rectangular and is preferably approximately about 31 inches by about 21 inches.
- tunnel pad 104 may be manufactured from recycled polyethylene, since it is rather simple to produce sheets of recycled polyethylene. In order to produce a strong tunnel pad, however, it is preferred that the recycled material be sandwiched between two layers of virgin plastic. It is even possible that the polyethylene bags typically employed for covering banana bunches while the bunches are still growing on banana plants may be recycled for this use, particularly since there is a large supply of such used bags readily available.
- Ventilation holes 108 are preferably provided across the length of the tunnel pad 104, more preferably in the form of 5 spaced rows of holes 108. This spacing of the holes 108, permits more even ventilation when the various ends of the tunnel pad are disposed about rows of bananas.
- tunnel pad 104 In order to prevent excessive friction in rubbing between banana clusters, tunnel pad 104 must be of sufficient thickness. It is preferred that the tunnel pad 104 have the thickness of between about 5 and about 10 mils, most preferably about 7 mils. Preferably, tunnel pad 104 includes a perforation 106, or any other appropriate area of weakness, that extends across the width of the tunnel pad.
- each bag 82 of bananas After each bag 82 of bananas has been packed and sealed in packing box 99, it may be arranged with a plurality of other packed bags of bananas in a unitized, stable multi-tiered arrangement.
- This step of arranging the plurality of flexible bags 82 in a stable multi-tiered arrangement may comprise the above-described method of stacking a plurality of loaded flexible containers of produce using the tier sheet and
- flexible bags in a stable multi-tiered arrangement may comprise the above-described method of stacking a plurality of reusable, stackable shipping receptacles constracted in accordance with the present invention and as also discussed in detail hereinabove.
- the bananas After the bananas have been loaded and secured in the multi-tiered arrangement, they are then ready for shipment. When the packaged bananas arrive at either a port or distribution warehouse, a worker may remove each loaded bag
- each loaded bag 82 is preferably placed in an open-topped reusable container 130.
- container 130 should be at least as large, and preferably slightly larger in dimension, than the loaded bag 82 in order to facilitate shifting of the bananas without causing damage.
- container 130 comprises a light-weight, reusable container such as that typically employed in Europe for the transfer of fruits and vegetables to retailers.
- One particularly advantageous type of container which can be employed in the process of the present invention is that manufactured by Schoeller International GmbH, of Munich, Germany (distributed through its IFCO subsidiary in Dusseldorf), and described in U.S. Patent 5,398,834, by Umiker (Mar. 21, 1995), inco ⁇ orated herein by reference.
- These containers are made from plastic, and may be folded down flat
- FIG 28 shows a worker 68 removing one load of bananas 82 from a partial pallet using the tier sheet system of the present invention.
- Figure 29 similarly shows a worker 68 removing one load of bananas 82 from a partial pallet of the stackable dome bottomed receptacles 114 of the present invention.
- each bag 82 may either be placed in the reusable container 130 oriented in much the same fashion as it was on the palletized load, or it may be inverted at this time, rotated 180° and placed in the container 130 (as shown in Figures 28 and 29).
- the bag 82 may be rotated in container 130 after being shipped to the retailer.
- the perforation of the bag 100 and the perforation of the tunnel pad 106 may be torn.
- the various portions of the tunnel pad 104 and the bag 82 may be tucked away from the top row of bananas 136 in order to expose them to consumers.
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- Engineering & Computer Science (AREA)
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- Battery Mounting, Suspending (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU76865/98A AU7686598A (en) | 1997-06-09 | 1998-05-29 | Unitized, stable stacking system and method for packaging, storing, transferringand readying produce for retail use |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US87069697A | 1997-06-09 | 1997-06-09 | |
US08/870,696 | 1997-06-09 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO1998056680A2 true WO1998056680A2 (en) | 1998-12-17 |
WO1998056680A3 WO1998056680A3 (en) | 1999-03-11 |
Family
ID=25355932
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1998/009935 WO1998056680A2 (en) | 1997-06-09 | 1998-05-29 | Unitized, stable stacking system and method for packaging, storing, transferring and readying produce for retail use |
Country Status (7)
Country | Link |
---|---|
AU (1) | AU7686598A (en) |
CO (1) | CO5050379A1 (en) |
CR (1) | CR5845A (en) |
PA (1) | PA8453001A1 (en) |
TW (1) | TW374073B (en) |
WO (1) | WO1998056680A2 (en) |
ZA (1) | ZA984963B (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10230524A1 (en) * | 2002-07-05 | 2004-01-15 | Robert Bosch Gmbh | Crate for transporting pharmaceutical vials or ampoules comprises rectangular frame, into which base plate is lowered and fits on to reinforcing rim at base of frame, crate being made from recyclable plastic |
US20100233333A1 (en) * | 2007-09-04 | 2010-09-16 | Elizabeth Varriano-Marston | Method for controlling banana and plantain quality by packaging |
DE102016116082A1 (en) | 2016-08-29 | 2018-03-01 | Ronny Richter | casing |
CN116097987A (en) * | 2023-04-12 | 2023-05-12 | 黑龙江省农业科学院畜牧兽医分院 | Alfalfa germplasm resource storage device and storage method |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3450542A (en) * | 1965-02-23 | 1969-06-17 | United Fruit Co | Controlled atmosphere storage of green bananas |
FR2583719A1 (en) * | 1985-06-24 | 1986-12-26 | Nicollet Hugues Sa | Support frame for cellular tray, blank capable of producing such a support frame, and package with cellular tray or trays using this frame, particularly for the packaging of fruit. |
US5547081A (en) * | 1993-10-25 | 1996-08-20 | Chiquita Brands, Inc. | Unitized, stable stacking system with tier sheet stabilizer, and method |
DE19516025A1 (en) * | 1994-12-30 | 1996-10-10 | Delbrouck Franz Gmbh | Plastics crates for transporting and storing goods |
US5617711A (en) * | 1995-09-27 | 1997-04-08 | Chiquita Brands, Inc. | Method of producing a container of bananas and method of transferring bananas |
-
1998
- 1998-05-29 WO PCT/US1998/009935 patent/WO1998056680A2/en active Application Filing
- 1998-05-29 AU AU76865/98A patent/AU7686598A/en not_active Abandoned
- 1998-06-09 ZA ZA984963A patent/ZA984963B/en unknown
- 1998-06-09 PA PA8453001A patent/PA8453001A1/en unknown
- 1998-06-09 CO CO98032781A patent/CO5050379A1/en unknown
- 1998-08-21 CR CR5845A patent/CR5845A/en not_active Application Discontinuation
- 1998-12-07 TW TW087109159A patent/TW374073B/en active
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3450542A (en) * | 1965-02-23 | 1969-06-17 | United Fruit Co | Controlled atmosphere storage of green bananas |
FR2583719A1 (en) * | 1985-06-24 | 1986-12-26 | Nicollet Hugues Sa | Support frame for cellular tray, blank capable of producing such a support frame, and package with cellular tray or trays using this frame, particularly for the packaging of fruit. |
US5547081A (en) * | 1993-10-25 | 1996-08-20 | Chiquita Brands, Inc. | Unitized, stable stacking system with tier sheet stabilizer, and method |
DE19516025A1 (en) * | 1994-12-30 | 1996-10-10 | Delbrouck Franz Gmbh | Plastics crates for transporting and storing goods |
US5617711A (en) * | 1995-09-27 | 1997-04-08 | Chiquita Brands, Inc. | Method of producing a container of bananas and method of transferring bananas |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10230524A1 (en) * | 2002-07-05 | 2004-01-15 | Robert Bosch Gmbh | Crate for transporting pharmaceutical vials or ampoules comprises rectangular frame, into which base plate is lowered and fits on to reinforcing rim at base of frame, crate being made from recyclable plastic |
US20100233333A1 (en) * | 2007-09-04 | 2010-09-16 | Elizabeth Varriano-Marston | Method for controlling banana and plantain quality by packaging |
US10010089B2 (en) * | 2007-09-04 | 2018-07-03 | Windham Packaging, Llc | Method for controlling banana and plantain quality by packaging |
US10687539B2 (en) | 2007-09-04 | 2020-06-23 | Windham Packaging, Llc | Modified atmosphere packaging for transportation and ripening of bananas and plantains with extended quality preservation |
DE102016116082A1 (en) | 2016-08-29 | 2018-03-01 | Ronny Richter | casing |
DE102016116082B4 (en) * | 2016-08-29 | 2019-07-25 | Ronny Richter | casing |
CN116097987A (en) * | 2023-04-12 | 2023-05-12 | 黑龙江省农业科学院畜牧兽医分院 | Alfalfa germplasm resource storage device and storage method |
Also Published As
Publication number | Publication date |
---|---|
TW374073B (en) | 1999-11-11 |
ZA984963B (en) | 1999-03-15 |
PA8453001A1 (en) | 2000-05-24 |
CO5050379A1 (en) | 2001-06-27 |
CR5845A (en) | 1999-05-02 |
AU7686598A (en) | 1998-12-30 |
WO1998056680A3 (en) | 1999-03-11 |
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