U.S. patent application number 10/916115 was filed with the patent office on 2006-02-16 for packaged food products.
Invention is credited to Anthony SR. Huot, Mark Stenbeck.
Application Number | 20060034979 10/916115 |
Document ID | / |
Family ID | 35800277 |
Filed Date | 2006-02-16 |
United States Patent
Application |
20060034979 |
Kind Code |
A1 |
Stenbeck; Mark ; et
al. |
February 16, 2006 |
Packaged food products
Abstract
The present invention is a packaged food product for placement
in a refrigerated section of a retail store for sale to a retail
customer and adapted to have a specific shelf life when generally
maintained at a temperature between approximately 38.degree. F. and
approximately 48.degree. F. In one embodiment, the product includes
a container, an amount of cheese, an amount of meat, and an
atmosphere. The container includes a sealed interior volume at
least partially defined by a barrier with an oxygen permeability of
less than 0.5 cubic centimeters of oxygen per 100 square inches of
barrier area per 24 hours at 73.degree. F., zero percent relative
humidity and standard atmospheric pressure. The amount of cheese is
located within the sealed volume. The cheese is a natural cheese
(i.e., not a processed cheese) and is not frozen prior to being
sold to the customer. The amount of meat is located within the
sealed volume and is in physical contact with the amount of cheese.
The atmosphere is located within the sealed volume and has an
oxygen content of less than 0.5 percent.
Inventors: |
Stenbeck; Mark;
(Bloomington, MN) ; Huot; Anthony SR.; (Wauzeka,
WI) |
Correspondence
Address: |
S. Wade Johnson, Esq.;DORSEY & WHITNEY LLP
Intellectual Property Department
50 South Sixth Street, Suite 1500
Minneapolis
MN
55402-1498
US
|
Family ID: |
35800277 |
Appl. No.: |
10/916115 |
Filed: |
August 11, 2004 |
Current U.S.
Class: |
426/129 |
Current CPC
Class: |
B65D 81/2069 20130101;
A23C 19/105 20130101; B65B 25/001 20130101; B65D 51/246 20130101;
A23B 4/16 20130101 |
Class at
Publication: |
426/129 |
International
Class: |
B65B 25/06 20060101
B65B025/06 |
Claims
1. A packaged food product for placement in a refrigerated section
of a retail store for sale to a retail customer and adapted to have
a specific shelf life when generally maintained at a temperature
between approximately 38.degree. F. and approximately 48.degree.
F., the product comprising: a container including a sealed interior
volume at least partially defined by a barrier with an oxygen
permeability of less than 0.5 cubic centimeters of oxygen per 100
square inches of barrier area per 24 hours at 73.degree. F., zero
percent relative humidity and standard atmospheric pressure; an
amount of cheese located within the sealed volume, wherein the
cheese is a natural cheese, not a processed cheese, and is not
frozen prior to being sold to the customer, an amount of meat
located within the sealed volume and in physical contact with the
amount of cheese; and an atmosphere located within the sealed
volume, wherein the atmosphere has an oxygen content of less than
0.5 percent.
2. The product of claim 1, wherein the natural cheese is also a
non-pasteurized cheese.
3. The product of claim 1, wherein the shelf life is at least
approximately 90 days.
4. The product of claim 1, wherein the shelf life is approximately
90 days to approximately 180 days.
5. The product of claim 1, wherein the atmosphere is substantially
nitrogen.
6. The product of claim 1, wherein the atmosphere is substantially
carbon dioxide.
7. The product of claim 1, wherein the atmosphere is substantially
comprised of nitrogen and carbon dioxide.
8. The product of claim 1, the amount of cheese is treated with an
antimicrobiological agent.
9. The product of claim 8, wherein the antimicrobiological agent is
natamycin.
10. The product of claim 1, wherein the container is a clear cup
with ultra violet protection and a removable top.
11. The product of claim 10, wherein the ultra violet protection is
provided via an ultra violet resistant label about the cup.
12. The product of claim 10, wherein the removable top is a peal
type top with ultra violet protection.
13. The product of claim 12, wherein the container further
comprises a lid for placement over the peal type top and including
a detachable eating utensil.
14. The product of claim 1, wherein the container is a clear
flexible or semi-flexible bag.
15. The product of claim 14, wherein the bag has ultra violet
protection and/or a substantial percentage of the bag surface is
covered with printing.
16. The product of claim 14, wherein an eating utensil is included
with the bag.
17. The product of claim 14, wherein the bag includes a grooved
resealable opening.
18. A method of producing a packaged food product and providing the
product to a retail customer, wherein the product is adapted to
have a specific shelf life when generally maintained at a
temperature between approximately 38.degree. F. and approximately
48.degree. F., the product comprising: providing a container
including an interior volume at least partially defined by a
barrier with an oxygen permeability of less than 0.5 cubic
centimeters of oxygen per 100 square inches of barrier area per 24
hours at 73.degree. F., zero percent relative humidity and standard
atmospheric pressure; placing an amount of cheese into the volume,
wherein the cheese is a natural cheese, not a processed cheese, and
is not frozen prior to being provided to the customer, placing an
amount of meat into the volume and in physical contact with the
amount of cheese; injecting the volume with a gas such that the
volume ends up having an atmosphere with an oxygen content of less
than 0.5 percent; sealing the volume to maintain said atmosphere;
marking the container with a shelf life date that is at least
approximately 90 days subsequent to the date the volume was sealed;
placing the container into a refrigerated area that is generally
maintained at a temperature of between approximately 33.degree. F.
and approximately 49.degree. F.; and allowing the customer to
access the product in a retail store.
19. The method of claim 18, wherein the natural cheese is also a
non-pasteurized cheese.
20. The method of claim 18, wherein the volume is subjected to
vacuum conditions prior to being injected with gas.
21. The method of claim 18, wherein the shelf life date is at least
approximately 90 days subsequent to the date the volume was sealed,
but no more than approximately 180 days subsequent to the date the
volume was sealed.
22. The method of claim 18, wherein the gas injected into the
volume is substantially nitrogen.
23. The method of claim 18, wherein the gas injected into the
volume is substantially carbon dioxide.
24. The method of claim 18, wherein the gas injected into the
volume is substantially comprised of nitrogen and carbon
dioxide.
25. The method of claim 18, further comprising treating the cheese
with an antimicrobiological agent.
26. The method of claim 25, wherein the antimicrobiological agent
is natamycin.
27. The method of claim 18, wherein the container is a clear cup
with ultra violet protection.
28. The method of claim 27, wherein the cup is sealed with a peal
type top.
29. The method of claim 28, further comprising providing a lid over
the peal type top and including a detachable eating utensil.
30. The method of claim 27, further comprising placing a sleeve
label on the cup.
31. The method of claim 18, wherein the container is a clear
flexible or semi-flexible bag.
32. The method of claim 31, wherein the bag has ultra violet
protection and/or a substantial percentage of the bag surface is
covered with printing.
33. The method of claim 31, wherein an eating utensil is included
with the bag.
34. The method of claim 31, wherein the bag includes a grooved
resealable opening.
35. The method of claim 18, further comprising providing the meat
and cheese to split scales.
36. The method of claim 35, further comprising mixing together the
amounts of meat and cheese prior to placing them into the volume,
wherein the amounts of meat and cheese are placed into the volume
at generally the same instant.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to packaged food products and
methods for preparing packaged food products. More specifically,
the present invention relates to packaged meat and cheese food
products and methods of preparing such food products.
BACKGROUND OF THE INVENTION
[0002] Meat and cheese have complimentary tastes that consumers
enjoy experiencing at the same time. For example, meat and cheese
are often eaten together in sandwiches, pizza, and other foods.
Meat and cheese are also enjoyed together as a snack with nothing
else (e.g., a meat and cheese platter).
[0003] To capitalize on the consumer's desire to experience the
flavors of meat and cheese together with nothing else, retail
stores sell various meat and cheese products. For example, retail
stores sell shelf-stable meat products and shelf-stable cheese
products. Shelf-stable products are packaged within either shrink
poly or polypropylene bag material and, while these products have a
substantial shelf life and do not need to be refrigerated, they are
difficult to open. Furthermore, USDA regulations prohibit
shelf-stable meat and cheese from touching. As a result,
shelf-stable meat and cheese products must be packaged separately.
This hinders the consumer's ability to simultaneously enjoy meat
and cheese because two packages must be opened and manipulated at
the same time. Finally, shelf-stable products utilize processed
cheese, which has a less preferable taste and texture as compared
to natural cheese.
[0004] Retail stores sell meat and cheese products in their deli
sections. These deli-type products typically have meat and cheese
placed in a plastic tray. The plastic tray is then wrapped over
with plastic film or poly material. This is a typical arrangement
for a common meat and cheese platter. These deli-type products are
either prepared daily by the deli department of the retail store or
the products are frozen after manufacture and shipped to the retail
store. In either case, the deli-type product's shelf life is quite
limited, typically ranging from 5-14 days at best. Also, freezing
adversely impacts the taste and texture of cheese.
[0005] Retail stores sell meat and cheese products in their
refrigerated sections that are prepackaged by a manufacturer and
shipped to the retail store. An example of such a prepackaged
product would be a meat and cheese type platter sold by Oscar
Mayer.RTM. (i.e., Kraft Foods) under the name of Lunchables.RTM..
With this prepackaged product, the meat and cheese are placed in
separate sections of a tray. Each section has its own seal such
that the meat and cheese are sealed separately from each other.
Also, this prepackaged product utilizes processed cheese. The
typical shelf life for such prepackaged products is approximately
45 to 90 days.
[0006] There is a need in the art for a packaged food product that
allows convenient, simultaneous enjoyment of meat and natural
cheese and has a substantial shelf life. There is also a need in
the art for a method of producing such a package food product and
providing it to a retail customer.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention, in one embodiment, is a packaged food
product for placement in a refrigerated section of a retail store
for sale to a retail customer and adapted to have a specific shelf
life when generally maintained at a temperature between
approximately 38.degree. F. and approximately 48.degree. F. In one
embodiment, the product includes a container, an amount of cheese,
an amount of meat, and an atmosphere. The container includes a
sealed interior volume at least partially defined by a barrier with
an oxygen permeability of less than 0.5 cubic centimeters of oxygen
per 100 square inches of barrier area per 24 hours at 73.degree.
F., zero percent relative humidity, and standard atmospheric
pressure (i.e., approximately 1 atmosphere). The amount of cheese
is located within the sealed volume. The cheese is natural (i.e.,
not a processed cheese) and is not frozen prior to being sold to
the customer. In one embodiment, the natural cheese is also a
non-pasteurized cheese. The amount of meat is located within the
sealed volume and is in physical contact with the amount of cheese.
The atmosphere is located within the sealed volume and has an
oxygen content of less than 0.5 percent.
[0008] In one embodiment, the product has a shelf life of at least
approximately 90 days. In another embodiment, the product has a
shelf life of approximately 90 days to approximately 180 days.
[0009] In one embodiment, the atmosphere is substantially nitrogen.
In another embodiment, the atmosphere is substantially carbon
dioxide. In yet another embodiment, the atmosphere is substantially
comprised of nitrogen and carbon dioxide. In one embodiment, the
amount of cheese is treated with an antimicrobiological agent, such
as natamycin.
[0010] In one embodiment, the container is a clear cup with ultra
violet protection and a removable top. In one embodiment, the
removable top is a peal type top. In one embodiment, a lid, which
includes a detachable eating utensil, is placed over the peal type
top.
[0011] In one embodiment, the container is a clear flexible or
semi-flexible bag, which has ultra violet protection and/or a
substantial percentage of the bag surface is covered with printing.
In one embodiment, an eating utensil is included with the bag. In
one embodiment, the bag includes a grooved resealable opening.
[0012] The present invention, in another embodiment, is a method of
producing a packaged food product and providing the product to a
retail customer, wherein the product is adapted to have a specific
shelf life when generally maintained at a temperature between
approximately 38.degree. F. and approximately 48.degree. F. In one
embodiment, the product includes providing a container with an
interior volume, placing an amount of cheese into the volume,
placing an amount of meat into the volume, injecting the volume
with a gas, sealing the volume, marking the container with a
self-life date, placing the container into a refrigerated area, and
allowing the customer to access the product in a retail store.
[0013] In one embodiment, the interior volume of the container will
be at least partially defined by a barrier with an oxygen
permeability of less than 0.5 cubic centimeters of oxygen per 100
square inches of barrier area per 24 hours at 73.degree. F., zero
percent relative humidity and standard atmospheric pressure (i.e.,
approximately 1 atmosphere). The cheese is natural (i.e., not a
processed cheese) and is not frozen prior to being provided to the
customer, and the amount of meat is in physical contact with the
amount of cheese. In one embodiment, the natural cheese is also not
pasteurized. The gas is injected such that the volume ends up
having an atmosphere with an oxygen content of less than 0.5
percent, and sealing the volume helps to maintain the atmosphere in
this condition.
[0014] In one embodiment, the marked shelf life date is at least
approximately 90 days subsequent to the date the volume was sealed.
In another embodiment, the shelf life date is at least
approximately 90 days subsequent to the date the volume was sealed,
but not more than approximately 180 days subsequent to the date the
volume was sealed.
[0015] In one embodiment, the refrigerated area is generally
maintained at a temperature of between approximately 38.degree. F.
and approximately 48.degree. F. In another embodiment, the
refrigerated area is generally maintained at a temperature of
between approximately 33.degree. F. and approximately 49.degree. F.
or 50.degree. F. In one embodiment, the volume is subjected to
vacuum conditions prior to being injected with gas.
[0016] While multiple embodiments are disclosed, still other
embodiments of the present invention will become apparent to those
skilled in the art from the following detailed description, which
shows and describes illustrative embodiments of the invention. As
will be realized, the invention is capable of modifications in
various obvious aspects, all without departing from the spirit and
scope of the present invention. Accordingly, the drawings and
detailed description are to be regarded as illustrative in nature
and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a partially exploded isometric view of one
embodiment of the packaged food product wherein an amount of meat
and cheese is sealed within a cup container.
[0018] FIG. 2 is a section elevation of the cup taken along section
line AA in FIG. 1.
[0019] FIG. 3 is an isometric view of the lid with the integral
eating utensil removed.
[0020] FIG. 4 is an isometric view of the eating utensil in its
folded configuration immediately after being separated from the
lid, but prior to being assembled into its use configuration.
[0021] FIG. 5 is an isometric view of the eating utensil after
being assembled into its use configuration.
[0022] FIG. 6 is a front elevation of another embodiment of the
packaged food product wherein the amount of meat and cheese is
sealed within a bag.
[0023] FIG. 7 is a plan view of a packaging line for producing the
package food product of the subject invention.
[0024] FIG. 8 is a flow chart outlining the method of producing the
packaged food product and providing it to a retail customer.
DETAILED DESCRIPTION
[0025] In one embodiment, the packaged food product of the subject
invention includes an easily openable and conveniently sized
container enclosing amounts of meat and natural cheese in physical
contact. The packaged food product has features that allow it to
have a significant shelf life without resorting to processed
cheeses, freezing or making the meat and cheese shelf-stable, all
of which adversely impact the taste and texture of cheese. Thus,
the package food product offers a consumer the ability to
conveniently enjoy a low carbohydrate snack having the palatable
combination of meat and natural cheese.
[0026] For a detailed discussion of the packaged food product of
the subject invention, reference is now made to FIG. 1, which is a
partially exploded isometric view of one embodiment of the packaged
food product 2. As shown in FIG. 1, the packaged food product 2
includes amounts 4 of meat and natural cheese enclosed within a cup
6 sealed by a peal seal 8 and having a lid 10 adapted to fit onto
the top of the cup 6 and cover the peal seal 8. As indicated in
FIG. 1, in one embodiment, the lid 10 includes an eating utensil 11
formed into the lid 10.
[0027] As illustrated in FIG. 1, in one embodiment, the cup 6 is
clear (i.e., generally see-through) and has a label 12 encompassing
at least a portion of the cup 6. As shown in FIG. 1, the label 12
has a window 14 through which the amounts 4 of meat and natural
cheese may be viewed.
[0028] For a more detailed discussion of the sealed cup 6 and its
contents, reference is made to FIG. 2, which is a section elevation
of the cup 6 taken along section line AA in FIG. 1. As shown in
FIG. 2, the cup 6 has walls 6a that extend continuously between a
base 6b and a continuous lip 6c. The peal seal 8 is removably
affixed to the top surface of the cup's lip 6c. The walls 6a, base
6b and peal seal 8 define a volume within the cup that contains,
and completely encloses, the contents of the cup 6.
[0029] As indicated in FIG. 2, in one embodiment, the contents of
the cup 6 are amounts 4 of meat and natural cheese and an
atmosphere 16. The amounts 4 of meat and cheese are in physical
contact. In one embodiment, the atmosphere 16 is substantially
nitrogen and has an oxygen content of less than approximately 0.5
percent. In one embodiment, the atmosphere 16 is substantially
carbon dioxide and has an oxygen content of less than approximately
0.5 percent. In one embodiment, the atmosphere 16 is substantially
a combination of nitrogen and carbon dioxide and has an oxygen
content of less than approximately 0.5 percent. In one embodiment,
the atmosphere is substantially other types of inert gases or
combinations of inert gases and has an oxygen content of less than
approximately 0.5 percent.
[0030] In one embodiment, the cup's uppermost internal diameter is
approximately 2.8'', the external diameter of the cup's lip 6c is
approximately 3.2'', and the cup's height from the bottom of the
cup's base 6b to the top of the cup's lip 6c is approximately
3.4''. In one embodiment, the cup 6 is a clear barrier cup of
approximately six-ounce size and holding approximately 1.4 ounces
of meat and approximately 2.2 ounces of natural cheese.
[0031] In one embodiment, the cup 6 is made from thermoformed or
pressure-formed polypropylene with approximately three percent to
approximately eight percent EVOH. In one embodiment, the cup 6
weights between approximately six grams and approximately ten
grams. In one embodiment, the cup 6 is configured such that it has
thicknesses of approximately 60 mils for the cup's lip 6c,
approximately 12 mils for the cup's sidewall 6a, and approximately
20 mils for the cup's base 6b. Cups 6 having one or more of the
aforementioned features may be obtained from CPT Coextruded
Plastics Technologies, Inc. of 415 E. Fulton Street, Edgerton, Wis.
53534, Plasdecol, Avenida 37B, #44-31, Itaqui, Ant. Colombia; or
Huhtamaki Instanbul Ambalaj Sanayi A.S., SAN-BIR Bulvan 3. Bolge 6,
Cadde No: 46B, Cekmece, 34900 Instanbul, Turkey.
[0032] In one embodiment, the peal seal 8 is a multilayer
configuration that is approximately 2.8 to approximately 3.2 mils
thick. In one embodiment the multilayer configuration includes a
PET layer that is approximately 48 ga., an ink layer; a PEL layer
that is approximately 75 ga., and a Coex. EVOH single site LLDPE
layer that is approximately 1.75 mils thick. Peal seals 8 having
one or more of the aforementioned features may be obtained from
Curwood Bemis Co., 2200 Badger Avenue, Oshkosh, Wis. 54904 or
Plastopil, Kibbutz Hazorea 30060 Israel.
[0033] In one embodiment, the cup 6 and peal seal 8 provide a
barrier with an oxygen permeability of less than 0.5 cubic
centimeters of oxygen per 100 square inches of barrier area per 24
hours at 73.degree. F., zero percent relative humidity and standard
atmospheric pressure (i.e., approximately 1 atmosphere). In one
embodiment, the cup 6 and peal seal 8 will have the aforementioned
oxygen permeability when tested according to ASTM F1307-90. This
oxygen barrier feature helps to maintain the atmosphere 16 within
the sealed cup at an oxygen content of less than approximately 0.5
percent. Consequently, when the packaged food product 2 is
generally maintained at a temperature between approximately
38.degree. F. and approximately 48.degree. F., the contents of the
packaged food product 2 will have a shelf life of at least
approximately 90 days. In one embodiment, the shelf life will be
between approximately 90 days to approximately 180 days.
[0034] In another embodiment, where the packaged food product 2 is
generally maintained at a temperature between approximately
33.degree. F. and approximately 48.degree. F., the contents of the
packaged food product 2 will have a shelf life of at least
approximately 90 days. In one embodiment, the shelf life will be
between approximately 90 days to approximately 180 days. In one
embodiment, the packaged food product 2 will have one of the
aforementioned shelf lives if generally maintained at a temperature
of between approximately 33.degree. F. and approximately 49.degree.
F. or 50.degree. F.
[0035] In one embodiment, the contents of the cup 6 are protected
from ultra violet radiation. In one embodiment, as shown in FIG. 1,
this is achieved by wrapping an ultra violet resistant label 12
about the cup 6. In one embodiment, the label 12 is provided with
an ink layer that covers a substantial percentage of the label's
surface. As indicated in FIG. 1, in one embodiment, the label 12
has an inkless area that forms a generally see-through window 14
that allows the contents of the cup 6 to be viewed.
[0036] In one embodiment, the cup 6 itself is made of material that
is ultra violet resistant, but still allows the cup 6 to be
generally see-through (e.g., the above-discussed thermoformed or
pressure-formed polypropylene material having approximately three
percent to approximately eight percent EVOH and being provided with
an UV light inhibitor or stabilizer
[0037] Similarly, in one embodiment, the peal seal 8 is ultra
violet resistant. In one embodiment, this is achieved via a layer
of ink printing placed on the peal seal 8. In another embodiment,
the peal seal 8 is made of a polymer or other material that is
ultra violet resistant (e.g., the above-discussed peal seal 8 with
its multilayered configuration).
[0038] In one embodiment, the cheese sealed within the cup 6 is a
natural cheese. In other words, the cheese sealed within the cup 6
is not processed cheese. Processed cheese is a cheese product made
by combining one or more cheese types with other non-cheese
ingredients. For example, in making a processed cheese, one or more
natural cheese varieties (e.g., varieties such as cheddar, colby,
swiss, mozzarella, provolone, etc.) and/or one or more differently
aged portions of the same cheese variety are combined. The cheese
combination is then heated and mixed with emulsifiers, gums,
stabilizers, colorings, flavorings, etc. As compared to natural
cheeses, processed cheeses have longer shelf lives and are superior
when melted because they remain homogeneous and flow smoothly.
However, to achieve these benefits, processed cheeses have flavor
and texture that is less desirable than those of natural
cheeses.
[0039] In one embodiment, the cheese sealed within the cup 6 is
natural cheese that has not been frozen prior to selling it to a
retail customer. While freezing can significantly increase the
shelf life of a natural cheese, freezing can adversely impact the
taste and texture of a natural cheese.
[0040] In one embodiment, the cheese sealed within the cup 6 is a
natural cheese made from non-pasteurized milk. Thus, the cheese
within the cup 6 is a non-pasteurized natural cheese. While a
pasteurized natural cheese is generally considered to be safer to
eat than a non-pasteurized natural cheese (this is why the U.S.
Food and Drug Administration bans the sale of all cheeses made with
un-pasteurized milk that have not been aged for at least 60 days),
the pasteurized cheese typically will have a flavor and texture
that is less desirable than those of the non-pasteurized
cheese.
[0041] In one embodiment, the pieces of natural cheese sealed
within the cup 6 are treated with an antimicrobiological agent to
protect the natural cheese from mold and yeast growth. In one
embodiment, the antimicrobiological agent is natamycin.
[0042] For a more detailed discussion of the lid 10 and its
integral eating utensil 11, reference is made to FIGS. 3, 4 and 5.
FIG. 3 is an isometric view of the lid 10 with the integral eating
utensil 11 removed. FIG. 4 is an isometric view of the eating
utensil 11 in its folded configuration immediately after being
separated from the lid 10, but prior to being assembled into its
use configuration. FIG. 5 is an isometric view of the eating
utensil 11 after being assembled into its use configuration.
[0043] As indicated in FIG. 1, the lid 10 is provided with an
eating utensil 11 integrally formed into the lid 10. As shown in
FIG. 1, the eating utensil 11 forms a center strip of the lid in.
As can be understood from FIG. 3, when the eating utensil 11 is
separated from the lid 10, the lid 10 will have a gap or void 18
where the eating utensil 11 used to be attached to the lid 10.
[0044] As shown in FIG. 4, when the eating utensil 11 is first
removed from the lid 10, it exists in a folded configuration.
Specifically, the head 20 of the eating utensil 11 is folded back
onto the handle 22 of the eating utensil 11. The handle 22 has
rearward side portions 22a' that exist on each side of a rearward
center portion 22b' and forward side portions 22a'' that exist on
each side of a forward side portion 22b''.
[0045] As illustrated in FIG. 5, when the eating utensil 11 is
assembled into the use configuration, the side portions 22a are
folded up to join each other such that the two side portions 22a
and the center portion 22b form three sides of a handle 22 having a
triangular cross-section, and the head 20 of the eating utensil 11
is folded outwards. Depending on the embodiment, the head 20 of the
eating utensil 11 is a fork, pitchfork or other type of stabbing
instrument, a spoon, or a spork (i.e., a fork/spoon combination).
In one embodiment, the lid 10 and eating utensil 11 are made of
injection molded polypropylene, thermoplastic or other types of
polymers.
[0046] For a detailed discussion of another embodiment of the
packaged food product 2, reference is made to FIG. 6, which is a
front elevation of the packaged food product 2 having an amount 4
of meat and cheese sealed within a bag 30. In one embodiment, the
bag 30 is approximately 6.5-7.25 inches wide and approximately 9
inches tall. In one embodiment, the bag 30 holds approximately 2.5
ounces of meat and approximately 4.0 ounces of natural cheese.
[0047] As shown in FIG. 6, in one embodiment, the bag 30 has a
pre-made opening 32 that is resealable via a tongue and groove
arrangement as found on ziplock or zipper type polymer bags. In
other embodiments, where the bag 30 has no pre-made opening 32, the
consumer must tear or cut an opening.
[0048] In one embodiment, the bag 30 is employs a protective
packaging film such as Cupolene.RTM. Grade 7170 as manufactured by
Curwood Bemis Co. of 2200 Badger Avenue, Oshkosh, Wis. 54904. In
one embodiment, such a bag 30 has 3.0 mil thick walls that are a
sandwich comprising the following layers: a 48 ga. PET layer; an
ink layer; a 75 ga. PEL layer; and a 1.75 mil Coex. EVOH single
site LLDPE layer.
[0049] In one embodiment, the bag 32 provides a barrier with an
oxygen permeability of less than 0.5 cubic centimeters of oxygen
per 100 square inches of barrier area per 24 hours at 73.degree.
F., zero percent relative humidity and standard atmospheric
pressure (i.e., approximately 1 atmosphere). In one embodiment, the
bag 32 will have the aforementioned oxygen permeability when tested
according to ASTM F1307-90. This oxygen barrier feature helps to
maintain the atmosphere 16 within the sealed bag 30 at an oxygen
content of less than approximately 0.5 percent. Consequently, when
the packaged food product 2 is generally maintained at a
temperature between approximately 38.degree. F. and approximately
48.degree. F., the contents of the packaged food product 2 will
have a shelf life of at least approximately 90 days. In one
embodiment, the shelf life will be between approximately 90 days to
approximately 180 days.
[0050] In one embodiment, the contents of the bag 30 are protected
from ultra violet radiation. In one embodiment, as shown in FIG. 6,
this is achieved by providing an ink layer that covers a
substantial percentage of the bag's surface. As indicated in FIG.
6, the bag 30 may have an inkless area that forms a generally
see-through window 14 that allows the contents of the bag 30 to be
viewed. In one embodiment, the bag 30 is made of material that is
ultra violet resistant, but still allows the bag 30 to be generally
see-through. Such materials are known in the art.
[0051] In one embodiment, the bag 30 is provided with an eating
utensil, such as a fork, pitchfork, spoon or spork. Such eating
utensil may be provided within the bag 30 or affixed to the
exterior of the bag 30.
[0052] The packaged food product 2 may contain a variety of natural
cheeses. For example, in one embodiment, the pieces of natural
cheese in the package food product 2 may be all cheddar, colby,
jack, swiss, mozzarella, provolone, or etc. In one embodiment, the
pieces of natural cheese in the packaged food product 2 may be a
variety of cheeses. For example, the packaged food product 2 may
include pieces of cheddar and pieces of Swiss. Alternatively, the
packaged food product 2 may include pieces of colby and pieces of
mozzarella. As can be understood, a nearly infinite number of
natural cheese combinations may be provided in the packaged food
product 2. Also, the cheese could be formed in a nearly infinite
number of shapes such as letters, numbers, stars, baseball bats,
footballs, hockey pucks and smile faces.
[0053] The packaged food product 2 may contain a variety of USDA
inspected meats. For example, in one embodiment, the pieces of meat
in the packaged food product are all beef, chicken, turkey, lamb,
pork, fish, spiced meats (e.g., peppered meat or jerky), or etc. In
one embodiment, the pieces of meat in the packaged food product 2
may be a variety of meats. For example, the packaged food product 2
may include pieces of beef and pieces of chicken. Alternatively,
the packaged food product 2 may include pieces of turkey and pork.
As can be understood, a nearly infinite number of meat combinations
may be provided in the packaged food product 2. Also, the meat
could be formed in a nearly infinite number of shapes such as
letters, numbers, stars, baseball bats, footballs, hockey pucks and
smile faces.
[0054] For a discussion of the method of producing the packaged
food product 2 and providing it to a retail customer, reference is
now made to FIGS. 7 and 8. FIG. 7 is a plan view of a packaging
line for producing the package food product 2 of the subject
invention. FIG. 8 is a flow chart outlining the method of producing
the packaged food product 2 and providing it to a retail
customer.
[0055] As can be understood from FIGS. 7 and 8, multiple lots of
USDA inspected/approved meat and natural cheese are shipped to a
packaging facility 50 (block 100). Samples from each lot of meat
and cheese are pulled for microbiological testing and the lots are
placed in cold storage 52 (block 102). Amounts of meat and cheese
are removed from the packaging of their respective lots in the
stripping room 54 (block 104).
[0056] As indicated in FIGS. 7 and 8, amounts of meat are placed in
the meat hopper 56, and amounts of cheese are placed in the cheese
hopper 58 (block 106). Amounts of meat move up the meat conveyor 60
to the meat side of the split scale 62, and amounts of cheese move
of the cheese conveyor 64 to the cheese side of the split scale 62
(block 108). The amounts of meat and cheese are weighed separately
at the split scale 62 (block 110). The amounts of meat and cheese
are combined, mixed and placed in the container (i.e., the cup 6 or
bag 30 of the packaged food product 2) at the container-filling
machine 66 such that the pieces of meat and cheese enter the
container at generally the same instant (block 112).
[0057] As can be understood from FIGS. 7 and 8, the filled
containers travel along a conveyor 68 to the container
flushing/sealing machine 70 (e.g., the VGF R-20 Rotary Heat Seal
Machine as manufactured by Orics Industries, Inc. of College Point,
N.Y. 11356 or a Pack-Line Model PXG-2 machine manufactured by Pack
Line Corp. of Pine Brook, N.J. 07058) where the volumes of the
containers are subjected to a vacuum, flushed with an inert gas
(e.g., nitrogen, carbon dioxide, a combination of nitrogen and
carbon dioxide, or other inert gases or combinations thereof) and
sealed (block 114). In one embodiment, the containers are simply
flushed with an inert gas and sealed. In another embodiment, a
liquid inert gas is placed into the container, the liquid inert gas
vaporizes into an inert gas, and the container is then sealed.
[0058] In one embodiment, when the volumes of the containers are
flushed with an inert gas, or at some point prior to the flushing
the container volumes by an inert gas, an antimicrobiological agent
is also injected into the volume to treat the amounts of cheese and
meat. In the embodiment of the packaged food product 2 that has a
cup 6 for its container, a lid 10 with an integral eating utensil
11 is attached over the top of the peel seal 8 of the cup 6.
[0059] Regardless of whether the packaged food product 2 employs
the aforementioned cup 6 or bag 30, the packaged food product 2 of
the subject invention now exists and the volume of the sealed
container is filled with amounts of meat and cheese and an
atmosphere that has less than approximately 0.5 percent oxygen. The
packaged food products 2 travel along a conveyor 72 from the
flushing/sealing machine 70 to a metal detector 74 (block 116).
[0060] As indicated in FIGS. 7 and 8, the packaged food products 2
continue along the conveyor 72 to a label machine 76 that places a
label on the packaged food product 2 and a date coder 78 that
places a shelf life indicating date on the label (block 118). In
one embodiment, the shelf life indicating date is a date that is at
least approximately 30 days subsequent to the date the volume was
sealed. In one embodiment, the shelf life indicating date is a date
that is at least approximately 60 days subsequent to the date the
volume was sealed. In one embodiment, the shelf life indicating
date is a date that is at least approximately 90 days subsequent to
the date the volume was sealed. In anther embodiment, the shelf
life indicating date is a date that is at least approximately 180
days subsequent to the date the volume was sealed.
[0061] As can be understood from FIGS. 7 and 8, sample packaged
food products 2 are pulled for microbiological testing and the
remaining packaged food products 2 are boxed 12 via a boxing
machine 79 (block 120). The boxes of packaged food products 2 then
pass through a corner labeler 80, are taped closed, placed on a
pallet 82, and returned to cold storage 52 for shipping to a retail
outlet (block 122). At the retail outlet, the packaged food
products 2 are placed in a refrigerated section of the retail
outlet (block 124).
[0062] In one embodiment, the natural cheese in the packaged food
product 2 has not been frozen at any time prior to the retail
customer's purchase of the packaged food product 2. Instead, the
natural cheese contained in the packaged food product 2 is
generally maintained at a temperature of between approximately
38.degree. F. and approximately 48.degree. F. at essentially all
times prior to the packaged food product being purchased by a
retail customer.
[0063] Packaged food products 2 having the aforementioned features,
produced according to the aforementioned method, and maintained
within the aforementioned temperature range provides retail
customers with a conveniently sized and accessed packaged food
product containing amounts of USDA meat and natural cheese that has
a shelf life of between approximately 90 days and approximately 180
days. Although the present invention has been described with
reference to preferred embodiments, persons skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *