WO2001026524A1 - Single use cutting board for food preparation - Google Patents

Abstract

A disposable, single use cutting board (10) composed of wood pulp which is economical to manufacture and sold as a package of cutting boards. The cutting boards have a cutting surface which absorbs moisture from food products, provides frictional resistance, and is tough and resistant to manual cutting ordinarily used to cut food products. The cutting board may also have a ribbed or other non-smooth cutting surface, and/or be provided with a substance to reduce bacterial reactivity.

Description

SINGLE USE CUTTING BOARD FOR FOOD PREPARATION

Field of the Invention

The present invention pertains to a cutting board, and particularly to a disposable, single use cutting board for greater kitchen hygiene and sanitation. Background of the Invention

Cutting boards are extensively used in home and commercial kitchens for the cutting of all kinds of food products. However, many problems associated with contamination and sanitation persist. Cutting boards are commonly used to cut all kinds of food products being prepared for a single meal, including fruits, vegetables, and meats. The cutting board is thus inundated with the food stuffs and juices of the different items as well as any bacteria, contaminants or other harmful constituents in any of the food being prepared. The contamination is then passed from product to product through preparation of the food on the same cutting board. Cross contamination of food from a cutting board has at times been cited as a factor in identifying the sources of outbreaks of food borne illnesses.

The problem of spreading contaminants is exacerbated when vegetables and fruits are cut on a cutting board where raw meat has already been cut. While subsequent cooking of the meat may render the bacteria or other contaminants harmless for consumption, later cut fruits and vegetables are often not cooked or not sufficiently cooked to be sanitary. In one survey of U.S. homes, over a quarter of the people surveyed indicated that they use the same cutting board to cut raw and cooked meats, and would not wash the cutting board between cutting raw meat and cutting fresh vegetables for a salad. However, even when the cutting boards are rinsed, wiped or even washed following the cutting of meat or other foods, the cleaning process is often simply not sufficient to avoid unsanitary conditions. Conventional wooden cutting boards have been known to absorb and retain moisture and nutrients which can form a prolific breeding ground for bacteria. Moreover, even the non-absorbent plastic boards have been shown to retain bacteria absent the most rigorous cleaning processes. Cleaning difficulties are also compounded by cuts, nicks, and cracks in the cutting boards. In fact, one household study showed that 3 out of every 10 kitchen cutting boards contained undesirable levels of bacteria. Even in commercial environments, one U.K. study showed that 65% of the initial preparation areas and 57% of the final preparation areas were contaminated with various kinds of bacteria.

Glass cutting boards have been touted as providing a surface which is non- absorbent and easier to clean. Nevertheless, the use of glass cutting boards may cause small shards to chip off and become embedded in the food products. The USDA has recommended that glass cutting boards not be used for the cutting of meat for this very reason. While minute particles can be released from all kinds of cutting boards, the glass shards pose a greater hazard. Glass cutting boards are also subject to being broken if dropped or knocked, and have been known to cause premature dulling of knives.

Non-absorbent cutting boards, such as glass and plastic, can also cause problems when cutting food products with excessive moisture content. With such cutting boards, the moisture tends to run over the cutting surface and off the edge, contaminating counter surfaces and making a mess to be cleaned up. A build up of moisture on the cutting surface also causes the food products to slip around on the board, which not only makes it harder to cut the food but also increases the risk of injury to the user.

A great need exists for a cutting board which enhances hygiene and sanitation, reduces the risk of injury, and minimizes the wear on knives. Summary of the Invention

The present invention is a disposable, single use cutting board composed of a sheet of wood pulp. The cutting board is tough and resistant to cutting, but does not cause premature dulling of knives. The cutting board is economical to manufacture so that it can be disposed of after each use. With a single use cutting board, the build up of bacteria can be eliminated and the cross-contamination of foods minimized. Further, the need for rigorous cleaning procedures, which are typically not practiced, is obviated.

The cutting board is absorbent and draws in the juices and moisture of the food products. In this way, the cutting board is clean and easy to use. The moisture does not build up to cause slipping of the food products during cutting. The surface texture further provides a frictional resistance to the slippage of the food during the cutting operation. In a preferred embodiment, the gripping aspect of the cutting board is enhanced with a ribbed surface, or cross-hatched surface texture.

The cutting board is clean, lightweight, and not susceptible to breakage. The cutting board is all-natural and compatible with food contact and preparation. The board is also easily bent for disposal so as to fold over and retain any loose food pieces remaining from the cutting and be more easily placed in a trash container. The board is made from natural wood fibers and is fully bio-degradable. Brief Description of the Drawings

Figure 1 is a perspective view of a cutting board in accordance with the present invention.

Figure 2 is a cross sectional view taken along line 2-2 in Figure 1.

Figure 3 is a schematic flow sheet of the manufacturing process for producing the cutting boards.

Figure 4 is an enlarged, partial perspective view of one side of an alternative embodiment of the present invention.

Figure 5 is a perspective view of a second alternative cutting board of the present invention.

Figure 6 is a cross-sectional view taken along line 6-6 in Figure 5. Detailed Description of the Preferred Embodiments

A cutting board 10 in accordance with a preferred embodiment of the present invention is composed of wood pulp without additives (Fig. 1 ). While the cutting board can be readily cut into any desired configuration, the cutting board is illustrated as a simple rectangle for easy storage, stacking and shipping. The use of a rectangle further minimizes the offal portion in cutting.

Cutting board 10 includes a pair of generally flat sides 12, 14 which are the same, such that either side could define the cutting surface. For illustration purposes, side 12 is shown as the cutting surface and side 14 as the base surface which rests against the table or other support. The sides 12, 14 are preferably cut to a size which is large enough for most cutting operations, but small enough to be easily handled and placed on a table. The cutting board is also preferably relatively small to avoid disposing of an undue amount of the material after use, and to permit easy placement in ordinary household trash containers. In one preferred construction, the board is 10 inches by 13 inches. Nonetheless, variations in size are contemplated for this invention.

The cutting board is relatively tough and resistant to the type of manual cutting to which cutting boards are usually subjected. As a result, the cutting board can stand up through many cutting operations to enable cutting of all the food for a entire meal without breaking down, even after absorbing moisture. Further, on account of the board strength, the cutting board can be thin, for example of an 1/8 inch thick or less, so as to use less material, be light weight, and easily packaged in a multiple pack of cutting boards. The inventive cutting board is also not subject to being broken if dropped or jarred. In fact, the board can be folded over on itself, in either direction, without breaking. This enables the user to fold up loose food pieces in the cutting board after the cutting is completed, and more easily place the used cutting board in a trash container.

The cutting board has a plush-like texture which tends to grip not only the food product on side 12, but also the support on side 14. Accordingly, the cutting board sets stably on the table or other support, and holds the food on the cutting surface without slippage. This improves the ease of cutting food and reduces the likelihood of injuring the user. The sides 12, 14 are further preferably formed with parallel ribs 16 which extend longitudinally across the entire cutting board to define the sides as corrugated surfaces which enhance the gripping of both the food and the support, especially when there is a large amount of juice or moisture from the items being cut (Figs. 1 and 2).

Cutting board 10 is also capable of absorbing a substantial volume of liquid. Accordingly, moisture which seeps from meats or fruits during a cutting operation is soaked up by the cutting board. As a result, the cutting of the food is cleaner with no contamination of the underneath support surface, and is easier for the user. In a multi-use cutting board such absorbency can induce the breeding of bacteria and be harmful. However, there is no time for such growth activity in this inventive single-use cutting board.

The cutting board 10 is manufactured of wood pulp in an easy and economical manner to facilitate its single-use character. The cutting boards are preferably made in a manner which is known for producing large pulp boards which form a raw material for various paper making operations. For example, in a conventional pulp mill operation, the webs of wood pulp may be produced and cut into (approximately) 30 inches by 30 inches panels for easy storage and shipment to a paper making plant. At the paper plants, the panels are mixed with water and beaten back into individual fibers. These fibers are then mixed with various additives and further processed to form the desired paper.

In one preferred operation for making the cutting boards of the present invention, the same process may be used except that greater care is to be exercised to avoid microbial contamination and growth in the pulp. The cutting boards are to be produced so as to be compatible with their food handling purpose. In one preferred construction, the cutting boards are manufactured to meet the dairymen's standard of 250 bacteria per gram to ensure adequate sanitation and safety for users. These more stringent microbial concerns have not been needed in pulp boards used for paper making. As an alternative, the cutting boards may be made using standard procedures for producing large pulp boards commonly used in the paper making industry, so long as the boards are subsequently sanitized by radiation or other means.

As an example for making the cutting boards, a single process is described below. Other processes for making pulp boards, however, could also be used to produce the novel cutting boards of the present invention. In this one process logs are debarked and chipped into relatively uniform pieces at a woodyard and chipping site 20 (Fig. 3). The cutting boards are preferably formed of hardwood pulp because the hardwood fibers are significantly shorter than softwood fibers, which results in a pulp board which is less tough and easier to cut into the desired cutting board shape. Nevertheless, softwood logs or a combination of the two could be used if desired.

The chips are sent to a cooking stage 22 where they are mixed with a pulping liquor solution typically including sodium hydroxide and other chemicals. The alternative use of sulphite or acid pulping chemistry also produces pulp suitable for this invention. The mixture is subjected to high temperature and pressure within vats to dissolve the lignin and release the fibers from one another. The resulting liquid is referred to as a "black liquor."

Once the cooking is completed, the fibers are sent to washers 24 and a screening stage 26 where they are washed and rinsed to remove and drain off the black liquor. In the rinsing operation 26, the fibers are deposited onto fine mesh screens and showered with water.

The fibers are then further processed through a bleaching stage 28. In general, chlorine dioxide and other chemicals are used to oxidize the contaminants so that essentially pure cellulose remains. The fibers of the hardwood cellulose are generally about 1 mm or less in length.

During the cooking stage 22 and the bleaching stage 28, the pulp is rendered virtually sterile to eliminate the microbial activity which may have existed within the wood. While not critical for paper making operations, the making of cutting boards 10 in this described process includes steps to avoid contamination of the cutting boards. For example, the water used in the washing and screening operations, particularly in rinsing the fibers after the bleaching stage 28, is to be treated, clean water. Moreover, the equipment is to be routinely cleaned to maintain a level of cleanliness which is compatible with food processing.

Following the bleaching step, the fibers are placed in high density towers 29 for temporary storage. The towers provide a buffer in the operation in case there is a temporary stoppage or slow down before or after the towers so as to help maintain a generally steady state operation. However, strict controls are preferably maintained over the towers in this process to ensure that microbial growth does not begin so as to contaminate the pulp. For instance, the pulp is preferably agitated in an effort to avoid dead spots and held within the towers for only a limited span of time. Additional safeguards, such as adding bacteriacides and/or avoiding the use of fibers in a tower after shut down, may also be taken to ensure that microbial activity is kept beneath an acceptable minimum. Periodic testing of the pulp for microbial activity is preferably conducted at this and/or other stages to ensure the desired standards are maintained. Periodic testing of the cutting boards following manufacture is also preferred. Alternatively, the pulp may be routed directly from the bleaching stage 28 to a second cleaning and screening stage 30 (i.e., without the use of towers) to reduce the risk of contaminating the pulp.

When the fibers are removed from the towers, they are sent to the second cleaning and screening operation 30 where they are rinsed to remove any remaining bleaching constituents. As discussed above, the fibers are deposited onto fine mesh screens and showered. Once the fibers are sufficiently rinsed and cleaned, they are pressed by pinch rollers (commonly referred to as a press section — not shown) which function to (1 ) remove liquid from the fibers and (2) press the fibers into a continuous web. The rollers are generally ribbed to provide a more effective pressing operation. These rollers form the ribs 16 which are present in cutting board 10. Alternatively, the rollers could provide a cross- hatching pattern with criss-crossing ribs 16a, 16b (Fig. 4) on one side 12a (or both sides) of cutting board 10a. In addition, various patterns, or even trademarked brand logos, could be included in the surface of the pinch rollers so as to form the configurations in the sides of the cutting boards.

Following the pinch rollers, the web is sent through a drying machine 32 where the remainder of the liquid is removed to produce a thoroughly dried web of pulp board. The web is typically very wide, for example 15-30 feet wide, when it leaves the drying machine. The web is then preferably sliced into narrow strips at the finishing stage 34 and cut into individual rectangular sheets of very clean pulp by subsequent roller cutters. These sheets could be the cutting boards 10 themselves, or used as base stock sheets which are then subsequently cut into individual cutting boards. The subsequent cutting operation could be performed by any known cutting machine, including a subsequent trimming to size or die cutting operation which could cut the web into virtually any desired configuration for a finished product. The cutters are to be cleaned and maintained in a matter compatible with food handling. For example, the cutting may be cleaned with alcohol (or other food safe bactericidal solvent), and lightly lubricated with an odorless, light petroleum hydrocarbons having status under 21 C.F.R. 178.3650 or the like. In addition, workers preferably wear clean white clothing, wear sterile rubber gloves or the like, and use hair and beard nets to ensure a highly sanitary product suitable for food preparation; although variations in personal requirements for workers could vary so long as sufficient cleanliness in the produced cutting boards is achieved.

As discussed above, the present cutting boards could be produced without concern for cleanliness and microbial growth and then sanitized, such as by radiation, prior to packaging.

The product is then packaged in a plastic shrink wrap or other wrapping to maintain its sanitary condition. Accordingly, the packaging equipment, like the production equipment, is to be cleaned to a level of satisfaction which is compatible with food safe products. The cutting boards are packaged singularly or in a multiple stack with safety suggestions for sanitary use of the cutting boards. The suggestions would instruct users on such things as using the cutting boards for only a single use, never cutting fruits and vegetables after cutting meat, and performing no further cutting on the cutting boards following the cutting of raw meat.

While the preferred embodiment is a substantially pure hardwood pulp sheet, other embodiments could include various different additives to enhance the performance of certain features. For instance, the sides 12, 14 could each be treated with a solution of citric and/or malic acid having a concentration of about 3-50 percent to impart a mild level of anti-viral/anti-bacterial reactivity. Citric and malic acids occur in certain citrus fruits and apples and would not be hazardous for consumption. The solution would preferably be sprayed onto each surface and dried between the drying machine and the finishing stage. Of course, other modes of applications of the solution could be used.

In another alternative embodiment, the web could be further treated with a wet strength resin (e.g., a resin sold under the trademark AMERES by Georgia-Pacific Corporation of Atlanta, Georgia). The resin would preferably be sprayed onto the sides 12, 14 to increase the wet strength of the board. Alternatively, the board could be completely penetrated by a more thorough spraying or other application of the resin.

The cutting board 10 may be embossed with a pattern or logo, or provided with a watermark. Additionally, the cutting boards could be died a color and/or provided with a scent so long as food contact safe dies and scents were used.

The cutting board 10b can also be selectively scored (Figs. 5 and 6) to create one or more deep grooves 40 cut in on side 14b. Grooves 40 allow a portion of the cutting board to be separated for use when only a small cutting board is needed (e.g., to slice a piece of fruit). One side 12b of the cutting board would remain unchanged as the cutting surface to facilitate use of the entire board if desired. The grooves 40 can partition the board in any desired manner. See, for example, Figure 5 wherein groove 40a extends the width of the cutting board 10b to permit 1/3 of the cutting board to be manually separated for use, and groove 40b (in cooperation with one-half of groove 40a) permits 1/6 of the cutting board to be removed for independent use. Of course, numerous variations in the patterns of grooves 40 could be used to facilitate the separation of different sizes and shapes of the cutting board.

The various embodiments are generally not mutually exclusive and can be used in combination. While one example of making the cutting boards is described above, other processes for making the pulp cutting boards could be used to produce the present invention. Other variations are also possible without departing from the spirit and scope of the invention.

Claims

Claims:

1. A cutting board comprising a sheet of wood pulp having a first face and an opposite second face, the faces interchangeably forming a cutting surface for cutting food products and a base surface for engaging a supporting surface for the cutting board.

2. A cutting board in accordance with claim 1 in which the faces each include a plurality of generally parallel ribs extending substantially thereacross.

3. A cutting board in accordance with claim 2 in which series of first grooves are defined between each pair of adjacent ribs, and the cutting board further includes at least one second groove deeper than the first grooves to facilitate separation of the cutting board into separate smaller board pieces.

4. A cutting board in accordance with claim 3 wherein the cutting board has a maximum thickness of no more than about one-eighth of an inch.

5. A cutting board in accordance with claim 1 in which the faces each include a pattern of crossing ribs extending substantially thereacross.

6. A cutting board in accordance with claim 1 wherein each of the first and second faces has a non-smooth surface.

7. A cutting board in accordance with claim 1 in which the cutting board further includes means for facilitating manual separation of the cutting board into separate smaller cutting board pieces.

8. A cutting board in accordance with claim 1 wherein the cutting board has a maximum thickness of no more than about one-eighth of an inch.

9. A cutting board in accordance with claim 1 wherein the cutting board is composed of substantially pure wood pulp.

10. A cutting board in accordance with claim 1 wherein the cutting board further includes citric acid on at least the first and second faces.

11. A cutting board in accordance with claim 1 wherein the cutting board further includes malic acid on at least the first and second faces.

12. A cutting board in accordance with claim 1 wherein the cutting board further includes a substance on at least the first and second faces to impart a level of anti-bacterial reactivity.

13. A cutting board in accordance with claim 1 wherein the cutting board further includes a resin on at least the first and second faces to improve the wet strength of the cutting board.

14. A cutting board comprising a generally planar, flexible, moisture absorbing sheet of uniform construction having a first face and an opposite second face, the faces forming a cutting surface for cutting food products and a base surface for engaging an underlying support for the cutting board.

15. A cutting board in accordance with claim 14 wherein the faces have the same construction and are interchangeable as the cutting and base surfaces.

16. A cutting board in accordance with claim 15 wherein each of the faces includes a series of generally parallel ribs.

17. A cutting board in accordance with claim 16 wherein each face has a generally plush-like texture.

18. A cutting board in accordance with claim 16 in which a series of first grooves are defined between each pair of adjacent ribs, and the cutting board further includes at least one second groove deeper than the first grooves to facilitate separation of the cutting board into separate smaller board pieces.

19. A cutting board in accordance with claim 14 wherein at least one of the faces includes a series of generally parallel ribs.

20. A cutting board in accordance with claim 14 wherein each face has a generally plush-like texture.

21. A cutting board in accordance with claim 14 which further includes at least one groove to facilitate manual separation of the cutting board into separate smaller board pieces.

22. A cutting board in accordance with claim 14 wherein the cutting board has a maximum thickness of no more than about one-eighth of an inch.

23. A cutting board in accordance with claim 14 wherein the cutting board is composed of substantially pure wood pulp.

24. A cutting board in accordance with claim 14 wherein the cutting board includes citric acid on at least one of the faces.

25. A cutting board in accordance with claim 14 wherein the cutting board includes malic acid on at least one of the faces.

26. A cutting board in accordance with claim 13 wherein the cutting board includes a substance to impart a level of anti-bacterial reactivity.

27. A cutting board in accordance with claim 13 wherein the cutting board further includes a resin to improve the wet strength of the cutting board.

28. A cutting board in accordance with claim 13 wherein the cutting board is composed of substantially pure wood pulp.

29. A package of single use cutting boards comprising a plurality of discrete cutting boards stacked upon each other, each cutting board comprising a sheet of wood pulp having a first face and an opposite second face, the faces interchangeably forming a cutting surface for cutting food products and a base surface for engaging a support for the cutting board, and a packing material encasing the plurality of cutting boards.

30. A package in accordance with claim 29 wherein each of the faces includes a series of generally parallel ribs.

31. A package in accordance with claim 29 which further includes at least one groove to facilitate manual separation of the cutting board into separate smaller board pieces.

32. A package in accordance with claim 29 wherein the cutting board has a maximum thickness of no more than about one-eighth of an inch.

33. A package in accordance with claim 29 in which the packing material is a plastic shrink wrap material.

34. A package in accordance with claim 28 further including safety instructions for sanitary use of the cutting boards.