WO2022008126A1

WO2022008126A1 - Methods and apparatus for packaging

Info

Publication number: WO2022008126A1
Application number: PCT/EP2021/062949
Authority: WO
Inventors: John William FARLEY
Original assignee: I BOXIT Limited
Priority date: 2020-07-06
Filing date: 2021-05-17
Publication date: 2022-01-13
Also published as: GB2596806A; GB202010325D0

Abstract

Method and apparatus for packaging and transporting temperature-sensitive products, such as fish and other foods, in which cardboard boxes and ice-packs are used to hold the material. Methods and apparatus using a box within a box, having insulation or ice packs between the two boxes are also described, as is an external surrounding frame, or sleeve, to give strength to the cardboard box and provide locating lugs to secure boxes together for transport.

Description

METHODS AND APPARATUS FOR PACKAGING

Field of the Invention

The invention relates to methods and apparatus for transporting temperature-sensitive goods in a cool chain. The methods and apparatus are particularly applicable to the shipping of fresh produce such as fish, meat and cut flowers, and also medical supplies such as temperature-sensitive medicaments, blood and organs.

Background and Prior Art

It is often required to transport temperature-sensitive goods as part of a distribution chain to preserve their physical, chemical and microbiological integrity. This requirement extends across many fields of industry, including consumable produce, cut flowers, and medical supplies. It is a particular requirement in the food industry, for example in the transport of fresh fish (e.g. salmon) from the point of processing after catching to overseas markets and consumers. The present invention will be described in relation to such shipping of fresh fish, but it will be appreciated that the invention can be applied equally to other such temperature- sensitive goods.

Figure 1 illustrates a typical arrangement for shipping fresh fish from a production facility to a remote customer. A rigid box 1 with a lid 2 is typically used (shown in cross-section). The box 1 and lid 2 are made from expanded polystyrene, having a wall thickness of about 25mm. Fresh fish 3 are placed into the box, and an amount of crushed ice 4 added on top of the fish. The lid 2 is then placed on the box 1, and secured there with an encircling band (not illustrated).

One of the difficulties with this arrangement is that the empty boxes and lids are very bulky to store, even though they are lightweight. This increases the costs of shipping the empty boxes to the production facility, and needs the provision of storage space accommodate the supply of boxes. Once shipped out to a customer, the boxes and lids become a significant waste problem. The boxes, being made of expanded polystyrene which has inherent cracks and crevices in its surface, are very difficult, if not impossible, to clean adequately for re-use.

Even if such cleaning were possible, the logistics and cost of shipping them back to the beginning of the cold chain from multiple locations means that they are usually discarded. As the boxes are not biodegradable, this leads to an accumulation of plastic rubbish in landfill, or worse still, in the environment. Furthermore, the addition of ice on top of the product tends to be somewhat haphazard in the packaging environment. Often just a scoop or two of ice are added to the fish, with little consistency in the quantity added. Also, ice is usually not added below the fish to be transported, leading to unevenness in cooling. In addition, the ice will melt during transit leading to the product sitting in a pool of water in the box. This can create an environment where the growth of spoilage or pathogenic microorganisms is possible, leading to decreased shelf life or a risk of food-bome infection.

It is among the objects of the present invention to provide a solution to these and other problems.

Summary of the Invention

Accordingly, the invention provides a method of packaging a temperate-sensitive product comprising the steps of: (a) providing a box constructed from card; (b) providing a first ice pack; (c) placing said first ice pack in the base of the box; (d) placing a product on said first ice pack; (e) providing a second ice pack; (f) optionally positioning said box in a second, larger box constructed from card; (g) placing the second ice pack over the product; (h) providing a lid for said box or said second larger box; and (i) sealing said box or second larger box with the lid.

Preferably, said card is corrugated cardboard. Preferably also, said lid is made from card, and preferably corrugated cardboard.

In any aspect of the invention, it is also preferred that providing said box and/or said second larger box comprises forming the box and/or second larger box from sheet material directly before being used. Forming the boxes “on site” in this way reduces the costs associated with the transport of bulky, empty boxes.

Where a card lid is to be used, it is also preferred that the step of providing said lid comprises forming the lid from sheet material directly before being used.

In any such method, in which said second larger box is used, it is further preferred that: (a) the side walls of the box and second larger box are held in a spaced-apart configuration relative to each other; and (b) the gap between the side walls of the boxes is provided with either: (i) an ice pack; or (ii) an insulating material. In any described method of packaging a temperature-sensitive product it is preferred that at least one of said ice packs comprises ice contained within a water-resistant envelope, and more preferably at least one of said ice packs comprises frozen water immobilised in a gel. Where such an ice pack is used, it is favourable that providing said first or second ice pack comprises: (a) hydrating a hydrogel contained within an envelope; and (b) freezing said enveloped hydrated hydrogel directly before being used. In this way, transport of water within an ice pack is avoided.

In any described method of packaging a temperature-sensitive product it is preferred that at least one of said ice packs comprises a frozen ice-card composite. Preferably, said ice-card composite comprises an ice pack frozen onto the surface of sheet card. More preferably also, providing at least one of said ice packs comprises the step of forming said ice-card composite directly before being used.

In any described method of packaging a temperature-sensitive product it is preferred that said second ice pack is suspended above the product. This reduces the chance of mechanical damage to the product.

Also in any described such method, it is preferred that the step of sealing the box with a lid comprises gluing the lid to the box.

Also in any described method of packaging a temperature-sensitive product, it is preferred that at least a portion of the interior surface of said box, or the interior surface of the lid, or card comprised in an ice-card composite is provided with an anti -microbial coating. Such coatings are known in the art, such as triclosan-containing coatings, coatings containing silver or copper and their salts and , most preferably, biodegradable antimicrobial agents such as chitosan and chitin.

Also in any described method of packaging a temperature-sensitive product, it is preferred that the interior space within the box is not rectangular and the ice pack has a perimeter profile that reflects the interior shape of the box.

Also in any described method of packaging a temperature-sensitive product, it is preferred that said method comprises the further step of enclosing said box or said second larger box within a frame. Preferably, said frame comprises: (a) a base portion; (b) a top portion; and (c) two side portions extending between corresponding opposite edges of said base and top portions; and wherein said portions are releasably attachable to each other. Preferably, said side portions are of two-part construction, each having an upper and lower part, said parts being releasably-attachable to each other by a hinging connector.

Also in any described method of packaging a temperature-sensitive product, it is preferred that said method comprises the further step of enclosing said box or said second larger box within a frame. Preferably, said frame comprises: (a) a base portion; and (b) a top portion; wherein the base portion and the top portion are held in place by a pin and screw configuration.

Preferably also, said frame is formed of plastics.

Where a frame is used, it is preferred that the upper face of the top portion of said frame and the bottom face of the base portion of said frame are provided with corresponding cooperating indents and detents such that, when two frames are stacked on top of each other, the cooperation of indents and detents resists relative horizontal displacement of the frames.

More preferably, the arrangement of indents and detents is such that cooperation between indents and detents is effective if one frame is turned through 90° about a vertical axis, thereby allowing box-containing frames to be stacked in an overlapping configuration.

Also in any described method of packaging a temperature-sensitive product, it is preferred that said temperature-sensitive product is fish.

Also included within the scope of the invention is an ice-card composite for use in a method described herein comprising an ice pack frozen to the surface of sheet card.

Also included within the scope of the invention is a frame for use in a method according as described herein.

Brief Description of the Figures

The invention will be described with reference to the accompanying drawings in which:

Figure 1 illustrates, in cross-sectional view, packaged fish produced by a prior art method;

Figure 2A illustrates, in cross-sectional view, packaged fish produced by a method of the invention; Figures 2B and 2B illustrates details of attachment of a lid to a box, and an ice-card composite, respectively;

Figures 3 and 4 illustrate, in cross-sectional view, packaged fish produced by a method of the invention;

Figures 5 and 6 illustrate in perspective view, comer features of a box used as part of a method of the invention;

Figure 7 illustrates, in plan view, a net for forming a lid of a box;

Figure 8 illustrates, in perspective view, a lid of a box;

Figure 9 illustrates, in plan view, a net for forming a box;

Figure 10 illustrates, in plan view, a cardboard support for an ice-card composite; Figures 11-14 illustrate, in flowchart form, methods for forming a box, a lid, an ice support and a frozen ice-card composite respectively;

Figure 15 illustrates, in flow chart form, a method for packaging a temperature sensitive product;

Figure 16A illustrates, in plan view a box and ice pack;

Figure 16B illustrates, in cross-sectional or elevation view the ice pack illustrated in Figure 16A;

Figure 17A illustrates, in plan view a box and ice pack; and

Figure 17B illustrates, in cross-sectional or elevation view the ice pack illustrated in Figure 17A;

Figure 18 illustrates, in plan view, a box within a second, larger box and insulation material;

Figure 19 illustrates, in elevation view, an ice-card composite;

Figure 20 illustrates, in perspective view, a comer feature of the box of Figure 18; Figure 21 illustrates, in plan view, a lid for the box of Figure 18;

Figure 22 illustrates a cross-section view of a double-box arrangement used in the invention;

Figures 23 to 28 illustrate, in elevation view the use of a frame around a box, as part of the invention;

Figures 29 to 42 illustrate in plan, cross-section, and perspective views, elements of a frame for use in the invention;

Figures 43 and 44 illustrate in exploded perspective and perspective view respectively, a frame for use in the invention; and

Figures 45-46 illustrate, in plan view, laters of an arrangement of frames for use in the invention.

Figure 47 illustrates in exploded perspective view the use of a frame around a box, as part of the invention. Figures 2B and 2C illustrate details of attachment of a lid to a box, and an ice-card composite, respectively;

Figures 3 and 4 illustrate, in cross-sectional view, packaged fish produced by a method of the invention; Figures 5 and 6 illustrate in perspective view, comer features of a box used as part of a method of the invention;

Figure 7 illustrates, in plan view, a net for forming a lid of a box;

Figure 8 illustrates, in perspective view, a lid of a box;

Figure 9 illustrates, in plan view, a net for forming a box; Figure 10 illustrates, in plan view, a cardboard support for an ice-card composite;

Figures 11-14 illustrate, in flowchart form, methods for forming a box, a lid, an ice support and a frozen ice-card composite respectively;

Figure 15 illustrates, in flow chart form, a method for packaging a temperature sensitive product; Figure 16A illustrates, in plan view a box and ice pack;

Figure 17A illustrates, in plan view a box and ice pack; and

Figure 19 illustrates, in elevation view, an ice-card composite;

Figures 23 to 28 illustrate, in elevation view the use of a frame around a box, as part of the invention; Figures 29 to 42 illustrate in plan, cross-section, and perspective views, elements of a frame for use in the invention;

Figure 47 illustrates in exploded perspective view the use of a frame around a box, as part of the invention

5 Figure 48 illustrates a cross-section view elements of a frame for use in the invention.

Description of Preferred Embodiments

Figure 2A illustrates, in cross-sectional view, a temperature-sensitive product packaged according to a method of the invention. The product, illustrated in this example by fresh fish 3, is contained within a box 5 formed of corrugated card. The corrugations are not illustrated, for clarity, but in preferred embodiments the card comprises a double wall corrugated card having inner, centre and outer liners of Kraft paper; sandwiched between these liners are layers of corrugated paper, referred to as “flutes”. The box is provided with a lid 6, again formed of corrugated card.

Within the box 5 is a first ice-card composite 7 comprising an ice pack 8 frozen to a sheet of card 9. Figure 2B illustrates a section of the ice-card composite in more detail. The ice-card composite 7 is illustrated in a spaced-apart relationship with the bottom of the box 5 merely for clarity. In reality, the card portion 9 of the composite 7 will rest against the interior base of the box 5.

The ice pack 8 comprises frozen water immobilised by a hydrogel 10 contained within an envelope 11. The ice pack is secured to the card 9 by wetting the card and/or the outside of the ice pack, and freezing the two together causing a layer of ice 12 to secure the two elements together. This composite can be formed in a number of ways: e.g. a hydrated unfrozen ice-pack could be placed on a sheet of card with a layer of water between them, and then the assembly frozen to secure the ice pack to the card. Alternatively, the ice pack could be frozen and then placed on a card having a wet surface. In this way, the ice pack itself can freeze the water on the surface of the card thereby causing the two to stick together.

Returning now to Figure 2A, a second ice-card composite 13 is placed on top of the fish. This has essentially the same structure as the first ice-card composite 7 as described above.

Once the fish 3 and ice-card composites 7, 13 have been placed in the box 5, the lid 6 is added, and secured to the box. This is preferably achieved by use of an adhesive 14, and preferably a thermoplastic adhesive, as illustrated in Figure 2B.

The use of the first ice-card composite in the bottom of the box has the advantage of providing additional strength to the box. It is particularly useful to be able to provide additional strengthening in this region where water might accumulate, as the strength of the

6 overall package can thereby be increased whilst allowing a relatively thinner or weaker card to be used on the sides and lid of the box where moisture resistance is less crucial.

Additionally, forming the ice-card composite by freezing an ice pack onto sheet card means that, at the end of use when the ice pack thaws out, the card will automatically detach from the ice pack, allowing each to be further processed (e.g. for recycling of the card) without residue from any other fixing means such as adhesive or staples being present.

Figure 3 illustrates a further example of product packaged according to a method of the invention. Like elements already described are numbered accordingly. This arrangement is the same as that described in Figure 2 other than that the second ice pack 8 does not form part of an ice-card composite. In this way, if the ice pack is formed of individual pockets of ice, the pack can be allowed to deform when it is placed directly on the fish 3, or other product to be packaged.

Figure 4 illustrates a further example of product packaged according to a method of the invention. Like elements already described are numbered accordingly. This arrangement is the same as that described in Figure 2 other than that the second ice pack 8 is suspended above the fish 3 by resting the card portion 9 of the second ice-card composite on internal suspension points 15 located towards the top of the interior of the box 5. In this way, if the product is e.g. fragile, it can still be kept cool without having to support the weight of the second ice pack 8.

Figure 5 illustrates, in perspective view, a portion of the upper comer of a corrugated cardboard box 5 suitable for use in a method of the invention. The card for the box is cut into a net (i.e. an arrangement of edge-joined plane polygons that may be folded along the edges to form a three-dimensional structure, as described below) and perforated or fold lines added to allow the net to be folded into the box configuration. The region of the net forming one side 16 of the box is extended to allow the additional card to be folded to form a triangular configuration 17 at in internal comer of the box. The other side 18 of the box can then be glued to the folded card in order to make a box 5 having reinforced comers.

Figure 6 illustrates, in perspective view, an embodiment of a box of the invention. The form of this box is as described above and illustrated in Figure 5. In this embodiment, however, a portion of the net forming the triangular portion 17 has been removed, thereby providing a suspension point in the form of a ledge 19 onto which the card portion of an ice-card composite may be suspended, as illustrated in Figure 4.

7 Figure 7 illustrates, in plan view, a net 20 for forming a lid 6 for sealing the top of a box used in the method of the invention. The shape of the net 20 includes a top region 21, and four side regions 22, separated by fold lines 23. The net 20 may be folded to create a lid, as illustrated, in perspective view, in Figure 8.

Figure 9 illustrates, in plan view, a net 24 for forming a box for use in a method of the invention. The shape of the net includes a base region 25, four side regions 26, and extensions 27 that can be folded for form triangular configurations 17 to reinforce the sides of the box 5 when assembled. Fold lines 23 are illustrated by dashed lines. The extended regions 27 illustrated at the top of the net 24 are of the shape to form a box comer as illustrated in Figure 5. The extended regions 27' illustrated at the bottom of the net 24 are of a shape to form the suspension point in the form of a ledge 19 as illustrated in Figure 6.

Figure 10 illustrates, in plan view, a sheet of cut cardboard 9 to form part of a card-ice composite of the invention. The sheet is rectangular with the comers 28 cut away to allow the card to fit within a box 5 having reinforced comers such as those illustrated in Figures 5 and 6. Where an ice-card composite is to be suspended within the box 5, the card would of course merely be rectangular.

Figure 11 illustrates, in flowchart form, an embodiment of a method for forming an empty box as part of a method of the invention. Cormgated card 29, preferably in the form of a roll, is provided. This is then cut 30 into a net 24 suitable for forming a box, and appropriate fold lines added. The net 24 is then folded 31 to form the box configuration, and the box fastened 32 into this configuration, e.g. by the use of staples or, preferably by use of a glue, such as a thermoplastic glue, to form the box 5.

The first method step 30, where the net 24 for the box is produced, could be carried out remotely from the product packing location, with the nets 24 being transported to the packing location ready for folding into boxes. Alternatively, the net-forming equipment (known generally in the art) could also be provided at the product packing location. In any method, the box 5 is preferably formed from the net 24 directly before being used, in order to save the space that would be otherwise required for storing empty boxes. By “directly”, we mean preferably as part of the packing operation of the product in a timescale such that storage of empty boxes is not required.

8 Figure 12 illustrates, in flowchart form, an embodiment of a method for forming a lid 6 as part of a method of the invention. Corrugated card 29, preferably in the form of a roll, is provided. This is then cut 33 into a net 20 suitable for forming a lid 6, and appropriate fold lines added. The net 20 is then folded 34 to form the lid configuration, as illustrated in Figure 8. The step of forming 33 the net 20 could be carried out either remotely from the packing location, or as part of the packing process in a way analogous to that described above for the production of empty boxes.

Figure 13 illustrates, in flowchart form, an embodiment of a method for forming a card ice support 9 for use as part of an ice-card composite. Corrugated card 29, preferably in the form of a roll, is provided. This is then cut 35 into shape, either rectangular, or as illustrated in Figure 10. Again, the cutting process could be carried out either remote from, or as part of, the packing process.

Figure 14 illustrates, in flowchart form, a method of forming a frozen ice-card composite 7,

13 of the invention for use in a method of the invention. Dehydrated ice pouches 36 are provided, comprising one or more envelopes containing a dry hydrogel. Suitable such pouches are available under the Registered Trademark ICEPACK XL® from Inter Fresh Concepts BV, The Netherlands. The pouches are then rehydrated 37. An appropriately- shaped ice support 9 made from corrugated card is then provided, and the surface of the support 9 dampened with water 38. The rehydrated pouches 26 are then positioned 39 on the dampened ice support 9, and the two are frozen together 40 to form a frozen ice-card composite 7, 13.

In preferred embodiments of the invention, the step of rehydrating the pouches 37 and forming the ice-card composites is carried out in the same location as the packing of the product in order to minimise shipping costs.

Figure 15 illustrates, again in flowchart form, an embodiment of a method of packing temperature-sensitive goods for transport. An empty box 5 as described herein is provided, and a frozen ice-card composite 7 is added 41 to the box such that it sits on the box’s base 25 with the ice pouches facing uppermost. The items for shipping (e.g. fish 3) are added 42 on top of the frozen ice-card composite 7. A second ice-card composite 13 is then added 43 on top of the products. In alternative embodiments, a frozen ice pack 8 on its own might be used instead, as illustrated in Figure 3. A box lid 6 is then used to close 44 the top of the box 5, and the lid is glued 45 to the box 5 to produce the packaged goods 46. Securing the lid 6 to

9 the box 5 with glue provides a sealed box that is essentially tamper-proof, or at least tamper- evident.

In any aspect of the invention, it is preferred that that at least a portion of the interior surface of the box, and/or the lid and/or the ice support 9 is formed of card having an antimicrobial surface to inhibit the growth of microorganisms. The inventor has found that the use of such a coating can significantly increase the shelf life of the packaged products. Such coatings are known in themselves, including silver and copper compounds, organosilanes, and triclosan.

In any aspect of the invention where and ice pack 8 is used, and the interior space within the box 5 is not rectangular, it is particularly preferred that the ice pack 8 has a perimeter profile that reflects the interior shape of the box 5. Figure 16A illustrates, in plan view, a box 5, formed of double-walled corrugated card 29, and having a triangular configuration 17 at each of its comers to provide reinforcement to the box 5. An expanded view of a portion of the wall of the box is also shown. Features already described in previous embodiments are numbered correspondingly. In this instance an ice pack 8 is provided having pockets of frozen hydrogel 10 contained within individual envelopes 11. In order to increase the surface area that is in contact with the ice pack 8, the comers 47 of the ice pack 8 are shaped so as to reflect the shape of the comer features 17 of the box 5.

Figure 16B illustrates a cross-sectional (or elevation) of the ice pack 8 illustrated in Figure 16A.

Figure 17A illustrates, in plan view, a box 5, formed of double-walled corrugated card 29, also having a triangular configuration 17 at each of its comers to provide reinforcement to the box 5. An expanded view of a portion of the wall of the box is also shown. Features already described in previous embodiments are numbered correspondingly. In this case, the ice pack 8 has a single continuous pocket of frozen hydrogel 10 held within an outer envelope 11. Again, the comers 47 of the ice pack 8 are so shaped as to reflect the shape of the comer features 17 of the box 5.

Figure 17B illustrates a cross-sectional (or elevation) of the ice pack 8 illustrated in Figure 17A.

Shaped ice packs 8 as described in Figures 16A and 16B may be used above and below a product to be kept cool, either alone, or as part of an ice pack composite 7, 13. When used as a composite 7, 13, the comers of the card used to make the composite can also be similarly-

10 shaped to fit within the box. Alternatively, the second, upper ice pack composite 13 may be formed with a rectangular card, so it can hang on the ledge 19 formed by cut-away comers 28 of a triangular configuration 17 of the box 5 as illustrated in Figure 6.

Figure 18 illustrates, in plan view, and alternative arrangement for packaging a temperature- sensitive product comprising a box 5 constructed from card positioned within a second, larger box 48 such that the side walls 49 are spaced apart from the corresponding side walls 50 of the second larger box 48 creating a cavity 51 therebetween. Insulation material 52 may be positioned within the cavity 50 to reduce heat ingress into the inner box 5. In preferred embodiments, the insulation material is chosen to be biodegradable to reduce environmental impact of the packaging. Particularly suitable materials include wool, e.g. sheep’s wool, preferably contained within a surrounding envelope to prevent fibre movement, cork, and popped com kernels. Alternatively, or additionally, the cavity can contain ice packs 8 or ice pack composites as described above, and illustrated in plan view in Figure 19.

Figure 20 illustrates, in perspective view, a portion of a comer of the second, larger box 48 of Figure 18. One side 16 of the box is folded into a triangular configuration 17 having an upwardly-facing tab 53. This side 16 of the box is glued (or otherwise attached) to the other side 18 of the box to form the comer. Figure 21 illustrates, in plan view, a lid net 20 for forming a lid for the box of Figure 18 from corrugated card. Fold lines 23 are provided to allow the sides 55 of the lid to be formed. Slots 54 are provided at the comers of the top region 21 of the lid to allow the lid to be positioned on the tabs 53 of the triangular features of the box comer shown in Figure 20.

Figure 22 illustrates a cross section through a box as described in Figure 18, showing the first box 5, the second larger box 48, and the lid 56, which may be secured into position by attaching the sides 55 of the lid to the top portion of the larger box 48. A first ice pack 8 is placed in the bottom of the inside box 5, and adhered there by applying water to the surface of the card, and allowing a layer of ice 12 to form and thereby stick the pack to the card. A second ice pack 8' is similarly adhered to the inside of the lid 56, again with a layer of ice 12. The cavity 51 between the two boxes is provided with insulation 52 (as illustrated) or further ice packs. The product, e.g. fresh fish 3, is located within the first box 5, on top of the ice pack 8.

As before, preferred material for the boxes 5, 48 is corrugated card 29, and preferably such card as described in relation to Figure 17.

11 When multiple boxes (according to any aspect of the invention) are to be transported together, e.g. palletised for transport, a further element, in the form of a frame, or sleeve, may be used to give the stack of boxes more structural strength, and to prevent the boxes slipping relative to each other. Figure 23 illustrates such a frame 57, in cross-sectional view. The frame comprises a base portion 58, a top portion 59, and two side portions 60, releasably attached to each other. A recess is provided in the base portion 58 to allow a box 48 to be held in position within the frame. Features other than the outer box 48 are omitted in Figures 23 - 28, for clarity. The side portions 60 of the frame 57 are sized such that when the frame components 58, 59, 60 are attached together around the box 48, the box is held in position within the frame, and sitting within the bottom recess (not illustrated). As a result, side portions are not required for the frame, but may be provided if desired.

Structural strength can also be provided for a single box to be transported, in the form of a frame, or sleeve. In this case, it may be preferable that the frame comprises a base portion 58 and atop portion 59 but no side portions. The base portion and the top portion may be held together by any suitable means known in the art. Preferably, the base portion and top portion are held in place by a pin and screw configuration.

Figures 47 and 48 illustrate such a frame with no side portions, in perspective view and cross- sectional view, respectively. The frame comprises a base portion 58 and a top portion 59. A recess may be provided in the base portion 58 to allow a box 48 to be held in position within the frame. The top portion 59 and the base portion 58 may be held in place by pins 76 which protrude through the comer sections of the box 48. The top portion 59 and the base portion 58 may comprise pre-cut holes (apertures) in each comer to ensure that the pins seat correctly to protmde through the comer sections of the box 48. Further pins may be included along the edge of the top portion 59 and the base portion 58 as necessary.

In the embodiment exemplified in Figures 47 and 48, the top portion 59 and the base portion 58 are held in place by plastic threaded pins 76 which are the height of the box. The pins 76 protmde through pre-cut holes in the base portion 58 and through the comer sections of box 48. Once the box is filled, in this case, with the inner box 5 and gel ice packs 8 and/or insulation 52, the lid 56 is placed on top of the box 48. The top portion 59 of the frame is then placed on top of the pins 76 (via holes, optionally pre-cut) and is screwed to the pins 76 using screws 77. The pins 76 and screw 77 combination may be as described in W02019/101578. Preferably, the heads of the screws 77 and the bottom of the pins 76 are counter sunk into the top portion 59 and the base portion 58, respectively, thus making the box system flat on both the top and the bottom.

12 Once the box 4 reaches its destination, the screws can be undone, the gel ice packs 8 and/or insulation 52 lifted out and the produce removed. Once that’s done the end user simply needs to drop the gel ice gel packs or insulation back inside the box and loosely do up the screws. The entire box can be returned for recycling and/or re-use.

It is advantageous to use a frame without the side portions because it reduces the components with cracks and crevices and therefore eases cleaning of the frame and reduces the potential for contamination, enabling re-use.

The top portion 59 and the base portion 58 of the frame may have a smooth or anti-skid surface so assist with transportation of the boxes up and down slopes and along surfaces.

Figures 24 and 25 illustrate a cross-section of an alternative frame arrangement. Like elements already described are correspondingly numbered, and will not be described further. In this embodiment, the frame 57 has side portions that are constructed of two parts 60' and 60". These two parts are releasably connectable to each other, shown in this embodiment by a pin 61 and knuckle 62 arrangement. By making the frame portions from a resiliently- deformable plastics, the two parts 60' and 60" of the side portions bay be releasably connected together with the pins 61 deforming the knuckles 62 as the parts are pushed together, or pulled apart. Other such releasable attachment mechanisms will also be apparent to the skilled addressee. In use, and as shown in Figure 24, the box 48 and its contents, may be placed in the recess in the base portion 58 of the frame with just the lower parts 60" of the side portions in place. Providing the two-part construction of the sides 60 of the frame then allows the lid 56 to be secured to the box, e.g. by gluing, before the top portion 59 and the upper side portion 60' are connected, as illustrated in Figure 25.

Figures 26 illustrates a variant of the frame component of the packaging system, in elevation view. Again, like elements already described are correspondingly numbered and not further described needlessly. In this variant, the two parts 60', 60" of the side portions are again releasably attachably to each other, with the upper part 60' of the side portion being releasably attachable to the top portion 59 of the frame 57 and the lower part 60" of the side portion being releasably attachable to the base portion 58 of the frame 57. In this variant, the attachment mechanisms are of the hingeable type, e.g. using pins and knuckles as described above. This allows the frame to be folded flat when not holding a box as illustrated in the

13 dotted and sold line alternatives of the parts 60, thereby allowing it to be returned to the packaging facility in a more cost-effective manner for re-use. After the lid 56 has been secured onto the box 48 (illustrated by the solid and dotted variants) the side parts 60 of the side portions may be joined together to secure the box in the frame.

Figure 27 illustrates a further variant of a frame component of the packaging system, again in elevation view. Again, previously described features are correspondingly numbered and not further described. In this embodiment, a series of cooperating indents 63 and detents 64 is provided on the upper surface of the top portion 59 of the frame 57 and lower surface of the base portion 58. The indents and detents are so sized, shaped and located so as to cooperate with corresponding indents/detents on another like frame to resist the two frames sliding relative to each other during transportation. In the embodiment illustrated, the indents 63 are shown on the base portion 58 and the detents 64 on the top portion 59, but it will be appreciated that they could be either way round or even a combination of either arrangement. Further details of the indent-detents will be described below.

Figure 28 illustrates a particularly preferred variant of a frame component of the packaging system, again in elevation view. Again, previously described features are correspondingly numbered and not further described. In this embodiment, the upper parts 60' of the side portions are connected (preferably releasably) to the lower parts 60" by a hinged connection, such as the pin and knuckle arrangement described above. This allows the upper parts 60' to be swung downwards, as illustrated, with the box 48 in position in the recess of the base portion 58. This allows access to apply glue 65 (such as a hot melt glue) to the outer surface of the upper region of the side wall of the box. The lid net 21 may then be positioned on the box, with tabs 53 from the comer portions of the box engaging the slots 54 in the lid (if provided). The sides 55 of the lid may then be folded down, assisted by fold lines 23and illustrated by arrows 66, and then secured to the glued top edge of the box sides. The top parts 60' of the side portions may then be swung up into the vertical position, as illustrated by the arrows 67. Finally, the top portion 59 of the frame may then be connected to the top of the side portion 60', as illustrated by the arrows 68. As for all of the frame embodiments illustrated, the frame may be secured in its fully-connected configuration if required, e.g. for tamper-evident security, by a surrounding band. This step is not, however, recommended as it introduces an element to the packaging that may be hard to re-use or recycle. Figures 29A-32 illustrate a preferred embodiment of a top portion 59 forming part of a frame 57. Again, previously described features are correspondingly numbered and not further described. Figure 29A shows a plan view of the upper surface of the frame and illustrates one

14 suitable arrangement of detents 64 disposed on the upper surface. Twelve such detents are illustrated, arranged around the edge of the top portion, and equally spaced apart. The centre portion 69 is left open (i.e. the top portion has the form of a rectangular annulus) to reduce weight and material usage. Figure 29B shows a plan view of the underside of the top portion 59 of the frame and illustrates a series of eight hingeable connection elements 70 each comprising a knuckle 62 for receiving a pin from a side portion (not illustrated). Figure 30 shows a cross section of the top portion 59 along the line A — A in Figure 29. The angled regions 71 adjacent the knuckles in the hingeable connection elements 70 assist in locating the pins in the side portions.

Figures 31 and 32 illustrate, in perspective view, the upper and lower surfaces respectively of a top portion 59 of the frame of Figures 28-30. Again, previously described features are correspondingly numbered and not further described.

In an analogous way to Figures 28-32, Figures 33-38 illustrate a preferred embodiment of a base portion 58 forming part of a frame 57. Again, previously described features are correspondingly numbered and not further described. Figure 33 shows a plan view of the lower surface of the frame and illustrates one suitable arrangement of indents 63 disposed on the lower surface. Twelve such indents are illustrated, arranged around the edge of the top portion, and equally spaced apart, and located in correspondent positions as the detents of Figures 28 and 31. The centre portion 72 is left open (i.e. the base portion also has the form of a rectangular annulus) to reduce weight and material usage. Figure 34 shows a plan view of the upper surface of the base portion 58 of the frame and illustrates a series of eight hingeable connection elements 70 each comprising a knuckle 62 for receiving a pin from a side portion (not illustrated). The inner faces of the connection elements 70 define a recess in which a box 48 may be positioned.

Figures 35 and 36 illustrate cross-sections through the base portion 58 of Figure 34 along lines A — A and B — B respectively.

Figures 37 and 38 illustrate, in perspective view, the upper and lower surfaces respectively of abase portion 58 of the frame of Figures 33-34. Again, previously described features are correspondingly numbered and not further described. A finger recess 73 is provided on the lower face of opposing sides of the base portion 58 to enable an operator to more readily pick up a single frame from a stack of frames.

Figures 39-40 illustrate, in perspective view the outside faces of the top 60' and lower parts 60 of a two-part side portion 60 of a frame 57. The figures illustrate the provision of pins 61

15 that interact with the knuckles of the top portion 59 of a frame 57 and the top edge of a lower part 60 of a two-part side portion. It can also be seen that outwardly-extended portions 74 are provided at each end of the side portions 60. These provide that, when two frames are stacked adjacent to each other, side-by-side, there is little or no gap between the adjacent frames. This is of benefit to prevent wind ingress between the frames during transport, which can otherwise cause instability in a stack of frames.

Figures 41-42 illustrate, in perspective view the inside faces of the top 60' and lower parts 60 of a two-part side portion 60 of a frame 57. Again, previously described features are correspondingly numbered and not further described.

Figures 43 and 44 illustrate in exploded and non-exploded perspective view, a frame 57 of a preferred embodiment of the invention to show how the various parts fit together. Again, previously described features are correspondingly numbered and not further described.

Figures 45 and 46 illustrate how the cooperating indents 63 and detents 64 on the top and bottom of the frames can be used to secure the frames together when in transport, e.g. on a pallet. Figure 45 illustrates, in plan view, an arrangement of twelve frames 57 forming a first layer of frames arranged e.g. on a pallet. The positions of the indents/detents 75 is indicated. Some of the frames 57' are oriented in one direction, and other frames 57 are oriented relatively at 90°.

Figure 46 similarly illustrates, in plan view, an arrangement of twelve frames 57 forming a second layer of frames arranged above the first layer of Figure 45. It can be seen that, not only do the indents align with each other, but their arrangement allows for some frames to be turned by 90°, preventing vertical planes of weakness in the stack of frames. Thereby leading to a more stable stacking arrangement.

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Claims

1. A method of packaging a temperate-sensitive product comprising the steps of:

(a) providing a box constructed from card; (b) providing a first ice pack;

(c) placing said first ice pack in the base of the box;

(d) placing a product on said first ice pack;

(e) providing a second ice pack;

(f) optionally positioning said box in a second, larger box constructed from card; (g) placing the second ice pack over the product;

(h) providing a lid for said box or said second larger box; and

(i) sealing said box or second larger box with the lid.

2. A method according to Claim 1 wherein said card is corrugated cardboard.

3. A method according to either Claim 1 or Claim 2 wherein said lid is made from card, and preferably corrugated cardboard.

4. A method according to any preceding claim wherein providing said box and/or said second larger box comprises forming the box and/or second larger box from sheet material directly before being used.

5. A method according to Claim 4 wherein providing said lid comprises forming the lid from sheet material directly before being used.

6. A method according to any preceding claim in which said second larger box is used, and wherein:

(a) the side walls of the box and second larger box are held in a spaced-apart configuration relative to each other; and (b) the gap between the side walls of the boxes is provided with either:

(i) an ice pack; or

(ii) an insulating material.

7. A method according to any preceding claim wherein at least one of said ice packs comprises ice contained within a water-resistant envelope.

8. A method according to any preceding claim wherein at least one of said ice packs comprises frozen water immobilised in a gel.

9. A method according to Claim 7 wherein providing said first or second ice pack comprises:

(a) hydrating a hydrogel contained within an envelope; and

(b) freezing said enveloped hydrated hydrogel directly before being used.

10. A method according to any preceding claim wherein at least one of said ice packs comprises a frozen ice-card composite.

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11. A method according to Claim 10 wherein said ice-card composite comprises an ice pack frozen onto the surface of sheet card.

12. A method according to Claim 11 wherein providing at least one of said ice packs comprises the step of forming said ice-card composite directly before being used.

13. A method according to any preceding claim wherein said second ice pack is suspended above the product.

14. A method according to any preceding claim wherein the step of scaling the box with a lid comprises gluing the lid to the box.

15. A method according to any preceding claim wherein at least a portion of the interior surface of said box, or the interior surface of the lid, or card comprised in an ice-card composite is provided with an anti -microbial coating.

16. A method according to any preceding claim wherein the interior space within the box is not rectangular and the ice pack has a perimeter profile that reflects the interior shape of the box.

17. A method according to any preceding claim comprising the further step of enclosing said box or said second larger box within a frame.

18. A method according to Claim 17 wherein said frame comprises:

(a) abase portion;

(b) a top portion; and (c) two side portions extending between corresponding opposite edges of said base and top portions; and wherein said portions are releasably attachable to each other.

19. A method according to Claim 18 wherein said side portions are of two-part construction, each having an upper and lower part, said parts being releasably-attachable to each other by a hinging connector.

20. A method according to any of Claims 17 to 19 wherein said frame is formed of plastics.

21. A method according to any of Claims 17 to 20 in which the upper face of the top portion of said frame and the bottom face of the base portion of said frame arc provided with corresponding cooperating indents and detents such that, when two frames are stacked on top of each other, the cooperation of indents and detents resists relative horizontal displacement of the frames.

22. A method according to Claim 21 wherein the arrangement of indents and detents is such that cooperation between indents and detents is effective if one frame is turned through 90° about a vertical axis, thereby allowing box-containing frames to be stacked in an overlapping configuration.

23. A method according to any preceding claim wherein said temperature-sensitive product is fish.

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24. An ice-card composite for use in a method according to any of Claims 9 to 16 comprising an ice pack frozen to the surface of sheet card.

25. A frame for use in a method according to any one of Claims 18 to 23.

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