WO2017027918A1

WO2017027918A1 - Food storage tray

Info

Publication number: WO2017027918A1
Application number: PCT/AU2016/050752
Authority: WO
Inventors: Darren John WILLIAMES
Original assignee: Auzfresh Holdings Pty Ltd
Priority date: 2015-08-14
Filing date: 2016-08-15
Publication date: 2017-02-23
Also published as: AU2016309956A1

Abstract

A tray (3) for storing a food product includes (a) a main tray body (7) for storing the food product, such as uncooked meat product, and (b) a drainage plate (5) dividing the tray body into a food storage chamber (41) for storing the food product above the plate and a liquid drainage chamber (43) below the plate. The drainage plate has a plurality of drainage nozzles (9) extending from the plate. In use of the tray, the nozzles allow liquid that leaks from the food product into the food storage chamber to flow into the lower liquid drainage chamber.

Description

FOOD STORAGE TRAY

Technical Field The present invention relates to a tray for storing food products .

The present invention relates particularly, although not exclusively, to a tray for holding meat such as poultry meat.

The present invention also relates to the separate components of a tray body and a liquid drainage plate that form the tray.

The present invention also relates to methods of manufacturing the tray body and the liquid drainage plate.

Background

Meats and some other food products are often stored and transported in plastic trays .

Such trays typically comprise an open-top shallow dish or body. In use, the body holds the meat products and the tray is wrapped in a plastic wrap or a top lidding film is welded 'film' to close the open top and thereby reduce exposure of the meat to oxygen.

Uncooked meat products are usually packaged and stored in the trays in a frozen or semi-frozen state, and retained liquids (water and blood) leak from the meat over time and, particularly, as the meat thaws prior to the meat being cooked. The liquids in the trays are often unsightly and detract significantly from the presentation of the packaged meat products to consumers at points of sale .

The trays may contain absorbent pads or other products that are designed to absorb the liquids that leak from the meat into the trays. However, these absorbent products often become discoloured, often do not absorb all the free liquid, and have a soggy appearance that is unsightly and detracts from the visual presentation of the packaged meat products .

It would be useful to provide a tray that can drain liquids away from meat products in the tray so that the liquids are not visible at the point of sale and do not impact on the visual presentation of the packaged meat products at the point of sale .

The above description is not to be taken as an admission of the common general knowledge in Australia or elsewhere .

Summary of the Invention

In accordance with the invention there is provided a tray for storing a food product that includes (a) a main tray body for storing the food product, such as uncooked meat product, and (b) a drainage plate dividing the tray body into a food storage chamber for storing the food product above the plate and a liquid drainage chamber below the plate, with the drainage plate having a

plurality of drainage nozzles extending from the plate, whereby in use of the tray the nozzles allow liquid that leaks from the food product into the food storage chamber to flow into the lower liquid drainage chamber .

The tray may be formed so that it is difficult for liquid that has leaked from the food product to flow back into the food storage chamber from the liquid drainage chamber, for example when the tray is turned onto a side of the tray or turned upside down. From a practical viewpoint, this is an important feature because it is often the case that food product trays will be turned onto a side or turned completely upside down when a purchaser transports the trays from a point of sale, such as a supermarket, to a home.

The tray body and the drainage plate may be formed as separate components of the tray and, in use, be assembled together to form the tray. The tray body may include a base and a side wall extending from the base and forming an open-topped tray.

In one embodiment, the tray base may form a platform that supports the drainage plate.

The tray base may include a plurality of chambers , for example in the form of channels, that define the food storage chamber and are adapted to hold liquid that leaks from the food product.

The chambers may be below the level of the support platform defined by the tray base when the tray is in an upright position.

The tray base may include a plurality of lands that separate the chambers and define part of the support platform of the tray base.

The tray body may be rectilinear with opposed sides and opposed ends .

In a situation in which the chambers are channels, the channels may be parallel and extend between the opposed sides of the tray body and be spaced apart along the length of the tray.

The channels may have narrower inlets and wider channel sections. The narrower inlets help to make it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber.

With this arrangement, the drainage plate is

supported by the support platform of the tray base, with the nozzles extending into the channels in the tray base.

With this arrangement, in an assembled tray, the drainage plate may sit on and not be connected directly to the support platform of the tray base.

Alternatively, in an assembled tray, the drainage plate may be connected to the support platform of the tray base, for example by being heat welded to the support platform.

The nozzles and the inlets of the channels may be formed so that there is a tight fit of the nozzles in the channel inlets. The tight fit may form a seal between outer walls of the nozzles and inner walls of the channel inlets. The seal may also help to make it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber.

The nozzles may extend at least 40%, typically at least 50%, typically at least 60%, typically at least 90%, into the depth of the channels. This feature also helps to make it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber. In particular, when the tray is on its side or turned upside down the depth of the liquids in the upturned channels would need to be greater than the distance the nozzles extend into the channels for any of the liquids to flow into the outlets of the nozzles and then into the food storage chamber via the nozzles.

The nozzles for this and other embodiments of the invention may be formed, for example by being tapered along the length of the nozzles, so that the inlets having larger transverse cross-sectional areas than the outlets.

An upper surface of the drainage plate may include a plurality of channels extending from the nozzle inlets for collecting liquids and allowing the liquids to flow to the nozzle inlets.

In another, although not the only other, embodiment, the side wall of the tray body may be formed to retain the drainage plate in position with respect to the tray body.

With this arrangement the drainage plate may be clear of the base of the tray.

The side wall of the tray body may include an outwardly extending recess at a required height of the side wall or another outwardly or an inwardly extending formation at the required height that receives and supports an outer edge of the drainage plate and positions the drainage plate within the tray body.

The recess may extend completely or partly around the perimeter of the side wall at the required height. The recess or the other formation may be formed so that there is a snap-fit of the drainage plate in the recess or the other formation.

The nozzles in the drainage plate may be formed to make it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber.

For example, the nozzles may extend at least 40%, typically at least 50%, typically at least 60%, typically at least 90%, into the depth of the channels so that it is difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber when the tray is on its side or turned upside down. Specifically, as described above, the depth of the liquids in the tilted or upturned channels would need to be greater than the distance the nozzles extend into the channels for any of the liquids to flow into the outlets of the nozzles and then into the food storage chamber via the nozzles.

The nozzles may be formed, for example by having frusto-conical walls that extend from the drainage plate, so that the nozzle inlets have larger transverse cross- sectional areas than the nozzle outlets.

The nozzle outlets may be defined by inwardly and upwardly extending nozzle walls.

The upwardly directed ends of the nozzle walls may be formed to pierce larger-size droplets of liquids flowing through the nozzles from the food storage chamber and break up the droplets into smaller-size droplets that flow into the liquid storage chamber. In use, typically, larger-size droplets form in the liquid storage chamber.

The inwardly and upwardly extending nozzle walls at the nozzle outlets may be formed with smooth outer surfaces that do not break larger-size droplets in the liquid storage chamber when the tray is upturned, and therefore prevents liquid flow from the liquid storage chamber back into the food storage chamber. This is a further example of nozzle formation that makes it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber.

The drainage plate may be formed with inclined plate sections that channel liquid flow to the nozzle inlets.

The body may have an open top .

The present invention also provides a packaged food product that includes the above-described tray, a food product in the food storage chamber of the tray, and plastics film closing the open-top of the tray.

The tray may be formed from any appropriate material , including plastics materials, such as polypropylene, polyethylene terephthalate (PET) , high impact polystyrene (HIPS) and biodegradable plastics.

The food product may be a food that leaks liquids while in a food storage tray. By way of example, the food product is uncooked meat products.

The present invention also provides the above- described drainage plate for use as a component of the above-described tray for storing a food product.

The present invention also provides the above- described tray body for use as a component of the above- described tray for storing a food product.

The above-described drainage plate and the tray body may be formed by any suitable method. By way of example, thermoforming and injection moulding technologies may be used to form the drainage plate and the tray body from plastics materials .

The present invention also provides a method of manufacturing the above-described drainage plate that includes (a) thermoforming a sheet of polymeric material into a mould that includes a plurality of cavities that define the nozzles and forming nozzles having closed ends and (b) punching or otherwise forming open ends of the nozzles .

The polymeric material may be any suitable

thermoformable polymeric material . Brief Description of the Drawings

Embodiments of the tray of the invention and

embodiments of the separate components of the tray body and the drainage plate of the invention are now described by way of non-limiting example only, with reference to the accompanying drawings in which:

Figures 1 to 3 are diagrams which illustrate the operation of one embodiment of the tray in accordance with the invention when in upright, side and upside down orientations, respectively, of the tray with liquid in the tray;

Figure 4 is an exploded perspective view which illustrates embodiments of the tray body and the drainage plate in accordance with the invention that form the embodiment of the tray shown diagrammatically in Figures 1 to 3 ;

Figure 5 is an enlarged view of part of the drainage plate shown in Figure 4 that illustrates the drainage channels in the drainage plate;

Figures 6 to 8 are diagrams which illustrate the operation of another embodiment of the tray in accordance with the invention when in upright, side and upside down orientations, respectively, of the tray with liquid in the tray;

Figure 9 is a perspective view of the tray shown in Figures 6 to 8 ;

Figure 10 is a top plan view of the tray shown in Figures 6 to 9 ;

Figure 11 is a side view of the tray shown in Figures

4 to 10;

Figure 12 is an end view of the tray shown in Figures 4 to 11;

Figure 13 is a cross-section along the line 13-13 of Figure 10;

Figure 14 is an enlargement of the circled area in Figure 13 ; Figure 15 is a perspective view of the drainage tray of the tray shown in Figures 6 to 14 ;

Figure 16 is an enlargement of the circled area in Figure 15 ;

Figure 17 is a perspective view of the tray body of the tray shown in Figures 6 to 16

Figure 18 is a cross-section along the line 18-18 of Figure 17;

Figures 19 and 20 are diagrammatic cross-sections through another, although not the only other, embodiment of the tray in accordance with the invention when in upright and upside down orientations, respectively, of the tray with liquid in the tray, with the Figures also illustrating embodiments of the tray body and the drainage plate in accordance with the invention that form the embodiment of the tray shown in these Figures; and

Figures 21-26 are a series of diagrams that

illustrate the steps of one embodiment of a method of manufacturing the drainage plates of the embodiments shown in Figures 1 to 5, Figures 6-18 and Figures 19 and 20 respectively in accordance with the invention.

Detailed Description The Figures illustrate three of a larger number of embodiments of a tray 3 for storing food products in accordance with the invention.

The trays 3 shown in the Figures are formed from two separate components , namely a tray body 7 and a drainage plate 5, that are assembled together to form the trays 3.

In an assembled tray, the tray body 7 and the drainage plate 5 may remain as separate components or may be physically connected together.

The tray bodies 7 shown in the Figures are themselves separate embodiments of tray bodies in accordance with the invention . In addition, the drainage plates 5 shown in the Figures are themselves separate embodiments of drainage plates in accordance with the invention.

In each embodiment, the tray body 7 forms a shallow trough or recess in which one or more pieces of meat or other food products are positioned in use of the tray 3 for transportation and storage and display for sale at a point of sale location, such as a supermarket.

In each embodiment, the drainage plate 5 divides the tray 3 into two chambers , namely an upper food storage chamber 41 above the drainage plate 5 and a lower liquid drainage chamber 43 below the drainage plate 5.

In use of each embodiment, once the food storage chamber of the tray 3 is filled with meat, the tray 3 is sealed using a plastic wrap (not shown) or other suitable option for sealing the tray. The plastic wrap envelops the body 7 to isolate the volume of the body 7 , and thus the meat in the body 7, from ambient air.

The body 7 and the drainage plate 5 of each

embodiment may be formed from any appropriate material , including plastics materials, including polypropylene, polyethylene, PET, HIPS and biodegradable plastics and may be fabricated in various shapes and sizes depending on the amount of meat to be stored in the tray 3.

The body 7 and the drainage plate 5 of each

embodiment may be formed by any suitable method. By way of example, thermoforming and injection moulding

technologies may be used to form the body 7 and the drainage plate 5 from plastics materials.

A key feature of each embodiment is that the tray 3 is formed so that it is difficult for liquid that has leaked from the food product and flowed into the liquid drainage chamber to flow back into the food storage chamber from the liquid drainage chamber, for example when the tray is turned onto a side of the tray or turned upside down. From a practical viewpoint, this is an important feature because it is often the case that food product trays will be turned onto a side or turned completely upside down when a purchaser transports the trays from a point of sale, such as a supermarket, to a home. As will be evident from the following description of the embodiments, a key (although not the only)

structural feature of the tray that makes it possible to make this flow-back difficult is a plurality of drainage nozzles 9 in the drainage plates 5. Embodiment shown in Figures 1 to 5

With reference particularly to the exploded view of Figure 4 , the embodiment of the tray 3 shown in Figures 1 to 5 includes the above-described tray body 7 and drainage plate 5.

As is indicated by the arrow shown in Figure 4 , in use, the drainage plate 5 is positioned in the tray body 7 when the tray 3 is assembled and divides the tray 3 into the above-described food storage chamber 41 above the drainage plate 5 and liquid drainage chamber 43 below the drainage plate 5.

The tray body 7 shown in Figure 4 is open at the top and includes a base 13, a side wall 15 extending from the base 13, and an outwardly extending rim 17 that extends around the perimeter of the side wall 15. The side wall

15 includes corrugations that reinforce the side wall 15.

The body 7 is rectangular in top plan view with a pair of opposed longer sides and a pair of opposed longer ends and has rounded corners .

The base 13 includes a platform section 19 that supports the drainage plate 5.

The base 13 also includes a plurality of chambers in the form of channels 21 in this embodiment that define the liquid storage chamber section 43 of the base. The channels 21 are adapted to hold liquid that leaks from meat in the food storage chamber. It can be appreciated that the channels 21 are below the level of the support platform section 19 of the base 13 and the drainage plate 5 when the tray is in an assembled and upright position. The channels 21 are parallel to each other and extend across the base 13 from one longer side to the opposite longer side of the tray body 7. The channels 21 are spaced apart along the length of the tray body 7 from one end to the opposed end. The channels 21 are uniformly spaced-apart but could be spaced-apart as required in any situation. In effect, as can best be seen in Figure 4, the support platform section 19 defines a series of parallel lands for supporting the drainage plate 5.

With reference to Figures 1-3, the channels 21 have narrower inlet, i.e. throat, sections and wider channel sections. In use, liquid that leaks from meat in the food storage chamber 41 accumulates in the wider channel sections. The narrower inlet sections help to make it difficult for liquid to flow back into the food storage chamber 41 from the liquid drainage chamber 43 when the tray 3 is not in an upright position.

The drainage plate 5 is rectangular with rounded corners. The size and the shape of the plate 5 are selected so that the plate 5 is a tight fit against the side wall 15 of the tray body 7 so that there is a seal between the edge of the drainage plate 5 and the side wall 15 when the drainage plate 5 is positioned on the support platform section 19 of the tray body 7.

The drainage plate 5 includes a plate 23 and a plurality of drainage nozzles 9 extending from the plate 23 with nozzle inlets formed in the plate 23.

The nozzles 9 are tapered along the length of the nozzles 9, with the nozzle inlets having larger transverse cross-sectional areas than the nozzle outlets. The purpose of the nozzles 9 is to allow liquid that leaks from the meat in the food storage chamber 41 to flow into the channels 21 that define the liquid drainage chamber 43. This function of the nozzles 9 is illustrated in Figure 1 in which the tray 3 is shown in an upright orientation in an assembled form with the drainage plate 5 positioned on the base 13 of the tray body 7. The squiggle lines in the Figure illustrate the liquids that have already leaked from meat (not shown) in the food storage chamber of the tray 7 into the channels 21. The arrows in the Figure illustrate additional liquids that have leaked from the meat and are flowing towards the nozzle inlets and then into the channels 21.

It can be appreciated that the structure of the tray 3 moves liquids that leak from meat in the food storage chamber 41 of the tray 3 away from the meat into a separate liquid drainage chamber 43 so that the overall visual appearance of the packaged product in the food storage chamber 43 remains at a high level.

The nozzles 9 are centrally positioned between the opposed longer sides of the tray body 7 and are spaced apart in a straight line between the opposed ends of the tray body 7. The size, spacing and location of the nozzles 9 are not confined to that shown in the embodiment shown in Figures 1-5 and may be selected as required.

An upper surface of the plate 23 includes a plurality of channels 11 extending from the nozzle inlets for collecting liquids and allowing the liquids to flow to the nozzle inlets. The plate 23 is slightly inclined

downwardly from the sides to the line of centrally- positioned nozzle inlets to promote flow of liquids to the nozzle inlets.

The locations of the nozzles 9 are selected having regard to the locations of the channels 21 in the base 13 of the tray body 7 so that the nozzles 9 extend into the channels 21 when the tray 3 is assembled.

The nozzles 9 and the inlet sections of the channels 21 in the tray base 13 are selected so that there is a tight fit of the nozzles 9 in the channel inlet sections. The tight fit forms a seal between outer walls of the nozzles 9 and inner walls of the channel inlet sections. The seal helps to make it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber. This point is illustrated in Figure 2 in which the tray 3 is located on its side — as may easily be the case when the tray 3 containing packaged meat has been purchased and transported by the purchaser from a point of sale to a home. The squiggle lines in the Figure illustrate the liquids in the channels 21. It is evident from the Figure that the seal between the nozzles 9 and the inlet sections of the channels 21 prevents liquid flow from the channels 21 into the food storage chamber.

Therefore, the liquids are trapped in the channels 21.

The nozzles 9 extend at least 40%, typically at least 50%, typically at least 60%, typically at least 90%, into the depth of the channels 21 in the tray base 13. This feature also helps to make it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber. In particular, when the tray 3 is turned upside down the depth of the liquids in the upturned channels would need to be greater than the distance the nozzles 9 extend into the channels 21 for any of the liquids to flow into the outlets of the nozzles 9 and then into the food storage chamber 41 via the nozzles 9. This point is evident from Figure 3. Figure 3 illustrates the tray 3 in an upside down orientation. The squiggle lines in the Figure illustrate the liquids in the channels 21. The upper level of the liquids in the channels 21 in this instance is below the outlets of the nozzles 9 and, therefore, the liquids cannot flow into the nozzles 9 from the upturned channels 21 into the food storage chamber 41. Therefore, the liquids are trapped in the channels 21.

It can be appreciated from the above description in relation to Figures 2 and 3 that the structure of the tray 3 makes it difficult for liquids to flow from the liquid storage chamber 43 back into the food storage chamber 41.

It can also be appreciated that the drainage plate 5 makes it possible to position the meat or other food products in the tray 3 closer to the top of the tray 3. This improves the visual presentation of the packaged food product, while maintaining the same level of C0₂ to the meat when the meat is packaged as a modified atmosphere packaged meat product.

Embodiment shown in Figures 6 to 18

The same reference numerals are used in Figures 6 to 18 to describe the same structural features described by the reference numerals in Figures 1 to 5.

With reference to Figures 6 to 18, the embodiment of the tray 3 shown in the Figures includes the above- described tray body 7 and drainage plate 5.

The drainage plate 5 is positioned in the tray body 7 when the tray 3 is assembled and divides the tray 3 into the above-described food storage chamber 41 above the drainage plate 5 and liquid drainage chamber 43 below the drainage plate 5.

The tray body 7 shown in the Figures is open at the top and includes a base 13, a side wall 15 extending from the base 13, and an outwardly extending rim 17 that extends around the perimeter of the side wall 15. The body 7 is rectangular in top plan view with a pair of opposed longer sides and a pair of opposed longer ends and has rounded corners .

The base 13 includes a platform section 19 in the form of a plurality of parallel elongate flat, narrow lands that support the drainage plate 5. The drainage plate 5 may simply rest on the platform section 19.

Alternatively, the drainage plate 5 may be welded, i.e. heat formed, onto the drainage plate 5.

The base 13 also includes a plurality of chambers in the form of channels 21 in this embodiment that define the liquid storage chamber section 43 of the base. As is the case with the embodiment shown in Figures 1 to 5, the channels 21 are adapted to hold liquid that leaks from meat in the food storage chamber. The channels 21 are below the level of the support platform section 19, i.e. the plurality of lands, of the base 13 when the tray is in an assembled and upright position. The channels 21 are parallel to each other and extend across the base 13 from one longer side to the opposite longer side of the tray body 7. The channels 21 are spaced apart along the length of the tray body 7 from one end to the opposed end and are uniformly spaced-apart but could be spaced-apart as required in any situation.

The drainage plate 5 includes a plate 23 and a plurality of drainage nozzles 9 extending from the plate 23 into the liquid drainage chamber 43. The nozzles 9 are formed so that the nozzle inlets in the plate 23 have larger transverse cross-sectional areas than the nozzle outlets .

The locations of the nozzles 9 are selected having regard to the locations of the channels 21 in the base 13 of the tray body 7 so that the nozzles 9 extend into the channels 21 when the tray 3 is assembled, with one nozzle 9 extending into each channel 23. The arrangement is such that, in use, the nozzles 9 allow liquid that leaks from the meat in the food storage chamber 41 to flow into the channels 21 that define the liquid drainage chamber 43.

Figure 6 shows a part of an assembled tray 3 in an upright position with a volume of liquid (shown by the shaded areas) in the channels 21 that form the liquid drainage chamber 43, with the liquid having flowed into the chamber 43 via the nozzles 9 from the food storage chamber 41. When the tray 3 is turned onto its side or upside down as shown in Figures 7 and 8 , respectively , the liquid flows within the channels 21 to the positions shown in shades outline in the Figures. It can be appreciated form Figures 7 and 8 that the nozzles 9 and the plate 23 of the drainage plate 5 prevent the liquids flowing back into the food storage chamber 41. Therefore, the liquids are trapped in the channels 21. It can be appreciated from the above description that the structure of the tray 3 moves liquids that leak from meat in the food storage chamber 41 of the tray 3 away from the meat into a separate liquid drainage chamber 43 so that the overall visual appearance of the packaged product in the food storage chamber 43 remains at a high level .

Embodiment shown in Figures 19 and 20 The same reference numerals are used in Figures 19 and 20 to describe the same structural features described by the reference numerals in Figures 1 to 5.

With reference to Figures 19 and 20, the embodiment of the tray 3 shown in the Figures includes the above- described tray body 7 and drainage plate 5.

The tray body 7 shown in Figures 19 and 20 is open at the top and includes a flat base 13, a side wall 15 extending from the base 13 , and an outwardly extending rim 17 that extends around the perimeter of the side wall 15.

Whilst not evident from Figures 19 and 20, the body 7 is rectangular in top plan view with a pair of opposed longer sides and a pair of opposed longer ends and has rounded corners .

The side wall 15 of the tray body 7 is formed to retain the drainage plate 5 in position with respect to the tray body 7. With this arrangement the drainage plate 5 is clear of the base 13 of the tray body 7.

Specifically, in the embodiment shown in Figures 19 and 20, the side wall 15 of the tray body 7 includes an outwardly extending recess 29 at a required height of the side wall 15 that receives and supports an outer edge of the drainage plate 5 and positions the drainage plate 5 within the tray body 7. The recess 29 extends completely around the perimeter of the side wall 15 at the required height. The recess 29 is formed so that there is a snap- fit of the drainage plate 5 in the recess 29.

It can readily be appreciated that there other structural options for the side wall 15 for retaining the drainage plate 5 within the tray body 7.

The drainage plate 5 includes a plate 23 which has an inwardly turned perimeter edge 31 and a plurality of drainage nozzles 9 extending from the plate 23 with nozzle inlets formed in the plate 23.

The inwardly turned perimeter edge 31 is formed to cooperate with the recess 29 in the wall 15 of the tray body 7 to snap-fit the drainage plate 5 in the recess 29.

The nozzles 9 are centrally positioned between the opposed longer sides of the tray body 7 and are spaced apart in a straight line between the opposed ends of the tray body 7. The drainage plate 5 is formed with inclined wall sections that channel liquid flow to the nozzle inlets.

The nozzles 9 in the drainage plate 5 are formed to make it difficult for liquid to flow back into the food storage chamber 41 from the liquid drainage chamber 43.

Specifically, the nozzles 9 have frusto-conical walls 33 that extend downwardly and inwardly from nozzle inlets in the drainage plate 5 so that the nozzle inlets have larger transverse cross-sectional areas than the nozzle outlets .

In addition, the nozzle outlets are defined by inwardly and upwardly extending nozzle walls 35.

The upwardly directed ends of the nozzle walls 35 are formed to pierce larger-size droplets 27 of liquids flowing through the nozzles 9 from the food storage chamber and break up the droplets into smaller-size droplets 39 that flow into the liquid storage chamber 43. This is illustrated in Figure 19. The Figure shows a large liquid droplet 27 in a nozzle inlet. The Figure shows that the upwardly directed ends of the nozzle walls 35 penetrate the liquid drop and disrupt the droplet surface tension and produces smaller-size droplets 39 that can readily pass through the narrower diameter nozzle outlet into the liquid storage chamber 43. In use, typically, larger-size droplets 69 form in the liquid storage chamber .

The inwardly and upwardly extending nozzle walls 35 at the nozzle outlets are formed with smooth outer surfaces that do not break larger-size droplets 69 in the liquid storage chamber 43 when the tray 3 is upturned, and therefore prevents liquid flow from the liquid storage chamber back 43 into the food storage chamber 41. This is illustrated in Figure 20.

It can be appreciated that the structure of the tray

3 moves liquids that leak from meat in the tray 3 into a separate liquid drainage chamber 43 so that the overall visual appearance of the packaged product in the food storage chamber 41 remains at a high level.

It can also be appreciated that the structure of the tray 3 makes it difficult for liquids to flow from the liquid storage chamber 43 back into the food storage chamber 41.

Method of manufacturing drainage plates — Figures 21-26

The drainage plates 5 of the embodiments shown in Figures 1 to 5, Figures 6 to 18 and Figures 19 and 20, respectively, each have nozzles 9. One embodiment of a method of manufacturing the drainage plates 5 of the embodiments is illustrated in diagrammatic form in Figures 21-26 and involves

thermoforming the drainage plates 5 in the steps described below .

It is noted that the Figures illustrate thermoforming one nozzle 9 as shown in Figures 6 to 18 and another nozzle 9 as shown in Figures 19 and 20. Step 1 - Figure 21

A sheet 51 of a suitable polymeric material is heated to a thermoforming temperature and positioned across a mould 53 as shown in Figure 21 and then clamped by downwardly acting clamping knifes 55 at the perimeter of the mould 53. The mould 53 defines a mould cavity 71 and includes a series of air vents 59 for air flow from the mould cavity 71 during the moulding process. The mould cavity 71 is closed when the sheet 51 is positioned as shown in Figure 21.

Step 2 - Figure 22

Compressed air indicated by the reference numeral 57 is supplied downwardly against an upper surface of the sheet 51 of heated polymeric material and forces the sheet 51 downwardly into the mould cavity 71 against the upper wall of the mould 53, thereby causing the flat sheet 51 to deform to conform to the profile of the upper wall 57 of the mould 53. The profile of the upper wall 57 of the mould 53 is shaped to include a nozzle-shaped profile and forms the sheet into a nozzle 9 with a closed end 73. The upper wall 57 of the mould 53 is also shaped to include an under-cut 61 around the perimeter of the mould 53. The under-cut forms the inwardly turned perimeter edge 31 in the moulded drainage plates 5 (see Figure 19) that facilitates locking the drainage plates 5 into engagement with the tray bodies 9 when assembling the trays 3. The air vents 59 allow air within the mould cavity 71 to escape from the mould cavity 71 as the sheet 51 is forced into the mould cavity 71. The mould 53 acts as a heat sink that cools the polymeric material so that the sheet 51 remains in the moulded profile when the moulding steps are completed.

Step 3 - Figure 23

The clamping knives 55 are actuated to cut the sheet 51 and separate the partly-moulded drainage plate 5 from the sheet 51.

Step 4a — Figure 24 — nozzle 9 of Figures 6 to 18 In order to form the "long" nozzle 9 of the

embodiment of Figures 6 to 18 , a punch 65 is moved downwardly into the mould cavity 71 and punches out the polymeric material at the end 73 of the nozzle 9.

Step 4b - Figures 25/26 - nozzle 9 of Figures 19/20 In order to form the "short" nozzle 9 of the

embodiment of Figures 19/20, a hollow die 67 is moved downwardly into the mould 53 against an inner surface of the closed end 73 of the nozzle 9. A punch 69 with a pointed end is moved upwardly against an outer wall of the end of the nozzle 9 between the wall of the die 67 and pierces the centre of the end and forces the end to fold inwardly and upwardly to form the nozzle walls 35 shown in Figures 19/20.

It will be appreciated that the order of some of the above method steps may be changed without departing from the spirit of the invention, and all such permutations of steps, inclusion of additional steps and exclusion of mentioned steps, are intended to fall within the scope of the present disclosure either explicitly or implicitly.

In more general terms, it will be understood that modifications may be made to the tray 3 shown in the Figures without departing from the spirit and scope of the invention . By way of example, the invention is not confined to the specific shape and dimensions of the tray 3, including the drainage plate 5 and the tray body 7 , shown in the Figures .

By way of further example, the invention is not confined to the method of thermoforming the drainage plate 5 shown in Figures 21-26.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Claims

1. A tray for storing a food product that includes (a) a main tray body for storing the food product, such as uncooked meat product, and (b) a drainage plate dividing the tray body into a food storage chamber for storing the food product above the plate and a liquid drainage chamber below the plate, with the drainage plate having a

2. The tray defined in claim 1 wherein the tray body and the drainage plate are formed as separate components of the tray and, in use, are assembled together to form the tray .

3. The tray defined in claim 1 or claim 2 wherein the tray body includes a base and a side wall extending from the base and forming an open-topped tray.

4. The tray defined in claim 3 wherein the tray base forms a platform that supports the drainage plate.

5. The tray defined in claim 4 wherein the tray base includes a plurality of chambers, for example in the form of channels, that define the food storage chamber and are adapted to hold liquid that leaks from the food product.

6. The tray defined in claim 5 wherein the chambers are below the level of the support platform defined by the tray base when the tray is in an upright position.

7. The tray defined in claim 5 or claim 6 wherein the chambers have narrower inlets and wider channel sections, with the narrower inlets making it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber .

8. The tray defined in any one of claims 5 to 7 wherein the drainage plate is supported by the support platform of the tray base and the nozzles extend into the chambers in the tray base.

9. The tray defined in claim 8 wherein the nozzles and the inlets of the chambers are formed so that there is a tight fit of the nozzles in the channel inlets.

10. The tray defined in claim 9 wherein the tight fit forms a seal between outer walls of the nozzles and inner walls of the chamber inlets that makes it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber.

11. The tray defined in any one of claims 5 to 10 wherein the nozzles extend at least 40% into the depth of the channels so that it is difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber when the tray is on its side or turned upside down.

12. The tray defined in any one of claims 5 to 11 wherein the nozzles are formed, for example by being tapered along the length of the nozzles, so that the inlets having larger transverse cross-sectional areas than the outlets.

13. The tray defined in any one of claims 4 to 12 wherein an upper surface of the drainage plate includes a

plurality of channels extending from the nozzle inlets for collecting liquids and allowing the liquids to flow to the nozzle inlets.

14. The tray defined in claim 3 wherein the side wall of the tray body is formed to retain the drainage plate in position with respect to the tray body, whereby the drainage plate is clear of the base of the tray body.

15. The tray defined in claim 14 wherein the side wall of the tray body includes an outwardly extending recess at a required height of the side wall or another outwardly or an inwardly extending formation at the required height that receives and supports an outer edge of the drainage plate and positions the drainage plate within the tray body.

16. The tray defined in claim 15 wherein the recess extends completely or partly around the perimeter of the side wall at the required height.

17. The tray defined in claim 15 or claim 16 wherein the recess or the other formation is formed so that there is a snap-fit of the drainage plate in the recess or the other formation .

18. The tray defined in any one of claims 14 to 17 wherein the nozzles in the drainage plate are formed to make it difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber.

19. The tray defined in claim 18 wherein the nozzles extend at least 40% into the depth of the channels so that it is difficult for liquid to flow back into the food storage chamber from the liquid drainage chamber when the tray is on its side or turned upside down.

20. The tray defined in claim 18 or claim 19 wherein the nozzles are formed, for example by having frusto-conical walls that extend from the drainage plate, so that the nozzle inlets have larger transverse cross-sectional areas than the nozzle outlets.

21. The tray defined in claim 20 wherein the nozzle outlets are defined by inwardly and upwardly extending nozzle walls.

22. The tray defined in claim 21 wherein the upwardly directed ends of the nozzle walls are formed to pierce larger-size droplets of liquids flowing through the nozzles from the food storage chamber and break up the droplets into smaller-size droplets that flow into the liquid storage chamber .

23. The tray defined in claim 21 or claim 22 wherein the inwardly and upwardly extending nozzle walls at the nozzle outlets are formed with smooth outer surfaces that do not break larger-size droplets in the liquid storage chamber when the tray is upturned, and therefore prevents liquid flow from the liquid storage chamber back into the food storage chamber .

24. The tray defined in any one of claims 14 to 23 wherein the drainage plate is formed with inclined wall sections that channel liquid flow to the nozzle inlets.

25. A packaged food product that includes the tray defined in any one of the preceding claims, a food product in the food storage chamber of the tray, and plastics film closing the open-top of the tray.

26. The drainage plate defined in any one of claims 1 to 24.

27. The tray body defined in any one of claims 1 to 24.

28. A method of manufacturing the drainage plate defined in claim 26 includes (a) thermoforming a sheet of

polymeric material into a mould that includes a plurality of cavities that define the nozzles and forming nozzles having closed ends and (b) punching or otherwise forming open ends of the nozzles.