U.S. patent application number 11/176013 was filed with the patent office on 2006-07-06 for products, methods and apparatus for fresh meat processing and packaging.
This patent application is currently assigned to Case Ready Solutions LLC. Invention is credited to Anthony J.M. Garwood.
Application Number | 20060147588 11/176013 |
Document ID | / |
Family ID | 36640733 |
Filed Date | 2006-07-06 |
United States Patent
Application |
20060147588 |
Kind Code |
A1 |
Garwood; Anthony J.M. |
July 6, 2006 |
Products, methods and apparatus for fresh meat processing and
packaging
Abstract
Improved processing and packaging for perishable goods such as
red meats providing a processing system wherein ambient air is
excluded and suitable gases such as carbon dioxide are provided at
a suitable pressure and in such a manner as to increase the
quantity of the gases dissolved in the perishable goods. Then
providing a base and placing the perishable goods over the base. A
flexible web of plastic wrapping material (second web) is then
applied over the base and the goods and air or gas evacuated
therefrom and replaced with a suitable gas. The base includes a
cup-shaped tray with a recess (first web), of plastics or other
suitable material, with side walls extending upwardly to connect to
a narrow horizontally disposed flange. The first web, goods and
second web are located inside a depression in a third web of gas
barrier material and there together placed into an enclosed
evacuation chamber. A suitable gas is provided in the chamber in
such a manner as to displace substantially all other gas and
particularly atmospheric oxygen that may be present with the
enclosed goods and web materials. The third web is then sealed so
as to enclose the goods with first and second webs. that the
pressure of the gas may be increased to a level above atmospheric
pressure. Most preferably the quantity of gas dissolved into the
goods will be increased. Most preferably the gas introduced into
the chamber and the space will enhance preservation of the
packaging goods when contacting the goods. The first web, second
web and third web are sealed together thereby producing a
hermetically sealed package with the goods and a gas filled space
contained therein to provide a sealed package. The sealed package
can be stored for any convenient period of time after which the
third web is can be removed so as to allow ambient air to contact
the goods. The invention further includes the method and apparatus
for producing the processed goods and packaging.
Inventors: |
Garwood; Anthony J.M.;
(Mercer Island, WA) |
Correspondence
Address: |
CHRISTENSEN, O'CONNOR, JOHNSON, KINDNESS, PLLC
1420 FIFTH AVENUE
SUITE 2800
SEATTLE
WA
98101-2347
US
|
Assignee: |
Case Ready Solutions LLC
Mercer Island
WA
|
Family ID: |
36640733 |
Appl. No.: |
11/176013 |
Filed: |
July 5, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
09724287 |
Nov 28, 2000 |
|
|
|
11176013 |
Jul 5, 2005 |
|
|
|
PCT/US00/29038 |
Oct 19, 2000 |
|
|
|
09724287 |
Nov 28, 2000 |
|
|
|
09550399 |
Apr 14, 2000 |
|
|
|
PCT/US00/29038 |
Oct 19, 2000 |
|
|
|
09392074 |
Sep 8, 1999 |
|
|
|
09550399 |
Apr 14, 2000 |
|
|
|
09039150 |
Mar 13, 1998 |
|
|
|
09392074 |
Sep 8, 1999 |
|
|
|
60040556 |
Mar 13, 1997 |
|
|
|
60129595 |
Apr 15, 1999 |
|
|
|
60141569 |
Jun 29, 1999 |
|
|
|
60144400 |
Jul 16, 1999 |
|
|
|
60148227 |
Jul 27, 1999 |
|
|
|
60149938 |
Aug 19, 1999 |
|
|
|
60152677 |
Sep 7, 1999 |
|
|
|
60154068 |
Sep 14, 1999 |
|
|
|
60160445 |
Oct 19, 1999 |
|
|
|
60175372 |
Jan 10, 2000 |
|
|
|
Current U.S.
Class: |
426/392 |
Current CPC
Class: |
B65D 81/2076 20130101;
A23B 4/16 20130101; A23L 3/3418 20130101; B65D 81/264 20130101;
B65B 25/067 20130101; B65B 7/164 20130101 |
Class at
Publication: |
426/392 |
International
Class: |
B65B 25/06 20060101
B65B025/06 |
Claims
1-215. (canceled)
216. A method for processing meat, comprising: cutting meat
containing deoxymyoglobin in an atmosphere substantially deficient
of oxygen to provide cut meat having freshly cut meat surfaces; and
inhibiting contact between the freshly cut meat surfaces with
oxygen from just after cutting the meat through packaging the meat
in a package to extend the shelf life of the packaged meat.
217-265. (canceled)
266. The method of claim 216, further comprising immersing the
freshly cut meat surfaces within an atmosphere substantially
deficient of oxygen until the cut meat is packaged.
267. The method of claim 216, wherein cutting meat comprises
grinding the meat.
268. The method of claim 216, wherein the atmosphere comprises
substantially carbon dioxide gas and not more than 0.4% carbon
monoxide.
269. The method of claim 216, further comprising pre-conditioning
the meat with carbon dioxide gas at a pressure equal to or above
atmospheric pressure prior to cutting the meat.
270. The method of claim 216, further comprising pre-conditioning
the meat with carbon dioxide gas at a pressure above atmospheric
pressure prior to cutting the meat so that when the meat is
returned to atmospheric pressure, the carbon dioxide will be
released at or near the freshly cut meat surfaces to inhibit
contact with oxygen.
271. The method of claim 216, further comprising lowering the
temperature of the meat prior to cutting the meat.
272. The method of claim 216, further comprising lowering the
temperature of the meat to less than 32.degree. F. prior to cutting
the meat.
273. The method of claim 216, further comprising adding solid
carbon dioxide with the meat during cutting to cover the freshly
cut meat surfaces with carbon dioxide to inhibit contact between
the freshly cut meat surfaces with oxygen.
274. The method of claim 216, further comprising transferring the
cut meat in an enclosed, carbon dioxide- or nitrogen-filled conduit
to a packaging machine to minimize the contact of the freshly cut
meat surfaces to the oxygen in the ambient atmosphere.
275. The method of claim 216, wherein the atmosphere comprises not
more than 5% oxygen.
276. The method of claim 216, wherein the atmosphere comprises
carbon dioxide, nitrogen, and not more than 5% oxygen.
277. The method of claim 216, wherein the atmosphere comprises at
least one of pentane, propane, butane, methane, a CFC, an HCFC,
carbon monoxide, or sulfur dioxide.
278. The method of claim 216, wherein the atmosphere is about 100%
carbon dioxide gas.
279. The method of claim 216, wherein cutting comprises grinding
the meat with a grinder and the outlet of the grinder is coupled to
a conduit containing a packaging machine, wherein packaging of the
meat is done in an atmosphere substantially deficient of
oxygen.
280. The method of claim 216, wherein cutting comprises grinding
the meat with a grinder and the outlet of the grinder is coupled to
a vessel containing an atmosphere substantially deficient of
oxygen.
281. The method of claim 216, wherein cutting comprises grinding
the meat with a grinder and the outlet of the grinder is coupled to
a conduit containing a packaging machine, wherein the conduit is
filled with an atmosphere substantially deficient of oxygen.
282. The method of claim 216, wherein cutting comprises grinding
the meat with a grinder and the outlet of the grinder is coupled to
a conduit containing a packaging machine, wherein the conduit
contains a controlled atmosphere substantially deficient of oxygen,
wherein the packaging machine includes a thermoforming machine to
form trays in an atmosphere substantially deficient of oxygen.
283. The method of claim 216, wherein cutting comprises grinding
the meat with a grinder and the outlet of the grinder is coupled to
a conduit containing processing and packaging equipment, wherein
the conduit contains a controlled atmosphere substantially
deficient of oxygen, wherein the packaging machine includes a chub
packaging machine to form pouches within an atmosphere
substantially deficient of oxygen.
284. A method for processing meat, comprising cutting meat to
provide cut meat having freshly cut meat surfaces; and, thereafter,
inhibiting contact between the freshly cut meat surfaces with
oxygen from just after cutting through processing and then
packaging in a package.
285. A method for pre-conditioning meat prior to cutting,
comprising: pre-conditioning meat prior to cutting with carbon
dioxide gas at a pressure above atmospheric pressure to displace
ambient atmospheric gases and substantially saturate the liquid
phase of the meat with carbon dioxide; and after cutting the
pre-conditioned meat, allowing the saturated gas to be released
from the meat to inhibit contact of the cut surfaces with oxygen
which lasts through packaging the pre-conditioned meat in a
package, wherein the meat can release carbon dioxide into the
package.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of prior
application Ser. No. 09/550,399, filed Apr. 14, 2000, which in turn
is a continuation-in-part of application Ser. No. 09/392,074, filed
Sep. 8, 1999, which in turn is a continuation of application Ser.
No. 09/039,150, filed Mar. 13, 1998, now abandoned, which in turn
claims the benefit of U.S. Provisional Application No. 60/040,556,
filed Mar. 13, 1997. In addition, this Application claims the
benefit of U.S. Provisional Application Ser. Nos. 60/129,595, filed
Apr. 15, 1999; 60/141,569, filed Jun. 29, 1999; 60/144,400, filed
Jul. 16, 1999; 60/148,227 filed Jul. 27, 1999; 60/149,938, filed
Aug. 19, 1999; 60/152, 677, filed Sep. 7, 1999; 60/154,068, filed
Sep. 14, 1999; 60/160,445, filed Oct. 19, 1999; and 60/175,372,
filed Jan. 10, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to products, methods,
apparatus, and the products made therefrom used for processing and
packaging perishable foods and particularly to processed perishable
foods that are packaged in plastic food trays that are overlaid
with one or more layers of sealable plastic materials. The present
invention also relates to apparatus for processing and pre-treating
perishable foods and associated packaging with gases.
BACKGROUND OF THE INVENTION
[0003] For the entire history of fresh red meat processing for
human consumption, where slaughtered, eviscerated, and chilled
carcasses are produced in the normal process, improvements in terms
of reducing labor and or reducing costs of the process, have been
sought. Few major improvements have been achieved in the recent
past and it is a purpose of this present invention to expose
opportunities and to provide methods, apparatus and products of
improving the efficiency and competitiveness of the red meat
industry. Such opportunities are epitomized by, for example, the
condition that all carcasses contain a great deal of bone and other
materials that are not used for human consumption and yet the
entire carcass must be chilled prior to further processing, in
order to chill those parts that are used for human consumption.
Furthermore, the shape of all animals used for human consumption
are of irregular and inconvenient profile. Conversely, packaging
trays that have been cost effectively and efficiently manufactured,
are invariably rectangular and/or square in profile. By adopting
procedures disclosed herein it will be seen that costs of chilling
are reduced since, for example, the skeleton can be removed before
chilling thereby saving costs of such chilling process. Fresh red
meat tissue is typically quite soft and easy to cut immediately
after the animal has been slaughtered and prior to the natural,
"hardening" effects of rigor mortis has occurred. It can therefore
be easier and quicker to cut primal portions from animal carcasses,
during the normal animal "disassembly" process prior to rigor
mortis and chilling. Those fresh red meat primal items, that are
intended for human consumption, can then be shaped by placing into
molds of a specifically designed and desired profile prior to rigor
mortis and then chilled during the natural rigor mortis process.
This device will provide a method to change and adjust the shape of
fresh red meat primal items so that, for example, fresh red meat
primal items can be readily and automatically processed during the
slicing and cutting process as required prior to packaging.
Furthermore, profiles of primal meat portions can be arranged so as
to be more convenient when slices of fresh red meat primal items
are loaded into improved packaging, such that more can be loaded
into improved packaging while still maintaining a space efficient,
appealing and attractive appearance for the consumer at the point
of retail display and/or foodservice outlet.
[0004] Typical modified atmosphere packages for fresh foods, such
as red meats and other perishable foods, having a limited shelf
life, typically include a thermoformed tray or other package
composed of EPS/tie/PE (barrier foam trays) plastics material or
other suitable substantially gas impermeable material, i.e. tray,
overlaid with a single transparent web of plastics material that
can be heat sealed to the tray. A typical substantially gas
impermeable heat sealable composite web includes a biaxially
oriented polyester (PET) layer/tie layer/gas barrier layer (such as
PVDC) an adhesive layer/heat sealing layer (such as polyethylene),
which in turn is finally adhered by a heat sealer to the tray. The
polyethylene layer is a heat sealable layer that is tied to a gas
barrier layer such as polyvinylidene chloride which is in turn
adhered to polyester. Because of the diverse types of materials
that are employed in the foregoing package, it is difficult to
reprocess and recycle the post-consumer package. Moreover, the cost
associated with post-consumer recycling of multiple layer plastics
material renders the process impractical and substantially not
economically feasible.
[0005] Commonly used modified atmosphere packages for fresh foods
such as red meats and other perishable foods having a limited shelf
life typically comprise a tray thermoformed from a sheet of EPS
(expanded polystyrene) laminated to a web of substantially gas
impermeable web material or other suitable substantially gas
impermeable material. A lid, such as a single or composite
transparent web of plastics material that can be bonded to the
flanges of the tray. Both tray and lid materials are typically
substantially gas impermeable heat sealable composite structures
and cannot be readily recycled. Lid material typically comprises a
laminated structure including several layers such as bi-axially
oriented polyester bonded to a gas barrier layer (such as PVDC)
which is sandwiched between an adhesive or heat sealing layer (such
as polyethylene). Because of the diverse types of materials that
are employed in the foregoing package, it is difficult to reprocess
and recycle the "post-consumer" package. Moreover, the cost
associated with post-consumer recycling of multiple layer plastics
material, such as the aforementioned, renders the process
impractical and substantially not economically feasible.
[0006] A further limitation of packaging perishable goods such as
fresh red meats in hermetically sealed gas barrier packages results
from the need to enclose a relatively large volume of gas, and
particularly carbon dioxide, within the package. Clearly, consumers
have no interest in purchasing these gases that accompany the red
meat. Minimizing the size and bulky appearance of such packaging is
desirable, therefore it is a goal to reduce the overall size and
volume of the packaging to a minimum size. Additionally, a major
proportion of red meat production occurs at locations that are
located at a substantial distance from the point of retail sale of
red meats to consumers. Most US beef is produced in the central
plains around Kansas, Nebraska and Iowa and the major markets are
situated on the coastal regions such as New York or California.
Costs of shipping these fresh red meat items from the point of
production and packaging can be reduced if the packages are reduced
in volume. However, reduction in the volume of gases provided
within a package can have a deleterious effect on shelf life of the
perishable goods and red meat contained therein.
[0007] Typical methods used for production of ground meats and
patties, that are substantially composed of fat, muscle tissue,
protein and water, have remained unchanged for many decades and are
inefficient when compared with other food production methods that
are commonly applied in other industries. These inefficiencies that
result in large part from poor controls and questionable safety
standards, often cause significant and unnecessary wastage of meat
in addition to occasional loss of human life.
[0008] A limitation of producing perishable goods such as fresh
beef patties at the point of source animal slaughter results from
shelf life limitations inherent with current packaging systems. A
major proportion of beef patties production occurs at locations
that are situated at a substantial distance from the point of sale
of these products. Beef patties are often produced at locations
remote from the point of slaughter due to short shelf life. The
present invention provides an improved, automated fresh pattie
processing system that can be readily integrated at the point of
animal slaughter.
[0009] The packaging industry has therefore felt the need for
simplified individual packaging structures that will provide
finished package performance including label requirements for a
variety of applications. Additionally, if the packaging can be
handled economically both in the pre-consumer handling and in
post-consumer recycling, significant economic advantages are
available.
[0010] With conventional packaging of meats and other perishable
type goods, the shelf life is limited due to bacterial growth
within the package. The growth can be inhibited when the package
contains carbon dioxide gas, however, carbon dioxide will dissolve
in liquids such as water contained within the goods in the package.
After time, carbon dioxide can become substantially dissolved in
the water and shelf life may be limited by this. After time,
discoloration due to formation of, for example, metmyoglobin on the
outer surface of the red meat also reduces consumer appeal of the
packaged goods. It is also known to provide other gases within the
package to enhance the keeping of the packaged goods. In the case
of red meat blends of CO.sub.2 and N.sub.2, in varying proportions
and up to 100% of each single gas have been used. When carbon
dioxide dissolves into liquids and water, this can cause the
package to collapse inwardly. Collapsing causes the appearance of
the package to be unacceptable to consumers and can also cause the
package to rupture.
[0011] In order to extend shelf and storage life of the packaged
goods several inventions have been disclosed and examples of known
packaging for this purpose are given in the following US patents:
TABLE-US-00001 5,779,832 Kocher Method and Apparatus for making a
peelable film 5,629,060 Garwood Packaging with Peelable Lid
5,560,182 Garwood Packaging Method 5,534,282 Garwood Packing
Perishable Goods 5,514,392 Garwood Packaging for Perishable Goods
5,323,590 Garwood Method of producing food packaging with gas
between tensioned film and lid 5,226,531 Garwood Food Packaging
with gas between tensioned film and Lid 5,155,974 Garwood Food
Packaging with gas between tensioned film and Lid 5,115,624 Garwood
Thermoplastic skin packing means 5,129,512 Garwood Packaging
[0012] The subject matter of the above patents is hereby
incorporated by reference.
[0013] Prior art as described in U.S. Pat. No. 5,779,832 to Kocher,
discloses a method of making a multilayer peelable film. Kocher
discloses a method of co-extruding two webs of material
simultaneously in the form of a multilayer film that can be
delaminated into a third web and a second web and then after
treating the second web to improve gas permeability therethrough,
re-laminating the third and second webs together. These two
re-laminated webs can be sealed to a first web of gas barrier
material and thereby produce a package. The first web may have a
depression formed therein into which goods such as red meat can be
placed before heat sealing the third and second webs to the first
web. Typically, goods will not completely fill the depression and
space will remain in the depression in addition to the goods. A
blend of gases or a single gas such as CO.sub.2 can be provided in
the space with the goods and thereby can contact the goods. After
storage and prior to retail display at an intended point of sale to
consumers, the third web can be peeled from the package allowing
atmospheric oxygen to permeate the second web of gas permeable
material and to contact the goods. The atmospheric oxygen can then
allow generation of a bright red colored substance such as
oxymyoglobin thereby providing an appearance attractive to the
consumers.
[0014] It has been found that when applying the second and third
webs extruded in the manner as disclosed in Kocher to packaging as
that disclosed in the inventor's own U.S. Pat. No. 5,534,282, a
dull appearance of the second web can result with reduced clarity
when compared with other webs of material that are produced in a
single web such as plasticized PVC (pPVC). Furthermore, after
removal of the third web, from the re-laminated co-extrusion, by
peeling, as described in U.S. Pat. No. 5,534,282, distortions and
ripples can appear in the second web. This occurs, partly, as a
result of inadequate lateral tension provided in the second web
when limited by the inherent limitations of co-extruding the second
and third webs simultaneously. This can, therefore, severely
detract from the visual appearance of the package in the eyes of
consumers.
[0015] A further limitation of packaging perishable goods such as
fresh red meats in hermetically sealed gas barrier packages results
from the need to enclose a relatively large volume of gases, and
particularly carbon dioxide, within the package. Clearly, consumers
have no interest in purchasing gases with red meat and minimizing
the size and bulky appearance of the package is desirable.
Additionally, a major proportion of red meat production occurs at
locations that are situated at a substantial distance from the
point of sale for red meats. Costs of shipping the goods from point
of production and packaging can be reduced if the packages are
reduced in size. However, reduction in the volume of gasses
contained within a package can have a deleterious effect on the
shelf life of perishable goods and red meats contained therein.
[0016] Conventional modified atmosphere "case ready" retail
packaged fresh red meats and other perishable type goods experience
limited shelf life because of bacterial growth, such as aerobic and
anaerobic bacteria, on the packaged goods; rancidity "off flavors"
caused, in part, by oxidizing fats; and discoloration to visible
meat surfaces. The growth can be inhibited when goods are treated
by exposure to certain agents prior to packaging and then providing
certain gasses and/or other agents with the goods within the
finished and sealed package. Such a gas, blend of gasses agent or
agents may include one or a combination of the following: oxygen,
carbon dioxide, ozone, hydrogen, nitrogen, argon, krypton, neon,
helium, xenon, hydrogen peroxide, potassium permanganate, chlorine
dioxide, fluorine, bromine, iodine and/or any other suitable
substances. However, some gasses such as carbon dioxide gas, for
example, can quickly dissolve in substances such as oils and water
contained in the goods. After time, carbon dioxide can become
substantially dissolved in water which may limit shelf life.
Furthermore, when oxygen is present and more particularly when a
quantity of approximately 5,000 to 30,000 parts per million of
oxygen is present in a gas within a package, discoloration due to
formation of metmyoglobin on the visible surface of red meat,
reduces consumer appeal of the packaged goods. When carbon dioxide
dissolves (into another substance) the combined volume of the
residual substances is substantially reduced which can cause the
package to collapse inwardly. Collapsing causes the appearance of
the package to be unacceptable to consumers and can also cause the
package to rupture and render it unfit for use. In compensating for
such a deleterious event, several existing packaging systems
require large volumes of gas to be packaged with the goods.
However, when large volumes of gas are provided, the resultant
"bulky" condition does not provide for cost efficient shipping and
distribution from the location of packaging to the point of retail
sale of the packaged goods.
[0017] Conventional packages for red meat are produced in one or
more sizes. When packaging red meats or other perishable goods, the
package must conform to the goods. Therefore, if a red meat portion
is too large for one size of a package, the next larger size must
be used. Oftentimes, this will lead to an overly large sized
package introducing inefficiency into the process because of the
wasted space. In order to maximize efficient use of the internal
space available in a typical road, rail or sea, refrigerated
shipping container or trailer, it is important to increase the
density and unit weight per unit volume of the packaged perishable
goods. The maximized efficient use of the space in the shipping
containers can be achieved by adjusting the shape of the
inconveniently shaped animal fresh red meat primal portions such
that slices of the fresh red meat primal portions will fit and
substantially fill the available space within trays of the improved
packaging.
[0018] High oxygen case ready packages are inefficient, in large
part, due to the inherent need to include a quantity/volume of gas
that is equal to, or greater than the volume of the package meat
contents. For example, a high oxygen package comprising a barrier
foam tray and clear barrier film lid, hermetically sealed to
flanges of the barrier foam tray and with a 2 lb quantity of meat
sealed therein will require approximately 1 liter of gas to be
enclosed and sealed within the package to ensure that an
approximate 10 day shelf life extension can be provided. Said gas
(referred to as modified atmosphere) will typically comprise 80%
Oxygen and 20% Carbon Dioxide but other combinations that may
include relatively small quantities (say <10%) of residual
atmospheric nitrogen are also typical. The relatively high level of
CO2 (when compared to ambient atmosphere) is provided to inhibit
bacterial growth, and with good storage temperature control a shelf
life for sound, fresh meat can be extended to over 10 days from
packaging. The bacterial controlling effect is a consequence, in
part, of a characteristic of bacteria entering a "lag phase" when
the environment in which it is placed, significantly changes . . .
eventually the bacteria will equilibrate and adapt to the
atmosphere that is present and commence normal reproduction and
extended infection. The shelf life extension will vary according to
several factors including, for example, the following: storage
temperature ie: the less variation from a minimum temperature of
approximately 29.5 degrees F. is optimum, (while ensuring that
freezing of the meat, which occurs at about 26-27 degrees F., does
not occur); the condition and age of the meat at packaging, the
conditions at the point of packaging such as hygiene, temperature
etc., muscle type and age of animal from which the meat was
harvested. Nevertheless, a shelf life extension of 10 days is
readily reproducible when conditions are maintained as required.
After a relatively short period of time, the CO2 provided within
the package will dissolve into the water and oils contained in the
meat and the oxygen is present to ensure that a consumer
appealing/acceptable "bloom: or "redness" is maintained. The
"bloom" is caused by the natural color of oxymyoglobin and
oxyhemoglobin that is present in freshly cut meat but when oxygen
is present, after approximately 9 to 10 days discoloration such as
browning due to increased levels of surface metmyoglobin, will
occur, rendering the product unsaleable or requiring a reduction in
price to sell to a consumer. Furthermore, the excessive volume of
the finished packages, results in excessive packaging material and
shipping costs and display case space at retail outlets and also
excessive costs incurred for disposal of additional cardboard etc.
at the supermarket outlets. Therefore by reducing volume of the
retail package, costs for packaging, shipping and display are
substantially reduced, which is a purpose of the inventions.
[0019] Effective packaging materials for existing, extended shelf
life, retail packaged, case ready perishable goods are often
relatively expensive and the associated packaging processes are
typically labor intensive. The use of EPS and FP can provide
desirable low cost packaging materials but the inherent cell
structure of these materials can retain residual oxygen (from air)
within the cell structure, even during and after exposure to very
low levels of air pressure (vacuum). When EPS and FP materials are
used in low residual oxygen modified atmosphere packaging, such as
described in U.S. patent application Ser. No. 09/039,150, residual
oxygen can diffuse and exchange from the cell structure, and become
present as a free gas within the master container thereby elevating
the level of oxygen present therein to a potentially undesirable
level. As described in the subject matter of US patent applications
in the name of the present inventor, apparatus for minimizing the
level of residual oxygen retained in the cell structure and master
containers are disclosed. However, such a process of gas exchange
is problematic and difficult to reliably maintain. Therefore,
packaging fabricated from solid plastics sheet, may be more
efficiently employed in this application.
[0020] Conventional "master container" or "master package" modified
atmosphere packaging (MAP) systems include loading perishable goods
into trays and then a plurality of loaded trays are subsequently
placed into a larger "master container" which may be manufactured
from a suitable gas barrier material. The "master container" is
typically evacuated of air and then filled with a gas blend that
may include a mixture of any desirable gasses which may include,
for example, 40% carbon dioxide and 60% nitrogen for a low oxygen
MAP system. The master container is then sealed with loaded trays
to provide an airtight, sealed master container, containing loaded
trays and a gas blend with a residual quantity of atmospheric
oxygen. Most desirably, for low oxygen MAP systems, the residual
quantity of atmospheric oxygen will not exceed an amount of 100 to
300 PPM (parts per million) with the balance of the gas blend
including nitrogen and carbon dioxide and/or other inert or oxygen
free gasses. Low cost packaging materials include foamed
polystyrene (EPS trays), however, the choice of material for tray
manufacture must exclude materials (unless treated in a manner that
will substantially remove atmospheric oxygen from the cell
structure), such as expanded (foamed) polystyrene (EPS), that have
a capacity to "retain" air, even after exposure to a high vacuum as
may occur in packaging processes. Therefore, in order to maintain
the residual quantity of atmospheric oxygen at not more than 100
PPM, untreated expanded (foamed) polystyrene (EPS) or FP trays
cannot be easily and efficiently used. By way of explanation, EPS
trays are typically thermoformed from extruded EPS sheet. A typical
method of producing EPS sheet is to "foam" the melted (liquid)
polystyrene by injection of a foaming agent, such as nitrogen,
carbon dioxide or pentane, into liquid polystyrene thereby causing
it to foam (become frothy, with bubbles and/or tiny gas filled
cells within the foam) and then extrude the foam through a slot in
a flat or annular die. The extruded EPS can then cool and solidify
into a sheet that can be slit and wound onto a roll prior to
further processing. Immediately after extrusion of the EPS sheet,
cells retained within the foam are filled with nitrogen or other
gas (foaming agent) used in the foaming process. However, such a
foaming agent gas, if not retained by other means in the cell
structure, can quickly exchange with the ambient air during storage
and the cells can become filled with air. When placed within a
vacuum chamber and exposed to a high level of vacuum, as is normal
in a "master container" packaging process for low oxygen MAP
systems, cells can retain a quantity of air, even during and
subsequent to evacuation (unless the exposure to vacuum is
significantly extended to the extent required). The retained
quantity of air in the cells, can subsequently exchange with gas
within the sealed "master container" which can, thereby, elevate
the residual oxygen content of the "free" gas contained within the
"master container" above a desirable level.
[0021] A fundamental need that resulted in the development of
thermoformed EPS trays initially arose in the modern supermarket.
Fresh meats and poultry were formerly processed and retail packaged
at the supermarket immediately prior to retail display and sale.
EPS foam trays were developed to meet these supermarket
requirements, and have provided a functional and low cost retail
package, when "over wrapped" with a low cost web of plastic
material such as plasticized PVC. However, with case ready MAP
systems, such EPS trays are now required to be shipped in trucks
and other means of transport from the point of packaging, which may
be located many hundreds of miles from the point of sale. Abuse and
damage can occur to the packaging during this shipping. In an
effort to protect against damage, rigid and heavy weight cartons
with sheets, cushions and/or columns, made from suitable materials
such as chipboard are manufactured and assembled with EPS trays and
goods contained therein. Such protective packaging is expensive,
bulky and results in excessive shipping costs. Furthermore,
excessive packaging, as required for the sole purpose of protection
during shipping, must be discarded at the supermarket thereby
creating excessive waste disposal problems with the attendant costs
to the environment.
SUMMARY OF THE INVENTION
[0022] Methods and apparatus of the present invention are directed
at saturating fresh meat with CO.sub.2 prior to packaging. In this
situation, adequate CO.sub.2 can be dissolved in the tissue of the
meat and to such a level that the meat can become a source of
CO.sub.2 after packaging. This can be achieved by lowering the
temperature of the meat to a minimum (typically about 29.5 degrees
F.) and exposing it to relatively high pressure (ambient to 200 psi
or more) CO.sub.2 gas. CO.sub.2 gas dissolves more readily at lower
temperatures and therefore a part of the method is to expose the
meat to high pressure CO.sub.2 at the lowest temperature above
freezing and then retail package the meat in a tray, then over
wrapped with a highly gas permeable web of material such as pPVC.
If an extended shelf life of say not more than 10 days is adequate,
then a barrier pouch master container may not be needed, the
CO.sub.2 gas "entrained" in the meat tissue prior to packaging will
gradually be released immediately after removal from a higher
pressure to ambient and as the temperature elevates during delivery
to the point of sale and this can be sufficient to inhibit
bacterial growth and atmospheric oxygen in unlimited quantities is
available to maintain the requisite "bloom". In this way, shipping,
packaging and display costs can be reduced substantially, while
providing an extended shelf life which may be sufficient for some
industry packers and supermarkets.
[0023] Thus, the present invention discloses a method of processing
and packaging goods, the method having a step for placing goods in
an enclosed vessel containing a gas to enhance the keeping of the
goods, a step allowing the gas to contact and dissolve in liquids
and oils present in the goods, a step restricting the formation of
oxymyoglobin by substantially displacing ambient air, that may
otherwise contact the surface of the goods, with the gas, a step
providing a retail package including two overlapping webs with a
space therebetween with at least one of the webs being gas
permeable, a step transferring the meats from the vessel to a
position between the two overlapping webs and into the space
without allowing significant formation of oxymyoglobin on surface
of the meats.
[0024] In a preferred embodiment, the method is suitable to use on
goods including fresh red meats wherein the gas is a substantially
oxygen free gas.
[0025] A further embodiment is a method of packaging goods, the
method having a step providing four or more overlapping web
sections, the two outer, first and second, web sections being gas
barrier webs, the inner web sections having folded, third web
material with at least one cup-shaped depression therein that
restricts nesting of the webs together, and a fourth gas permeable
web material with space between the third and fourth web sections,
a step providing goods between the folded third web material and
the fourth web material, a step for sealing the folded third web
material and the fourth web material so as to substantially retain
the goods in the cup-shaped depression but allowing gas to pass
into and out of the space, a step for sealing the overlapping webs
after sealing the third and fourth web material but prior to
sealing the first and second webs together at a seal path near the
perimeter of the packaging which will provide a hermetically sealed
package, a step for gas flushing the chamber means with a gas to
enhance the keeping of the goods, a step for sealing the first and
second webs together by a sealing means which defines a seal path
near what will be an outer perimeter of the packaging and which
encloses the third and fourth web material within a hermetically
and substantially gas impermeable package with the goods and the
gas sealed therein and allowing the gas to contact the goods.
[0026] A further embodiment includes one or more packaging tray(s),
each fabricated from a single web of thermoformed plastics material
web. Said packaging tray having upwardly disposed side walls,
defining depression(s) with space therein into which goods are
placed, a second web of gas permeable material overlapping said
first web which may have been stretched over said packaging tray
with goods therein and hermetically sealed to fully enclose said
packaging tray and goods therein, a third web of gas impermeable
material overlapping and hermetically sealed so as to fully enclose
one or more of said first and second webs with space therein, a
suitable gas in said space, said gas or blend of gases selected for
enhancing preservation of the packaging goods by contacting the
surface of said goods, a chamber means to enclose said first,
second and third webs, prior to sealing said third web, which can
be isolated from external atmosphere by valve means, providing a
suitable pressure to said gas in said chamber, hermetically sealing
said third web.
[0027] A further embodiment is a goods packaging tray having a base
with upwardly extending side walls that terminate at a flange that
extends around a perimeter of the tray to provide a cup-shaped
recess. The tray having at least one extension connected to the
flange at a hinge. The extension having a cup-shaped flap that can
be folded about the hinge and be sealed to at least one of the
upwardly extending side walls to provide an enclosed space. The
tray having apertures at a base of the side wall of the tray so as
to provide communication between the enclosed space and the tray
that will allow liquids to pass from the tray cup-shaped recess to
the enclosed space.
[0028] A further embodiment is an apparatus for producing packaging
trays having means for thermoforming plastics sheet to form and
trim a packaging tray with a base and upwardly extending side walls
that terminate at a flange that extends around a perimeter of the
tray to provide a cup-shaped recess with at least one extension
connected to the flange at a hinge having a cup-shaped flap that
can be folded about the hinge and be sealed to at least one of the
upwardly extending side walls to provide an enclosed space. The
apparatus further includes a sealer to seal the flap to the tray
wall around a perimeter of the flap and a device to optionally
provide apertures in the side wall of the tray recess so as to
provide a communication between the enclosed space and the tray
recess.
[0029] A further embodiment includes a method and apparatus for
grinding boneless beef directly into an enclosed chamber that has
been filled with a suitable gas such as CO.sub.2 and which
substantially excludes oxygen from contacting with the ground beef.
Adjusting temperature of the ground beef to a suitable
temperature.
[0030] Processing and mixing ground beef (meat), in a vessel or
series of vessels substantially excluding oxygen, so as to blend
and adjust the relative quantities of fat and muscle in the
finished product to a desired ratio. Maintaining the ground beef at
a suitable temperature.
[0031] Extruding ground beef in a stream of grinds by pumping
through an enclosed conduit with an exit end and a selected cross
sectional area and profile that is substantially similar to typical
beef patty, at a velocity that is adjustable while maintaining
pumping at a substantially constant rate. Pressurizing a stream of
ground beef in a conduit at a selected pressure and compressing any
voids such that CO.sub.2 gas contained therein dissolves into the
stream of ground beef. Maintaining ground beef at a suitable
temperature.
[0032] Intermittently adjusting the velocity of stream of grinds so
as to intermittently slow or stop its flow as it emerges from the
exit end of the enclosing conduit and allow slicing with knife
means to provide single beef patties in stacks of a chosen
quantity. Intermittent slowing or stopping of flow may exceed 500
cycles per minute.
[0033] Interfacing with a packaging system and packaging fresh meat
patties without exposure to air while maintained at a suitable
temperature.
[0034] The present invention provides an efficient method and
apparatus for processing fresh red meat products at the point of
animal slaughter for subsequent case ready packaging and delivery
to the consumer via a typical supermarket or retail sale outlet.
The consumer may be located thousands of miles away from the point
of slaughter which often results in distribution and delivery that
can require a period of time exceeding 20 days.
[0035] The present invention provides a most efficient method and
apparatus for packaging fresh red meat products at the point of
animal slaughter for subsequent delivery to the consumer via a
typical supermarket or retail sale outlet. Consumers, located
thousands of miles away from the point of slaughter and packaging
often results in distribution and delivery that can require a
period of time exceeding 15 days.
[0036] The present invention maximizes efficient use of the
internal space available in a typical road, rail or sea,
refrigerated shipping container or trailer, it is important to
increase the density and unit weight per unit volume of said
packaged perishable goods. Effective packaging materials for
existing case ready packaging systems are often expensive and the
associated packaging processes are typically labor intensive. The
present invention provides low cost packaging trays by utilizing
various packaging materials such as polypropylene or PET.
[0037] The present invention provides improved packaging for
perishable goods, an improved appearance of the packaging and a
means to increase the level of carbon dioxide dissolved into the
liquid and water contained on or with the perishable goods, thereby
reducing the total volume of the packages, increasing density for
more efficient shipping and subsequent display at the point of
sale. The goods includes fresh red meat and a further purpose of
this invention is to provide a means of enhancing the keeping
qualities of the goods.
[0038] The present invention provides several alternative methods
of stretching the second web such that after removal of the third
web, the second web will be in a substantially "ripple free",
clear, smooth, and at least partially tensioned condition.
Additionally, a further description of a method to pre-stretch the
second web, before sealing the first web, second web and third
webs, within a single chamber sealing means is disclosed. A further
description of methods to package goods in a single chamber sealing
and packaging machine when the first and second webs are applied
separately without having been re-laminated after treatment of the
second permeable web.
[0039] Therefore in accordance with a first broad aspect of the
present invention there may be provided improved packaging for
perishable goods including: a tray or first web over which the
goods are placed, the goods including oils, fats, protein, liquids
and water. The tray having upwardly disposed side walls, defining a
depression with space therein, the side walls having been urged
inwardly to a controlled and predetermined extent and are
tensioned, thereby retaining an outwardly urging force; a second
web of gas permeable material overlapping the first web which may
have been pre-stretched; a third web of gas impermeable material
overlapping the first and second webs; a gas in the space, the gas
or blend of gasses (preferably carbon dioxide and nitrogen)
selected for enhancing preservation of the packaging goods by
contacting the surface of the goods; a chamber means to enclose the
first, second and third webs, prior to sealing, which can be
isolated from external atmosphere by valves, providing pressure to
the gas in the chamber, the pressure being at a level above ambient
atmospheric pressure, thereby providing accelerating dissolving of
the gasses and carbon dioxide into the liquids and water; and
sealing the first, second and third webs together while retaining
the side walls of the first web tray in tension with the second and
third webs.
[0040] In this way, the shelf life of the packaged goods can be
extended and when the third web is removed, the tension between the
side walls and the second web can cause the second web to be
stretched and be substantially flattened with fewer ripples in its
surface. Thus the packaging will be pleasing to an intending
purchaser.
[0041] The invention provides a labor efficient, low cost
processing and packaging system for perishable goods that can
minimize the presence of undesirable levels of both anaerobic and
aerobic bacteria, fungi, virus and residual oxygen, for an extended
period of storage time by enhancing the keeping qualities of the
perishable goods. The processing and packaging system is disclosed
herein, with further disclosures providing details of several
package configurations produced from various packaging materials
including polypropylene, amorphous polyester, expanded polystyrene
(EPS) and foamed polyester (FP).
[0042] Additionally, the present invention provides efficient
methods and apparatus for delivering fresh red meat products from
the point of animal slaughter and retail packaging to the consumer
via a typical supermarket or retail sale outlet. The consumer may
be located thousands of miles away from the point of slaughter
which often results in distribution and delivery that can require a
period of time exceeding 14 to 25 days.
[0043] The present invention provides methods and apparatus for
reducing the processing costs, provide a method to reduce the labor
content of the process and separate the carcass into at least two
groups of components that can be either used for human consumption
or not for human consumption prior to chilling the carcass.
[0044] The present invention provides improved and accurate
"portion control." For example, a New York Strip primal that
includes a strip of muscle with a fat covering on one side, can be
substantially shaped into a uniform strip prior to slicing.
Additionally, such primal items as tenderloin that have a tapered
profile can be combined and pressed together to form a single
tenderloin of uniform cross-section and then sliced to produce
uniform slices of equal size and weight. In yet a further
embodiment, the present invention provides for the cutting of meat
containing deoxymyoglobin in an atmosphere that excludes oxygen and
substantially inhibiting and preventing contact of the freshly cut
surface with oxygen in the ambient atmosphere.
[0045] The present invention provides a labor efficient, low cost
processing and packaging system for perishable goods that can
minimize the presence of undesirable levels of bacteria, rancidity,
discoloration and enhance the keeping qualities of the perishable
goods.
[0046] Trays and packaging apparatus are disclosed in the present
invention that can incorporate either a low oxygen modified
atmosphere or alternatively a high oxygen modified atmosphere. A
high oxygen modified atmosphere may include a blend of gasses
including 20% carbon dioxide, 70% oxygen and 10% nitrogen. Part of
this blend of gas may include some residual ambient atmospheric
gases.
[0047] The tray construction and packaging disclosed in this
invention describe ways to substantially eliminate excessive
packaging by incorporating multifunctional features in a single
tray. The multifunctional features include devices to allow
stacking of a plurality of trays in a vertical stack, incorporation
of an in-built protective cushion around the perimeter of the tray
and a purge absorbing feature.
[0048] Additionally, the present invention provides a most
efficient means of delivering fresh red meat products from the
point of animal slaughter and retail packaging to the consumer via
a typical supermarket or retail sale outlet. The consumer may be
located many hundreds of miles away from the point of slaughter
which often results in distribution and delivery time that can
exceed 14 to 25 days.
[0049] The present invention increases the volume of carbon dioxide
gas within a package without increasing the size and volume of the
package. This can be achieved by carbonation and increasing the
quantity of dissolved carbon dioxide in the free liquids, oils and
water contained in the package with red meat prior to hermetically
sealing the package.
[0050] In order to maximize exploitation of the benefits of
improved packaging as described herein for use with packaging of
perishable goods such as cuts of fresh red meat, as detailed
herein, a method and apparatus of changing and/or adjusting the
shape and profile of the red meat primal, before slicing the
primal, such that slices of the primal will have a permanently
adjusted shape facilitating more efficient use of the improved
packaging, is highly desirable. The description contained herein
provides a method and apparatus of achieving an adjustment and or
shape of large fresh red meat primal portions and combinations of
smaller pieces pressed together.
[0051] The present invention provides a product, method and
apparatus for processing fresh meats such as ground beef, lamb and
pork and most particularly for production of ground beef, safe bulk
storage, sale in bulk form, further processing, and packaging
according to customer specifications that are provided immediately
prior to packaging and where the product and packaging
specifications are provided by customer via electronic transfer of
information, directly, or substantially directly to the ground beef
storage and packaging equipment. Said ground beef, in whichever
form, including beef patties, being intended or human consumption
and made in accordance with the present invention. The present
invention provides an automatic and enclosed fresh meats grinding
and/or cutting, blending, processing, storage and packaging process
including the electronic business method of specifying and
purchasing the finished meat products according to the purchasers
specifications which may be specified immediately prior to
production of the specified products.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The foregoing aspects and many of the attendant advantages
of this invention will become more readily appreciated as the same
becomes better understood by reference to the following detailed
description, when taken in conjunction with the accompanying
drawings, wherein:
[0053] FIG. 1 is a perspective view of one package made in
accordance with the present invention;
[0054] FIG. 2 is a perspective view of a corner section of the
package of FIG. 1 with the heat sealable layers up turned;
[0055] FIG. 3 is a cross-sectional view of the package of FIG. 1
taken along section line 3-3;
[0056] FIG. 4 is a schematic view of an assembly line for
manufacturing a package such as shown in FIG. 1;
[0057] FIG. 5 is a schematic view of a master bag method of
packaging individual packages for storage and transport in
accordance with the present invention;
[0058] FIG. 6 is an alternate embodiment of a tray having a vent
hole in accordance with the present invention;
[0059] FIGS. 7, 8, and 9 show another embodiment of a stackable
tray built in accordance with the present invention;
[0060] FIGS. 10-15 show another embodiment of a stackable tray
constructed in accordance with the present invention;
[0061] FIG. 16 shows another embodiment of a master package and
method for storing and transporting individual packages containing
edible materials in accordance with the present invention;
[0062] FIGS. 17 and 18 show an alternate valve arrangement to that
shown in FIGS. 14 and 15;
[0063] FIGS. 19-21 show another alternate valve arrangement;
[0064] FIGS. 22-26 show the incorporation of a material for
indicating the presence of E. coli bacteria into a tray,
constructed in accordance with the present invention;
[0065] FIGS. 27-30 show a production line and method in accordance
with the present invention for producing a material for indicating
the presence of E. coli bacteria.
[0066] FIG. 31 shows a perspective view of a tray with flaps
constructed according to the present invention;
[0067] FIG. 32 shows a perspective view of the tray of FIG. 31;
[0068] FIG. 33 shows a cross-sectional view of the tray of FIG. 32
taken along line 33;
[0069] FIG. 34 shows a finished package constructed according to
the present invention;
[0070] FIG. 35 shows a master container constructed according to
the present invention;
[0071] FIG. 36 shows the master container of FIG. 35 with finished
packages enclosed therein and sealed with a lid and enclosed in a
cardboard box;
[0072] FIG. 37 shows a cross-sectional view of a tray constructed
according to the present invention;
[0073] FIG. 38 shows a perspective view of a finished package
constructed according to the present invention;
[0074] FIG. 39 shows a cross-sectional view of a tray portion
including a flap in the up position;
[0075] FIG. 40 shows a bottom plan view of the flap of FIG. 39;
[0076] FIG. 41 shows a cross-sectional view of the flap of FIG. 39
in the down position;
[0077] FIG. 42 shows a schematic view of a tray sealing apparatus
constructed according to the present invention;
[0078] FIG. 43 shows a web material constructed according to the
present invention;
[0079] FIG. 44 shows a web material constructed according to the
present invention;
[0080] FIG. 45 shows a cross-sectional view of a finished package
constructed according to the present invention;
[0081] FIG. 46 shows a cross-sectional view of a web material
constructed according to the present invention;
[0082] FIG. 47 shows a perspective view of a finished package
constructed according to the present invention;
[0083] FIG. 48 shows a tray portion including a flap in a down
position, constructed according to the present invention;
[0084] FIG. 49 shows a cross-sectional view of a web material
constructed according to the present invention;
[0085] FIG. 50 shows a perspective view of a tray with flaps
constructed according to the present invention;
[0086] FIG. 51 shows a bottom perspective view of the tray of FIG.
50;
[0087] FIG. 52 shows a bottom plan view of the tray of FIG. 50;
[0088] FIG. 53 shows a side plan view of the tray of FIG. 50;
[0089] FIG. 54 shows a cross-sectional view of a tray constructed
according to the present invention;
[0090] FIG. 55 shows a perspective view of a tray constructed
according to the present invention;
[0091] FIG. 56 shows a cross-sectional view of a tray portion of
FIG. 55 taken along line 56;
[0092] FIG. 57 shows a cross-sectional view of a tray portion of
FIG. 55 taken along line 57;
[0093] FIG. 58 shows a cross-sectional view of a tray portion of
FIG. 55 taken along line 58;
[0094] FIG. 59 shows a cross-sectional view of a web material
constructed according to the present invention;
[0095] FIG. 60 shows a perspective view of a tray constructed
according to the present invention;
[0096] FIG. 61 shows a cross-sectional view of a tray portion of
FIG. 60 taken along line 61;
[0097] FIG. 62 shows a perspective view of stacked trays
constructed according to the present invention;
[0098] FIG. 63 shows a cross-sectional view of the stacked trays of
FIG. 62;
[0099] FIG. 64 shows a perspective view of a finished package
constructed according to the present invention;
[0100] FIG. 65 shows a perspective view of a tray with flaps
constructed according to the present invention;
[0101] FIG. 66 shows a schematic view of a tray portion including a
flap constructed according to the present invention;
[0102] FIG. 67 shows a cross-sectional view of a tray portion of
FIG. 65 taken along line 67;
[0103] FIG. 68 shows a cross-sectional view of a tray portion of
FIG. 65 taken along line 68;
[0104] FIG. 69 shows a detailed view of FIG. 68;
[0105] FIG. 70 shows a cross-sectional view of a tray portion
including a flap constructed according to the present
invention;
[0106] FIG. 71 shows a cross-sectional view of a web material
constructed according to the present invention;
[0107] FIG. 72 shows a cross-sectional view of a detailed tray
portion of FIG. 70;
[0108] FIG. 73 shows a cross-sectional view of a finished package
with a pealable label constructed to the present invention;
[0109] FIG. 74 shows a perspective view of the package with label
of FIG. 73;
[0110] FIG. 75 shows a cross-sectional view of a finished package
with over wrap web material constructed according to the present
invention;
[0111] FIG. 76 shows a perspective view of the finished package of
FIG. 75;
[0112] FIG. 77 shows a cross-sectional view of the finished package
of FIG. 76 with the over wrap in its loose state;
[0113] FIG. 78 shows a cross-sectional view of the finished package
of FIG. 76 with the over wrap in a stretched state;
[0114] FIG. 79 shows a cross-sectional view of a master container
containing finished packages, the master container being enclosed
within a cardboard box, constructed according to the present
invention;
[0115] FIG. 80 shows a portion of the master container of FIG.
79;
[0116] FIG. 81 shows a portion of the master container of FIG.
79;
[0117] FIG. 82 shows a perspective view of a tray with flaps
constructed according to the present invention;
[0118] FIG. 83 shows a cross-sectional view of the tray of FIG. 82
taken along line 83;
[0119] FIG. 84 shows a pair of tray pre-forms with ribs that are
arranged to provide enclosed pressure vessels after sealing;
[0120] FIG. 85 shows a side elevation of a packaging tray that has
been manufactured from a pair of pre-forms shown in FIG. 84;
[0121] FIG. 86 shows a cross-sectional view of a tray portion of
FIG. 85 taken along line 86;
[0122] FIG. 87 shows a cross-sectional view of the tray portion of
FIG. 86 taken along line 87;
[0123] FIG. 88 shows a three dimensional view of a complete
packaging tray comprising a base 303 with four upwardly extending
side walls terminating at a continuous flange 901 that follows a
path at a perimeter of the packaging tray and surround a cavity
110;
[0124] FIG. 89 shows a cross sectional view through the packaging
tray shown in FIG. 88;
[0125] FIG. 90 shows a plan view of a thermoformed pre-form that
can be fabricated by folding and bonding to form a packaging tray
as shown in FIG. 88;
[0126] FIG. 91 shows a cross-sectional view of a tray portion of
FIG. 89;
[0127] FIG. 92A shows a plan view of a thermoformed pre-form that
can be fabricated by folding and bonding flaps 10, 11, 13, 16, 14,
and 15 to form a packaging tray with cavity 12 as shown in FIGS. 95
and 96;
[0128] FIG. 92B shows a cross sectional view of a tray flap of FIG.
92A.
[0129] FIG. 93 shows two thermoformed and fabricated packaging
trays 20 and 21, that are nested and stacked together to provide a
stack of trays;
[0130] FIG. 94 shows a cross section through an apparatus that is
arranged to seal flaps (such as 10, 11, 13, 16, 14, and 15 shown in
FIG. 92) to the walls of a packaging tray (such as shown in FIG.
92) to produce trays such as 40 and 41 shown in FIG. 95;
[0131] FIG. 95 shows a side elevation of two packaging trays that
are stacked after flaps, such as 10, 11, 13, 16, 14, and 15 shown
in FIG. 92 have been sealed to walls of the tray;
[0132] FIG. 96 shows an end view of two packaging trays that are
stacked after flaps, such as 10, 11, 13, 16, 14, and 15 shown in
FIG. 92 have been sealed to the corresponding walls of the
tray;
[0133] FIG. 97 shows a three dimensional view of a packaging tray
60 with ribs 62, 63, 65 and 66 formed into the profile of flaps and
walls of the packaging tray;
[0134] FIG. 98 shows a cross-sectional view of tray 60 in FIG. 6
taken along line 2;
[0135] FIG. 99 shows a perspective view of a tray according to the
present invention;
[0136] FIG. 100 shows a cross-sectional view of a tray portion of
FIG. 99 taken along line 100;
[0137] FIG. 101 shows a cross-sectional view through a segment of a
preferred packaging tray embodiment;
[0138] FIG. 102 shows a cross-sectional view of a tray portion of
FIG. 101 taken along line 102;
[0139] FIG. 103 shows details of the components used to manufacture
a composite tray;
[0140] FIG. 104 shows a plan view of a web material to construct a
tray according to the present invention;
[0141] FIG. 105 shows a cross section through an apparatus with
housing 12, and a tapering screw 15 mounted therein; a piston 16,
with corresponding cylinder 25, is mounted to housing 12 and a
restricting conduit 18 is attached to the exit end of housing 12,
grinds 20 can be transferred into said housing 12 and screw 15 may
be used for pumping said grinds into a profiled conduit thereby
providing an extruded stream of grinds for subsequent slicing and
thereby production of patties;
[0142] FIG. 106 shows a cross section through an apparatus intended
for use in slicing extruded streams of ground meats to produce
patties, a temperature controlled conduit 45 is mounted adjacent to
a revolving blade 47, such that stacks of sliced patties 51 and 52
can be produced and transported to a packaging station via conveyor
belting 50 that is driven intermittently by drive roller 49 in
direction shown by arrow 52;
[0143] FIG. 107 shows a cross-sectional view of an apparatus
portion of FIG. 105 taken along line 107;
[0144] FIG. 108 shows a side elevation of an apparatus assembled to
produce fine ground boneless beef 77, from coarse ground boneless
beef 61, after fine grinding into vessel 70 from grinder 65, ground
beef 77 is pumped, in the direction shown by arrow 74, via servo
driven positive displacement pump 71, through conduit 73 which can
be connected directly to conduit 9, shown in FIG. 1. Conduit
connections 66 and 78 are provided to allow injection of gas such
as CO.sub.2 there through and conduit connection 79 is provided to
allow gases to be withdrawn from vessel 70;
[0145] FIG. 109 shows a side elevation, cross sectional view of an
apparatus that is arranged to automatically measure and slice
portions of meat primals that have been molded to a predetermined
profile corresponding with a temperature controlled conduit 81 of
similar profile, pre-conditioned and tempered primal cuts of
boneless meat 87 are located in an entry end of conduit 81 followed
by a plug such as 82, electromagnetic driving fixtures 83 are
arranged to intermittently drive and by magnetic bonding to each
plug, carry plugs such as 81, in a forward direction and a distance
equal to the selected thickness of a single slice of beef, blade 92
is controlled to intermittently slice during a single revolution
shaft 91, conveyor 94 is mounted in an enclosure 98, and adjacent
to the exit end of conduit 81, so as to conveniently carry slices
to a further processing or packing station;
[0146] FIG. 110 shows a cross-sectional view of an apparatus
portion of FIG. 109 taken along line 110;
[0147] FIG. 111 shows a cross-sectional view of an apparatus
portion of FIG. 109 taken along line 111;
[0148] FIG. 112 shows a cross-sectional view of a finished package
constructed according to the present invention;
[0149] FIG. 113 shows a perspective view of a finished package
constructed according to the present invention;
[0150] FIG. 114 shows a perspective view of a tray with flaps
constructed according to the present invention;
[0151] FIG. 115 shows a cross-sectional view of a tray portion
including flaps of FIG. 114;
[0152] FIG. 116 shows a cross-sectional view of a tray constructed
according to the present invention;
[0153] FIG. 117 shows a perspective view of a tray with a flap
constructed according to the present invention;
[0154] FIG. 118 shows a cross-sectional view of packages stacked
atop one another, constructed according to the present
invention;
[0155] FIG. 119 shows a top plan view of a tray constructed
according to the present invention;
[0156] FIG. 120 shows a cross-sectional view of a tray portion of
FIG. 119;
[0157] FIG. 121 shows a cross-sectional view of a tray portion of
FIG. 119;
[0158] FIG. 122 shows a cross-sectional view of a plurality of
stacked trays with flaps, constructed according to the present
invention;
[0159] FIG. 123 shows a cross-sectional view of a tray with a flap
constructed according to the present invention;
[0160] FIG. 124 shows a cross-sectional view of a finished package
constructed according to the present invention;
[0161] FIG. 125 shows a cross-sectional view of a master container
containing finished packages constructed according to the present
invention;
[0162] FIG. 126 shows a perspective view of a tray portion
constructed according to the present invention;
[0163] FIG. 127 shows a cross-sectional view of a tray portion of
FIG. 126;
[0164] FIG. 128 shows a cross-sectional view of stacked trays in a
master container constructed according to the present
invention;
[0165] FIG. 129 shows a cross-sectional view of a finished package
with a flap constructed according to the present invention;
[0166] FIG. 130 shows a cross-sectional view of a tray with flap
constructed according to the present invention;
[0167] FIG. 131 shows a top plan view of a tray portion with flap
constructed according to the present invention;
[0168] FIG. 132 shows a side plan view of a tray portion of FIG.
131;
[0169] FIG. 133 shows a side plan view of stacked trays according
to the present invention;
[0170] FIG. 134 shows a top plan view of a tray portion with flaps
constructed according to the present invention;
[0171] FIG. 135 shows a perspective view of a tray portion with the
flaps folded down according to the present invention;
[0172] FIG. 136 shows a cross-sectional view of a tray portion of
FIG. 135 taken along line 136;
[0173] FIG. 137 shows a cross-sectional view of a tray with flaps
constructed according to the present invention;
[0174] FIG. 138 shows a cross-sectional view of a tray with flaps
containing iron particles constructed according to the present
invention;
[0175] FIG. 139 shows a cross-sectional view of a tray portion of
FIG. 138;
[0176] FIG. 140 shows a schematic view of an apparatus for applying
iron particles according to the present invention;
[0177] FIG. 141 shows a cross-sectional view of an apparatus
portion of FIG. 140;
[0178] FIG. 142 shows a cross-sectional detailed view of an
apparatus portion of FIG. 141;
[0179] FIG. 143 shows a schematic view of an apparatus for applying
iron particles according to the present invention;
[0180] FIG. 144 shows a top plan view of a web material containing
iron particles according to the present invention;
[0181] FIG. 145 shows a cross-sectional view of the web of FIG. 144
taken along line 145;
[0182] FIG. 146 shows a schematic view of an apparatus for
packaging and forming holes in web materials according to the
present invention;
[0183] FIG. 147 shows a side plan view of a tray formed by the
apparatus of FIG. 146;
[0184] FIG. 148 shows a schematic view of a master container
sealing apparatus according to the present invention;
[0185] FIG. 149 shows a perspective view of an apparatus portion of
FIG. 148;
[0186] FIG. 150 shows a cross-sectional view of an apparatus
portion of FIG. 149 taken along line 150;
[0187] FIG. 151 shows a schematic view of a packaging, labeling,
and weighing apparatus according to the present invention;
[0188] FIG. 152 shows a top plan view of the apparatus of FIG.
151;
[0189] FIG. 153 shows a top plan view of a register formed
according to the present invention;
[0190] FIG. 154 shows a cross-sectional view of a vacuum chamber
constructed according to the present invention;
[0191] FIG. 155 shows a cross-sectional view of an apparatus
portion according to the present invention;
[0192] FIG. 156 shows a cross-sectional view of a vacuum chamber
constructed according to the present invention;
[0193] FIG. 157 shows a cross-sectional view of a tray with flaps
according to the present invention;
[0194] FIG. 158 shows a cross-sectional view of a tray portion with
flap of FIG. 157;
[0195] FIG. 159 shows a cross-sectional view of a sealing plate
constructed according to the present invention;
[0196] FIG. 160 shows a top plan view of a sealing plate according
to the present invention;
[0197] FIG. 161 shows a top plan view of a sealing plate according
to the present invention;
[0198] FIG. 162 shows a cross-sectional view of the sealing plate
of FIG. 161 taken along line 162;
[0199] FIG. 163 shows a cross-sectional view of a finished package
constructed according to the present invention;
[0200] FIG. 164 shows a cross-sectional view of a tray located in a
sealing plate according to the present invention;
[0201] FIG. 165 shows a top plan view of a sealing plate according
to the present invention;
[0202] FIG. 166 shows a schematic view of tray walls being bonded
when located in the sealing plate according to the present
invention;
[0203] FIG. 167 shows a cross-sectional view of a vacuum chamber
constructed according to the present invention;
[0204] FIG. 168 shows a schematic view of an apparatus for loading
and sealing trays according to the present invention;
[0205] FIG. 169 shows a schematic view of an apparatus for forming
a laminated web according to the present invention;
[0206] FIG. 170 shows a schematic view for an apparatus for
packaging trays using a laminated web according to the present
invention;
[0207] FIG. 171 shows a cross-sectional view of a web material
according to the present invention;
[0208] FIG. 172 shows a schematic view of a packaging and sealing
apparatus constructed according to the present invention;
[0209] FIG. 173 shows a cross-sectional view of a tray with a
laminated web;
[0210] FIG. 174 shows a cross-sectional view of a tray with a
single web;
[0211] FIG. 175 shows a schematic view of an apparatus for forming
master containers according to the present invention;
[0212] FIG. 176 shows a cross-sectional view of the apparatus of
FIG. 175 taken along line 176;
[0213] FIG. 177 shows a cross-sectional view of an apparatus
portion of FIG. 175 taken along line 177;
[0214] FIG. 178 shows a cross-sectional view of an apparatus
portion of FIG. 176;
[0215] FIG. 179 shows a finished package enclosed within a master
container;
[0216] FIG. 180 shows an apparatus for grinding and processing meat
constructed according to the present invention;
[0217] FIG. 181 shows an apparatus for grinding and processing meat
constructed according to the present invention;
[0218] FIG. 182 shows a cross-sectional view of an apparatus
portion of FIG. 181;
[0219] FIG. 183 shows a cross-sectional view of an apparatus
portion of FIG. 181;
[0220] FIG. 184 shows a front plan view of a manifold constructed
according to the present invention;
[0221] FIG. 185 shows a side plan view of the manifold of FIG.
184;
[0222] FIG. 186 shows a cross-sectional view of an apparatus for
grinding and processing meat according to the present
invention;
[0223] FIG. 187 shows a cross-sectional view of an apparatus for
processing meat constructed according to the present invention;
[0224] FIG. 188 shows a side plan view of an apparatus portion of
FIG. 187;
[0225] FIG. 189 shows a cross-sectional view of an apparatus
portion of FIG. 188 taken along line 189;
[0226] FIG. 190 shows a cross-sectional view of an apparatus
portion of FIG. 187 taken along line 190;
[0227] FIG. 191 shows a top plan view of a tube structure according
to the present invention;
[0228] FIG. 192 shows a cross-sectional view of an apparatus
portion having three meat processing tubes, constructed according
to the present invention;
[0229] FIG. 193 shows a cross-sectional view of an apparatus for
grinding and processing meat;
[0230] FIG. 194 shows a cross-sectional view of an apparatus
portion of FIG. 187;
[0231] FIG. 195 shows a cross-sectional view of a measuring device
constructed according to the present invention;
[0232] FIG. 196 shows a top plan view of a packaging and slicing
apparatus having a tunnel, constructed according to the present
invention;
[0233] FIG. 197 shows a cross-sectional view of the apparatus of
FIG. 196 taken along line 197;
[0234] FIG. 198 shows a schematic view of a meat processing
apparatus constructed according to the present invention;
[0235] FIG. 199 shows a schematic view of a meat processing and
packaging apparatus constructed according to the present
invention;
[0236] FIG. 200 shows a schematic view of a meat processing and
packaging apparatus constructed according to the present
invention;
[0237] FIG. 201 shows a schematic view of a meat processing and
packaging apparatus constructed according to the present
invention;
[0238] FIG. 202 shows a cross-sectional view of a web material
constructed according to the present invention;
[0239] FIG. 203 shows a perspective view of an over wrapping web
material constructed according to the present invention;
[0240] FIG. 204 shows a perspective view of an over wrapped package
constructed according to the present invention;
[0241] FIG. 205 shows a schematic view of an apparatus portion
constructed according to the present invention;
[0242] FIG. 206 shows a top plan view of an apparatus portion
constructed according to the present invention;
[0243] FIG. 207 shows a cross-sectional view of a meat blending
apparatus constructed according to the present invention;
[0244] FIG. 208 shows a cross-sectional view of the meat blending
apparatus of FIG. 207 taken along line 208;
[0245] FIG. 209 shows a schematic view of a meat processing and
conditioning apparatus constructed according to the present
invention;
[0246] FIG. 210 shows a cross-sectional view of a meat forming and
shaping apparatus constructed according to the present
invention;
[0247] FIG. 211 shows a side plan view of an apparatus portion of
FIG. 210;
[0248] FIG. 212 shows a perspective view of a meat forming and
shaping apparatus constructed according to the present
invention;
[0249] FIG. 213 shows a schematic view of a master container
sealing apparatus constructed according to the present
invention;
[0250] FIG. 214 shows a cross-sectional view of the apparatus of
FIG. 212;
[0251] FIG. 215 shows a cross-sectional view of a meat forming and
shaping apparatus constructed according to the present
invention;
[0252] FIG. 216 shows a side plan view of an apparatus portion of
FIG. 215;
[0253] FIG. 217 shows a cross-sectional view of a forming and
shaping apparatus for several primals, constructed according to the
present invention;
[0254] FIG. 218 shows a cross-sectional view of an apparatus
portion of FIG. 216;
[0255] FIG. 219 shows a cross-sectional view of an apparatus
portion of FIG. 218;
[0256] FIG. 220 shows a cross-sectional view of an apparatus
portion for forming and shaping meat primals constructed according
to the present invention;
[0257] FIG. 221 shows a cross-sectional view of an apparatus
portion for shaping and forming meat primals constructed according
to the present invention;
[0258] FIG. 222 shows a schematic view of an equipment layout
constructed according to the present invention;
[0259] FIG. 223 shows a cross-sectional view of a master container
vacuum chamber constructed according to the present invention;
[0260] FIG. 224 shows a schematic view of an equipment layout
constructed according to the present invention;
[0261] FIG. 225 shows a cross-sectional view of a tube apparatus of
FIG. 224 taken along line 225;
[0262] FIG. 226 shows a perspective view of a spool for storing web
material constructed according to the present invention;
[0263] FIG. 227 shows a schematic view of a thermoforming oven of
FIG. 224 taken along line 227;
[0264] FIG. 228 shows a schematic view of equipment layout
constructed according to the present invention;
[0265] FIG. 229 shows a cross-sectional view of a web material
constructed according to the present invention;
[0266] FIG. 230 shows a cross-sectional view of a web material
constructed according to the present invention;
[0267] FIG. 231 shows a detailed view of web material constructed
according to the present invention;
[0268] FIG. 232 shows a detailed view of web material constructed
according to the present invention;
[0269] FIG. 233 shows a detailed view of web material constructed
according to the present invention;
[0270] FIG. 234 shows a detailed view of web material constructed
according to the present invention;
[0271] FIG. 235 shows a detailed view of web material constructed
according to the present invention;
[0272] FIG. 236 shows a detailed view of web material constructed
according to the present invention;
[0273] FIG. 237 shows a detailed view of web material constructed
according to the present invention;
[0274] FIG. 238 shows a perspective view of a tray treatment
apparatus constructed according to the present invention;
[0275] FIG. 239 shows a perspective view of a tray treatment
apparatus constructed according to the present invention;
[0276] FIG. 240 shows a cross-sectional view of a tray forming
apparatus constructed according to the present invention;
[0277] FIG. 241 shows a cross-sectional view of a tray forming
apparatus constructed according to the present invention;
[0278] FIG. 242 shows a cross-sectional view of web material
constructed according to the present invention;
[0279] FIG. 243 shows a cross-sectional view of web material
constructed according to the present invention;
[0280] FIG. 244 shows a cross-sectional view of a web material
constructed according to the present invention;
[0281] FIG. 245 shows a cross-sectional view of a web material
constructed according to the present invention;
[0282] FIG. 246 shows a cross-sectional view of a web material
constructed according to the present invention;
[0283] FIG. 247 shows a cross-sectional view of formed web material
constructed according to the present invention;
[0284] FIG. 248 shows a cross-sectional view of formed web material
constructed according to the present invention;
[0285] FIG. 249 shows a cross-sectional view of a web material
constructed according to the present invention;
[0286] FIG. 250 shows a cross-sectional view of a web material
constructed according to the present invention;
[0287] FIG. 251 shows a perspective view of a tray portion with
ribs constructed according to the present invention;
[0288] FIG. 252 shows a cross-sectional view of formed web material
constructed according to the present invention;
[0289] FIG. 253 shows a cross-sectional view of formed web material
constructed according to the present invention;
[0290] FIG. 254 shows a cross-sectional view of a web forming
apparatus constructed according to the present invention;
[0291] FIG. 255 shows a cross-sectional view of a web forming
apparatus constructed according to the present invention;
[0292] FIG. 256 shows a cross-sectional view of a web material
constructed according to the present invention;
[0293] FIG. 257 shows a cross-sectional view of a web aperture
forming apparatus constructed according to the present
invention;
[0294] FIG. 258 shows a cross-sectional view of a web forming
apparatus constructed according to the present invention;
[0295] FIG. 259 shows a top plan view of an apparatus portion of
FIG. 258;
[0296] FIG. 260 shows a cross-sectional view of a formed web
material constructed according to the present invention;
[0297] FIG. 261 shows a cross-sectional view of a pressure chamber
for removing oxygen from the cell structure of EPS foam constructed
according to the present invention;
[0298] FIG. 262 shows a cross-sectional view of an apparatus for
removing oxygen within the cell structure of EPS foam constructed
according to the present invention;
[0299] FIG. 263 shows a perspective view of an apparatus portion of
FIG. 261;
[0300] FIG. 264 shows a front plan view of the apparatus of FIG.
262;
[0301] FIG. 265 shows a schematic view of an apparatus with vacuum
tubes constructed according to the present invention;
[0302] FIG. 266 shows a schematic view of equipment layout
constructed according to the present invention;
[0303] FIG. 267 shows a schematic view of equipment layout
constructed according to the present invention;
[0304] FIG. 268 shows a tray with flaps having crests and
indentations constructed according to the present invention;
[0305] FIG. 269 shows a perspective view of the tray of FIG. 268
with the flaps opened upward;
[0306] FIG. 270 shows a side plan view of stacked trays of FIG. 268
showing a space between the crest and a flap indentation;
[0307] FIG. 271 shows a perspective view of a tray with flaps
constructed according to the present invention;
[0308] FIG. 272 shows a perspective view of the tray of FIG. 271
with the flaps folded downward;
[0309] FIG. 273 shows a cross-sectional view of a tray portion with
substances located within a flap space constructed according to the
present invention;
[0310] FIG. 274 shows a cross-sectional view of a tray with flaps
having flap spaces;
[0311] FIG. 275 shows a schematic representation of an apparatus
for processing fresh meat such as ground beef;
[0312] FIG. 276 shows a schematic representation of a cross section
through a conveyor and packaging tray with goods;
[0313] FIG. 277 shows a perspective view of a tray with flaps
constructed according the present invention;
[0314] FIG. 278 shows a cross section of the tray of FIG. 277
through a wall after the corresponding flap has been folded
inwardly;
[0315] FIG. 279 shows a perspective view of a mold comprising an
extruded tube of any suitable cross sectional profile having
parallel sides with end plugs that are arranged to fit within the
extruded tube so as to slide readily in a gas tight manner;
[0316] FIG. 280 shows the profile of this particular extruded
molding tube with meat portion loaded therein;
[0317] FIG. 281 shows a detail of a section of the assembled and
loaded extruded tube with an end plug in position;
[0318] FIG. 282 shows a view of a pre-form web that can be either
thermoformed or injection molded from any suitable plastics
material such as polypropylene;
[0319] FIG. 283 shows a cross sectional view of the pre-form of
FIG. 282;
[0320] FIG. 284 shows a cross sectional view of a finished package
using the pre-form of FIG. 282;
[0321] FIG. 285 shows a prespective view of a pre-form web with
corrugated corners constructed according to the present
invention;
[0322] FIG. 286 shows a perspective view of a portion of a finished
tray constructed from the pre-form web of FIG. 285;
[0323] FIG. 287 shows a schematic illustration of a representative
portion of the Internet for transacting commerce according to the
present invention;
[0324] FIG. 288 shows a block diagram of the several components of
a seller server shown in FIG. 287 that is used to store a database
and control program for servicing buyers;
[0325] FIG. 289 shows a block diagram of the several components of
a buyer computer shown in FIG. 285 that are used to store and
implement certain portions of the database and control program;
[0326] FIG. 290 shows a block diagram of a method of transacting
commerce over a communications system according to the present
invention;
[0327] FIG. 291 shows a schematic illustration of an embodiment of
a plant layout according to the present invention;
[0328] FIG. 292 shows a schematic illustration of an embodiment of
a tray packaging layout according to the present invention;
[0329] FIG. 293 shows a schematic illustration of an embodiment of
tray treatment and finishing equipment according to the present
invention;
[0330] FIG. 294 shows a perspective view of a tray portion with
flaps having the flap ends contoured to fold overlapping the tray
corners;
[0331] FIG. 295 shows a perspective view of the tray portion of
FIG. 294 with the flap ends bonded to the tray corners;
[0332] FIG. 296 shows a schematic illustration of an embodiment of
a plant layout according to the present invention;
[0333] FIG. 297 shows a schematic illustration of a section of the
plant for packaging trays with meat products;
[0334] FIG. 298 shows a sectional view of the tray de-nesting
apparatus portion of FIG. 297 before the flap ends have been bonded
to the tray walls;
[0335] FIG. 299 shows a schematic illustration of an embodiment of
an apparatus for forming webs according to the present invention;
and
[0336] FIG. 300 shows a schematic illustration of the web material
of FIG. 299.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0337] As used herein, the following terms take the following mean,
unless otherwise indicated.
[0338] The term "case ready" refers to retail packaged fresh meats
(that were typically formerly prepared at the supermarket) that has
been packaged ready for retail sale from the meat case at a place
of production remote from the supermarket.
[0339] The term "high oxygen modified atmosphere" refers to a blend
of gases that includes some or all of the naturally occurring
atmospheric gases but in proportions that are different to air and
including a high level of oxygen which may be greater than 40%.
Such an example would be a gas comprising 80% oxygen and 20% carbon
dioxide, however in virtually all applications a residual quantity
of nitrogen remains in the sealed "high oxygen modified atmosphere"
package.
[0340] The term "low oxygen" or "no oxygen" modified atmosphere"
refers to a blend of gases that includes some or all of the
naturally occurring atmospheric gases (except oxygen) but in
proportions that are different to air and including a low (or zero
level of oxygen) which may be less than 300-500 parts per
million.
[0341] The term "MAP" refers to modified atmosphere packaging.
[0342] The term "CAP" refers to controlled atmosphere
packaging.
[0343] The term "Epsilon GMS-40" or "GMS-40" refers to an apparatus
that can be used to measure the fat and/or lean content of pumpable
ground meats. The GMS-40 is manufactured and supplied by Epsilon
Industries, of Austin, Tex. Additional information is available on
web site: www.epsilon-gms.com.
[0344] The term "AVS-ET system" refers to a system that can be used
to identify the composition of boneless meats. The system can
identify quantities of fat, muscle/lean tissue, contaminants, bone,
metal inclusions and other matter that is transferred, in a
continuous stream, through a conduit and into and then away from
the AVS-ET system. The system operates preferably when the
continuous stream is exclusive of any voids such as pockets of air.
The system is manufactured and supplied by Holmes Newman
Associates, 4221 Fallsbrae Road, of Fallbrook, Calif. 92028.
[0345] The term "statiflo blending devices" refers to a continuous,
static and enclosed material blending device that can introduce
gases such as CO.sub.2 to the blended material. STATIFLO is a
registered trademark of Statiflo International, The Crown Center,
Bond Street, Macclesfield, Cheshire SKI 16QS, UK. Information is
available on web site: sales@statiflo.co.uk.
[0346] The term "blending devices" refers to a continuous, static
and enclosed material blending device that can be used to
continuously blend such perishable goods as ground meats that
comprise substantially two components of fat and lean meat and may
also be used to introduce gases such as CO.sub.2 to the blended
materials.
[0347] The term "shelf life" refers to the period of time between
the date of retail packaging of perishable goods (that are slowly
deteriorating) of acceptable quality and a subsequent point in time
or date, prior to the perishable goods having deteriorated to an
unacceptable condition.
[0348] The term "PP" refers to polypropylene.
[0349] The term "EPS" refers to expanded polystyrene.
[0350] The term "pPVC" refers to plasticized polyvinylchloride.
[0351] The term "PET," polyester or "APET" refers to amorphous
polyethylene terephthalate.
[0352] The term "heat activated adhesives (or coating)" refers to
adhesives that become active and capable of bonding substances
together when heated to a suitable temperature that otherwise, at
ambient temperature, will not bond.
[0353] The term "OTR" refers to oxygen transmission rate.
[0354] The term "perishable goods" or "goods" refers to any
perishable foods such as sliced beef or other fresh meats, ground
meats, poultry pieces etc.
[0355] The term "liquids and oils" refers to water, liquids, blood,
purge, liquid animal fats and oils and the like.
[0356] The term "master container" generally refers to a
substantially gas barrier container that can be filled with
finished packages, evacuated of substantially all atmospheric air
and filled with any suitable gas. However, said "master container"
may also be gas permeable if so desired.
[0357] The terms "suitable substance", "suitable gas" or "suitable
gases" refer to any gas or blend of gasses, provided at any
pressure (suitable pressure) such as 45% oxygen and 55% carbon
dioxide at ambient pressure or any other blend of gases. A suitable
gas may include a blend of carbon dioxide and nitrogen and oxygen
with residual atmospheric gases in any relative proportions.
Examples are provided, but are not restricted to any of the
following:
[0358] 1. A blend of gases including argon, carbon dioxide,
nitrogen and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0359] 2. Air that has been filtered to remove substantially all
oxygen therefrom.
[0360] 3. Carbon dioxide and nitrogen in any relative
proportions.
[0361] 4. Carbon dioxide and oxygen where oxygen does not exceed 5%
and is not less than 5 PPM.
[0362] 5. Carbon dioxide and a quantity of oxygen that does not
exceed 5% and is not less than 5 PPM (parts per million).
[0363] 6. Nitrogen and a quantity of oxygen that does not exceed 5%
and is not less than 5 PPM (parts per million).
[0364] 7. A blend of inert gasses and a quantity of oxygen that
does not exceed 5% and is not less than 5 PPM (parts per
million).
[0365] 8. A blend of pentane and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0366] 9. A blend of propane and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0367] 10. A blend of butane and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0368] 11. A blend of a CFC and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0369] 12. A blend of an HCFC and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0370] 13. A blend of methane and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0371] 14. A blend of hydrogen sulfide and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0372] 15. A blend of carbon monoxide and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0373] 16. A blend of sulfur dioxide and nitrogen in any relative
proportions and a quantity of oxygen that does not exceed 5% and is
not less than 5 PPM (parts per million).
[0374] 17. A gas including 100% carbon dioxide
[0375] 18. A substance or agent including one or more of the
following: isoascorbic acid, ascorbic acid, citric acid, erythorbic
acid, lactic acid, succinic acid or mixtures of salts thereof.
Glycerol monolaurate, potassium sorbate, sodium sorbate, sodium
iodoacetate, potassium acetate, iodoacetomide, potassium
iodoacetate, sodium acetate or mixtures or acidic solutions
thereof.
[0376] The term "suitable gas pressure" or "water pressure" refers
to any pressure that is suitable for the application and may be
controlled within any of the following pressure ranges, or any
other suitable pressure:
[0377] Suitable gas pressure:
[0378] gas at a pressure of 1 PSI to 14 PSI.
[0379] gas at a pressure of up to 13 PSI.
[0380] gas at a pressure of 13 PSI to 50 PSI.
[0381] gas at a pressure of 50 PSI to 80 PSI.
[0382] gas at a pressure of 80 PSI to 120 PSI.
[0383] gas at a pressure of 120 PSI to 200 PSI.
[0384] gas at a pressure of 200 PSI to 500 PSI.
[0385] gas at a pressure above 500 PSI.
[0386] Suitable water pressure:
[0387] water at a pressure of 1 PSI to 14 PSI.
[0388] water at a pressure of up to 13 PSI.
[0389] water at a pressure of 13 PSI to 50 PSI.
[0390] water at a pressure of 50 PSI to 80 PSI.
[0391] water at a pressure of 80 PSI to 120 PSI.
[0392] water at a pressure of 120 PSI to 200 PSI.
[0393] water at a pressure of 200 PSI to 500 PSI.
[0394] water at a pressure above 500 PSI.
[0395] The term "suitable gas temperature" or "suitable water
temperature" refers to any temperature that is suitable for the
application and may be controlled within any suitable temperature
ranges for any suitable period of time, or at any other suitable
temperature. Suitable temperature also includes a temperature range
which may be a pasteurizing temperature range such as maintaining a
product such as a beef primal within a temperature range of not
less than 138.5 degrees F. to 140 degrees F. and for a suitable
period of time.
[0396] Bond or Bonding refers to sealing or welding of two or more
surfaces together by any suitable means such as with any suitable
adhesive, RF welding, ultrasonic welding heat sealing, or any other
suitable means.
[0397] Hermetic seal refers to a seal or bonding of two or more
surfaces of any suitable material together by any suitable means to
provide an enclosed space and wherein said enclosed space is
rendered fully enclosed in such a manner that will substantially
inhibit the passage or communication of any substance such as gas,
air or liquids from within said enclosed space to and with the
exterior of said enclosed space.
[0398] Pre-Form refers to a thermoformed or suitably fabricated
packaging component that has been arranged with one or more hinged
flaps that can be folded or bonded to produce a useful packaging
tray or container for goods. Pre-forms may also comprise more than
one component that are subsequently assembled together to provide
one or more components but where the number of items remaining
after assembly are less than the number of components from which
the remaining items are produced.
[0399] "Valve" refers to any suitable valve to suit the particular
needs of the disclosed application. Valves may be arranged to
control the flow of gas, liquid, or solids such as powders and can
be selected from manufacturers skilled in the arts of valve
manufacturing of any particular valve from any suitable
materials.
[0400] "CPU" refers to a central processing unit or any suitable
computer processor suitable for the application such as are
contained in most personal computers (PC).
[0401] "HHRCD" refers to a hand held remote controlling device such
as a PALM PILOT.RTM..
[0402] "Fat" content is a component of meat and may mean the
measured fat content of a quantity of boneless meat harvested from
any species of slaughtered animal such as beef.
[0403] "Meat" can mean any meat harvested from any species of
slaughtered animal wherein the meat comprises several components
but generally including water, fat, oils, and protein in relative
quantities that are not precisely known at the time of harvesting
and must be measured to determine the precise ratio of each
component.
Trays with Peelable Lids
[0404] In accordance with the present invention, trays having
peelable lids are disclosed herein. Perishable goods packaged in
trays with peelable lids have extended shelf life. A peelable lid
provides a method of delaying the exposure of fresh meat contained
within a package to ambient air at a predetermined period,
preferably at the point of sale.
[0405] Referring first to FIGS. 1, 2, and 3, a preferred package
100 made in accordance with the present invention includes a tray
102 into which meat 104 (FIG. 3) or other perishable food product
is placed. A first layer 106 and second layer 108 of heat sealable
material are then placed over the tray 102 and heat sealed to the
upper horizontal flange 110 that extends outwardly from the upper
periphery of the tray 102. By draftsman's license used in
accordance with the present invention, the layers 106 and 108 are
shown separated. In actuality, they are in intimate contact
throughout their entire length and width. The layers 106 and 108
are also shown to be heat sealed to each other by cross hatching
shown in the drawings at locations 112 between the two layers and
between the bottom layer 106 and the tray flange 110. In actuality
again, there is no substantial thickness at the heat sealed
locations, but in fact, the materials are in intimate contact with
each other and/or the flange 110 of the tray 102. Thereby
substantially expelling/removing air or gas from therebetween.
[0406] Depending upon the particular design and use of the tray,
the first layer 106 can be composed of a substantially gas
impermeable barrier layer or a substantially gas permeable layer.
Similarly, the outer layer 108 can either be substantially gas
impermeable or permeable. Substantially gas permeable materials
include plasticized polyvinyl chloride (pPVC) and polyethylene
(PE). Preferably, these are more typically used in thicknesses from
0.0004 inches to 0.001 inches. Preferably, suitable barrier layers
(substantially gas impermeable) are composed of amorphous
polyethylene terephthalate (APET) unplasticized polyvinyl chloride
(uPVC) and a composite material such as a biaxially oriented
polyester/tie/polyvinylidene chloride/tie/polyethylene. Other
suitable materials known to those of ordinary skill can also be
employed in accordance with the present invention. The trays are
preferably made of polyester (APET, amorphous polyethylene
terephthalate often referred to as polyester), polyvinyl chloride
or other suitable food grade polymers. As used herein, a web is a
sheet of material that may have one or a plurality of layers or
zones of differing compositions. Also, when the terms
"substantially gas permeable" or "substantially gas impermeable"
are used, they are intended to reflect the fact that no practical
heat sealable material is totally gas permeable or impermeable.
Materials disclosed herein as substantially gas impermeable will
serve as a barrier layer to the transfer of significant amounts of
gas over time. Likewise substantially gas permeable materials will
not function as a barrier but will allow ready diffusion of gas
therethrough.
Method for Producing Peelable Lids
[0407] A method is disclosed for producing the peelable lids
disclosed above which include a label.
[0408] Referring now to FIG. 4, a side elevation of a package
sealing arrangement for assembling a package of the type disclosed
in FIG. 1 is shown. Trays 102 are loaded with perishable edible
material 104 and placed in conventional carrier plates on a
conveyor (not shown) and conveyed toward a heat sealing station
114. A roll 116 of heat sealable material is supplied above the
conveyor. The sheet of material that will become the inner web 106
from the roll 116 travels downwardly and wraps around a roller 118
and then traverses horizontally in a left-to-right direction along
with the trays 102 being conveyed by a conveyor (not shown). A
label dispenser 118 positions a label 120 on the upper surface of
the inner web 106 of heat sealable material. The outer web 108 of
sheet material is then drawn from roll 122 downwardly around
another roller 124 and traverses horizontally from left-to-right,
where the label 120 is captured between the inner and outer webs
106 and 108. The two webs and the label are then run through a pair
of nip rolls 126 to cause the two webs and the label to come into
intimate contact and also substantially removing air from between
the webs. The webs of heat sealable material 106 and 108 are then
positioned at the heat sealing station 114. Corresponding tray 102
is positioned in the lower portion 114 of the heat sealing chamber.
The lower portion of the heat sealing chamber 162 is then raised
upwardly toward the upper portion 160 of the heat sealing chamber
wherein the webs 106 and 108 are sealed to each other and to the
upper surface of the flange/lip portion of the tray 102 around the
periphery at the flange. At the same time, a knife incorporated
into the mechanism trims the excess material neatly around the
outer edge of the tray flange 110. The scrap material 128 is then
passed around a roller 130 and onto a scrap retrieval roll 132. The
tray 102 is then moved onto another conveyor where the finished
packages 134 are moved from left to right to a transportation
and/or storage station.
Apparatus for Forming Peelable Lids
[0409] Referring to FIGS. 42-44, a schematic side elevation view
through a section of a package is shown. A schematic view is
provided so as to clearly disclose an example of a preferred
peelable seal mechanism that will facilitate peeling of the third
web from the package while the second web remains substantially
intact and sealed to the first web. The example is provided to show
preferred plastics materials that will seal as required when used
according to the present invention. Other selected materials may
also be used in similar manner without departing from the general
ambit of this invention. First 1002, second 1004, and third 1006
webs are shown where, in this instance, first web 1002 preferably
includes a thermoformed tray produced from a multilayer co-extruded
material including first, outer layer 1088 of Eastman 9921 about
0.008'' thick and a second inner layer 1086, about 0.004'' thick,
including a blend of about 50% PETG 6763 and about 50% Eastman 5116
(or Eastman PM14458 or equivalent shown in FIG. 42). Second web
1004 preferably includes a web of pPVC with a thickness of about
0.0008''. Referring to FIG. 41, third web 1006 preferably includes
a two layer co-extruded web with a first outer layer 1082 of
Eastman PET 9921 about 0.003'' in thickness and a second inner
layer 1084 about 0.003'' thick including a blend of about 16%
Eastman PETG 6763 and about 84% Eastman PET 9921. Referring now to
FIG. 40, preferably, a water cooled clamp 1104 is shown in position
above the flanges of first, second and third webs and two separate
heat seal bars 1106 and 1008 are arranged adjacent thereto and all
are separated by space and are each independently activated and
controlled and moved. Preferably, heat seal bar 1106 can have a set
temperature of about 385 degrees F. and heat seal bar 1108 can have
a set temperature of about 370 degrees F. Third web second inner
layer 1084 will heat seal to second web when the temperature at the
interface of second and third webs reaches about 385 degrees F. and
above. Preferably, second web will heat seal to second inner layer
1086 of first web 1002 when the temperature of the interface
between the first and second webs is about 370 degrees F. and
above.
[0410] Preferably, the water cooled clamp 1104 is mounted to an
independently activated pneumatic driver, providing downward
pressure such that the water cooled clamp can clamp against first,
second and third webs so as to hold them firmly against the rubber
seal 1110 located beneath the first web flange portions 1072 and
1074. Preferably, heat seal bars 1106 and 1108 are independently
attached to pneumatic drivers for applying pressure thereto so as
to facilitate a method to seal third, second and first webs
together under independently selected pressure. Preferably, heat
seal bar 1106 heat seals the third, second and first webs together
at 1112 and 1114 and heat seal bar 1108 heat seals the second web
1004 to the first web 1002 at 1116 but does not heat seal the
interface between the third 1006 and second 1004 webs. When the
package is assembled and sealed in the foregoing manner, the third
web 1006 can be peeled from the package without rupturing the
second web 1004. Preferably, second web 1004 may be perforated so
that after seals 1112, 1114 and 1116 have been provided, the second
1004 and third 1006 webs can be separated to provide a space 1118
therebetween.
[0411] Seals at 1112, 1114, and 1116 have been shown as heat seals,
however, effective sealing can be achieved with use of ultra sonic
devices or alternatively latex rubber adhesives when applied at the
interfaces of the webs at 1112, 1114, and 1116, or with any other
suitable method of sealing. Such sealing can provide improved
economics while still providing an effective peeling mechanism as
required and described above.
Stackable Trays, Trays with Valves
[0412] Conventional thermoformed trays are shaped in a mold which
have sides that generally are inclined to facilitate separation
between the mold and the tray. Thus, making them cumbersome to
stack when filled, because the smaller area at the bottom cannot be
suitably supported by the larger opening at the top. Trays
constructed according to the present invention include members, in
the form of flaps that provide a suitable resting area for the
lower portion of the tray when stacked atop one another.
Embodiment 1
[0413] Referring now to FIGS. 7-9, a preferred embodiment of a
stackable tray 200 constructed in accordance with the present
invention is illustrated. Referring first to FIGS. 7 and 8, a tray
202 has a recessed bottom 204 so as to form peripheral legs 206 on
which the tray rests. The longitudinal edges of the tray each
include a flange 208. The outer flange 208 is coupled to an inner
flange 210 of the tray by a hinge member 212. The inner flange is
integral with and extends outwardly from the upper edge of the tray
202. A recessed platform 214 is formed across the corner of the
tray at diagonal corners of the tray. The bottom of the platform
214 is lowered slightly relative to the level of inner flange 210.
The platform 214 in the edge of the tray carries a small depression
216, the bottom of which is perforated. During evacuation and
flushing, gases can rapidly enter through the perforation in the
depression 216, travel through the recess formed by platform 214
into the interior of the tray and vice versa. Adjacent to the
recessed platform 214, the flange 208 includes an outwardly
extended flap 218. In the unfolded position shown in FIG. 7, the
flap carries a concave dimple 220 (viewed from the top). The dimple
is located relative to the hinge 212 such that when the flange 208
is folded over on top of the flange 210, the dimple 220 resides
directly above and central to the depression 216. When desired, the
dimple can be depressed from the upper side so as to reverse its
concavity. When the concavity is reversed, it extends downwardly
into depression 216 to close off the perforation in the cavity and
thus seal the container.
[0414] Referring now to FIG. 8, a first and second web 222 and 224,
respectively, of heat sealable material overlay the upper portion
of the tray 202 and are heat sealed to the upper surface of the
flange 210. First web 222 may be incorporated by deleting web 222.
A label 226 or other indicia bearing material can be sandwiched
between the heat sealable layers 222 and 224. The method for
incorporating a label between a first and second web has been
described above.
[0415] The label 226 sandwiched between heat sealable webs 222 and
224 is optional and can cover the entire surface of the tray 202.
Alternatively, the label can cover only a portion of the product
contained in the tray. The label can carry graphics that, for
example, show the contents in a fully prepared and cooked condition
to suggest to the consumer how the product will look when cooked,
yet allowing the consumer to see at least a portion of the fresh
product in the tray. For example, if the tray contained fresh beef
patties, the label could cover half of the exposed upper surface.
The label may be arranged with a straight cut or opening running
the full length of the package. Alternatively, the label could be
positioned on one side of a diagonal through the package, while the
portion of the package on the opposite side of the diagonal would
be open for viewing the fresh, packaged product.
[0416] Referring again to FIG. 7, the remainder of the longitudinal
extent of the flanges 208 include lateral reinforcing ribs 228 that
extend upwardly from the flanges 208 when folded over the top of
flange 210. The reinforcing ribs 228 have a recess 230 that
receives the legs 206 of an identical container stacked on top of a
first container as shown in FIG. 9. The recesses inhibit lateral
movement of one tray relative to another. Thus, these containers
are stackable for use for example in the master bag evacuation
technique which will be described below in conjunction with FIG.
5.
Embodiment 2
[0417] Referring now to FIGS. 10-13, another embodiment of a
stackable tray 300 constructed in accordance with the present
invention is illustrated. The tray in plan form is generally
rectangularly shaped. The tray includes first and second sidewalls
302 and first and second end walls 304. Walls 302 and 304 are
generally upright and slope inwardly from their upper portion
toward the tray bottom 306 to facilitate separation from a mold.
The bottom 306 has a raised central portion 308 that slopes
downwardly toward the bottom of each end wall 304. The upper end of
the sidewalls 302 and end walls 304 terminate in an outwardly
extending horizontal flange 310 that extends completely around the
tray 300. The raised center portion 308 creates a cavity 312 in the
bottom of the tray. When the trays are filled and stacked, the
contents extend above the flange 310. The cavity 312 will
accommodate the raised contents without compression in a stacked
arrangement.
[0418] Referring to FIGS. 10-13, a horizontal platform 314 is
formed in diagonally opposed corners of the tray. The platform 314
is positioned at an elevation slightly below that of flange 310. A
wall segment 316 extends downwardly from the inner edge 318 of the
platform 314 and has edges that join the sidewalls 302 and end
walls 304. The platform 314 and the wall 316 form a recess on the
outside of the tray. An aperture 320 is formed in the center
portion of platform 314 and allows gas communication between the
inside of the tray and the outside of the tray via the recess when
a web is sealed over the tray to flange 310.
[0419] Referring now to FIGS. 14 and 15, the tray 300 also has
movable flanges 322 that are hinged via a hinge 324 to the outer
edges of the portions 310a of horizontal flanges 310 that extend
outwardly from the end walls 304. The flange 322 when open carries
a hemispherical shaped dimple 326. The center of the dimple 326 is
on a line perpendicular to the hinge 324 which line also runs
through the center of aperture 320. The centers of the aperture 320
and the dimple 326 are equidistantly spaced from the hinges. Thus,
as shown in FIG. 14, when the movable flange 322 is folded over the
flange 310, the dimple 326 resides over the aperture 320. Referring
to FIG. 14, when a web 328 of material is heat-sealed over the top
of the tray 300, the interior of the tray 300 remains open to the
atmosphere through the space between platform 314 and web 328
through aperture 320. As will be better understood below, it is
many times desirable to close the aperture 320. This is done by
pressing downwardly on the exterior of the dimple 326 forcing it to
reverse itself as shown in FIG. 15 and extend downwardly and fill
the aperture 320, thus closing it and sealing the inside of the
tray 300 from the external atmosphere.
Embodiment 3
[0420] Referring now to FIGS. 17 and 18, another embodiment of a
stackable tray with tray valve constructed according to the present
invention is shown. In this embodiment, a web 400 of substantially
gas permeable material is heat sealed at 402 to the top of the
peripheral flange 404 of a tray 406. A frustoconical tube 408
extends upwardly from ledge 410 and terminates in an opening 412
that is slightly above the level of the outer flange 404. After
heat sealing web 400 to the flange 404, the web 400 overlying the
opening 412 contacts the upper edge of the frustoconical member
thus forming an effective valve to close the interior of the
containers 406 from the atmosphere. During evacuation of the master
pack, the portion of the web 400 over the frustoconical member 408
will elastically extend away from the aperture until the gas inside
the package is completely withdrawn, allowing full evacuation of
the individual container. This occurs because the air/gas pressure
inside the package is greater than the air gas pressure outside the
package 406 during evacuation. When gas flushing occurs, which
immediately follows evacuation, the web at the opening 412 will
again be elastically extended and lifted off the rim of the
frustoconical member 408. This again occurs because a partial
vacuum remains in the recess of the dome 414 overlying the
frustoconical member. Moreover, during gas flushing, at least the
initial pressure in the container is less than that on the outside
thus allowing gas pressure on the outside to distend the web 400
away from the opening 412. After equilibration, the tension of the
web 400 over the rim of the frustoconical member 408 remains so as
to effectively close it and prevent ingress of undesirable material
into and/or egress of juice or matter from the container 406.
Embodiment 4
[0421] Referring now to FIGS. 20-22, another alternative
arrangement for a valve structure similar in operation to that
shown in FIGS. 17 and 18 includes a tube 700 that extends upwardly
from the upper surface of ledge 702. The tube is connected to the
ledge 702 by a concentric bellows structure 704 that allows the
tube 700 to move upwardly and downwardly relative to the ledge. In
practice, the upper lip of the tube (which forms an opening into
the tray from the outside) is in contact with the web. The dimple
710 resides over the upper edge of the tube 700. During evacuation
and gas flushing, the web 708 will distend away from the lip 706 of
the tube in the same manner as described in conjunction with FIGS.
17 and 18 as shown in FIG. 21. However, the tube may be more
permanently closed by depression and reversal of the dimple 710.
Full reversal of the dimple 710 would push the tubes 700 downwardly
against the resistance of the bellows structure 704 thus, forming a
very tight closure between the upper lip 706 of the tube and the
bottom surface of the reversed dimple 710.
Embodiment 5
[0422] Referring now to FIG. 6, another embodiment of a tray with
valve constructed in accordance with the present invention is
shown. In this embodiment, the tray 146 has an upper peripheral
flange 148 that extends outwardly from the entire upper periphery
of the tray 146. The tray sides extend downwardly to the
horizontally disposed bottom. A downwardly extending recess 150 is
cut in the tray corners. The edges of the recess 152 communicate
with the interior of the tray. At the inner portion of the recess,
the recess and the wall of the tray terminate in an opening 154
having its upper edge at the same level as the upper surface of the
flange 148. The opening 154 functions in a similar manner as the
apertures in the tray 202 shown in FIG. 7. However, in this
embodiment, if the tray is tipped, undesirable juices can flow into
the recess 150 and back out through the edges of the recess 152. In
this manner the undesirable juices/liquids will not easily exit the
package through the opening 154.
[0423] Trays constructed in accordance with the present invention
provide a closeable ventilation mechanism. In addition, trays
constructed according to the present invention provide for ledges
which allow the trays to be stacked in a convenient fashion in
master bag or master containers as shown in FIG. 5. Further, valves
according to the present invention may be one way only valves.
Master Containers, Master Bags
[0424] Packaged trays constructed according to the present
invention can be stacked in master containers, evacuated and
flushed with desirable gases, and the master container can be
sealed to enhance the shelf life of the packaged goods.
[0425] A description of the master container method of packaging
perishable good according to the present invention will now be
described with reference to FIGS. 5, 10-13, and 16.
[0426] One of the aforementioned trays make suitable packages for
use with the master container method provided the tray includes
foldable flaps and channels providing communication from the
interior of the package to the exterior surrounding environment,
for example the tray of FIG. 10. Referring now to FIG. 11, the
package can be used to store and transport red meat 330, for
example, ground beef. In accordance with the present invention, the
ground beef 330 may be ground in a conventional grinder. The
grinder may be modified so that preconditioned carbon dioxide at a
predetermined temperature is injected into the grinder head for two
purposes. The first is to cool the grinder head; the second is to
allow the carbon dioxide to mix with the ground beef 330 and become
dissolved in the liquid therein. The dissolved carbon dioxide will
aid in preservation of the ground beef during the storage period. A
web 328 of substantially gas permeable material is then placed over
the tray 300 and heat sealed to the flange 310 in a conventional
manner as shown in FIG. 12. The web is taught over the top of the
red meat to prevent its movement about the tray during handling. A
label 332 may be applied to the upper surface of the web 328 if
desired. Alternatively, a dual web can be employed as shown in FIG.
1 and a label sandwiched therebetween. Thereafter, the flaps or
movable flanges 322 are folded over the top of the flange portions
310a so that the dimples 326 reside over the apertures 320.
However, any of the aforementioned trays with valves can be used.
The flaps 322 are then further heat sealed along their outer edges
to the flanges 310 at a second heat sealing station to form a
completed package as shown in FIG. 13.
[0427] Referring now to FIG. 16, a preferred embodiment of a master
container constructed according to the present invention is shown.
The master container 334 can be thermoformed from substantially gas
barrier materials such as unplasticized PVC or alternatively a
coextruded material including amorphous polyethylene terephthalate
and polyethylene glycol. The material can be formed with the
polyethylene glycol layer on the inside of the tray allowing
exposure to the web of PVC material for heat sealing. The master
container 334 includes flange 336 located around the periphery of
the upper portion of the container 334. The master container
containing finished packages 300 with perishable goods therein are
evacuated and flushed with a gas of suitable composition. The
master container can be sealed by a web of material to the flange
336.
[0428] As shown in FIG. 16, a plurality of trays 300 may then be
positioned in a master tray 334. For example, in a 3 high by 4 wide
array. In accordance with the method of the present invention, the
master tray 334 can then be evacuated and flushed with
substantially oxygen free gases. At the same time, the individual
packages 300 are evacuated through the apertures 320 and flushed
with inert gases that enter the individual packages through
apertures 320 as well. A package formed in accordance with the
present invention allows the use of relatively large aperture 320,
which in turn enables very rapid evacuation and gas flushing of the
individual packages. With the disclosed system it is estimated that
only a few seconds will be needed to completely evacuate and gas
flush the master tray 334 and individual trays 300. After the
containers are evacuated and flushed, a master web 338 is heat
sealed to the top of the master tray 334. To form a completed
master tray 334, if desired, an oxygen absorber may be inserted in
the master tray 334 so that it is assured that the residual oxygen
content in the package will stay below about 0.05%. This low level
of oxygen is required to prevent irreversible oxidation of the
deoxymyoglobin in the red meat and forming of metmyoglobin.
[0429] Once the package reaches its destination, it can be stored
for several days in a sealed condition. When it is time to display
the meat, the master web 338 is removed from the master tray 334
and the individual packages can be weighed and labeled. At that
time, oxygen reenters the individual packages 300 through the
aperture 320 as well as through the substantially gas permeable web
328. The oxygen converts the deoxymyoglobin in the red meat to
oxymyoglobin, giving the meat a very fresh red appearance. Before
placing the package in the display case, the dimple 326, one
embodiment of which is shown in FIGS. 14-15, is depressed so as to
close the aperture 320 which prevents the entry of undesirable
elements such as insects into the package, and also substantially
seals the package so that juices from the red meat cannot escape
from the container if it is tipped on end.
[0430] Referring now to FIG. 5, a preferred alternate master bag
container constructed according to the present invention is
illustrated. Trays constructed according to the present invention
can be stacked conveniently atop one another because the trays have
been provided with flaps which fold inwardly to provide a ledge for
a tray resting atop another tray can rest. Once trays are placed
inside a master container as shown in FIG. 5, the gas inside the
master bag and trays can be evacuated through opening 140, because
trays constructed according to the present invention include valves
which allow the interior of sealed trays 136 to also be evacuated,
and then flushed with a gas of desirable composition. The gas is
preferably inert and substantially oxygen-free so as to reduce
oxidation of the edible products in the packages 136 during
storage. The number of cycles which are necessary to lower the
level of the undesirable gas will vary. Once the master bag reaches
an intermediate processing station prior to delivery to the
location of point of display, it can be opened and flushed with
high oxygen atmosphere containing 80% O.sub.2+CO.sub.2. The
packages can be weighed and labeled. Then the dimples may be
depressed to close the perforations in depressions at this station
or alternatively left open. In some alternates of the present
invention, the trays are provided with one-way valves which
eliminates the need for dimples. Other alternates of trays may have
no valves, because these packages will have been packaged in a low
oxygen atmosphere. After this step, the trays can then be replaced
into a master bag at which time the interior can be partially or
completely evacuated and flushed with a high oxygen content gas
such as 80% O.sub.2+CO.sub.2. The master bag can then be heat
sealed again. In this way, extra days of shelf life can be obtained
because the CO.sub.2 will tend to inhibit bacterial growth.
[0431] This method of packaging can be advantageously used for
other types of higher value products such as tomatoes, grapes,
peaches and the like.
[0432] Referring again to FIG. 5, an alternative to evacuating the
bag 138, includes an oxygen absorber such as an iron compound that
can be placed in a container 142 in the master bag 138. Thus,
instead of or additionally to evacuating and flushing with an inert
or substantially oxygen free gas, the oxygen-absorbing compound
quickly absorbs all remaining oxygen in the bag leaving only
nitrogen and other inert gases that will not adversely affect the
condition or value of the food or red meat products in the
containers.
[0433] In practice it is possible that all features described above
will be incorporated into individual retail package structures.
With the valve arrangement, free passage of air and/or gas through
the aperture is essentially restricted. In addition, small
microperforations in the overlying web may be employed to allow
more rapid gas/air exchange than would otherwise occur through a
normal substantially gas permeable material such as plasticized
polyvinyl chloride. Such microperforations would facilitate more
rapid reoxygenation of the deoxymyoglobin and generation of a
desirable bright red meat color.
Soaker Pads
[0434] Soaker pads provide absorptive materials to absorb liquids
extruded by the packaged goods. Soaker pads constructed according
to the present invention include bacteria sensing materials.
[0435] Referring now to FIG. 22, a tray constructed according to
the present invention is shown. Tray 800 is configured similarly to
that of the tray shown in FIG. 10, and carries a soaker pad 802
that lies on the bottom of the tray. A plan side view of soaker pad
802 is shown in FIG. 24 and a cross-sectional view C-C is shown in
FIG. 23. The ground beef 804 or other edible material is positioned
on the soaker pad and first and second webs 806 and 808 of heat
sealable material are placed over the tray and sealed to the
horizontal flanges 810 that extend outwardly from the upper edges
of the tray. The label 812 is included of a special polymeric
material that has the capability of indicating the presence of E.
coli bacteria. This material may be laminated into a three-layer
web including polypropylene/E. coli sensor material/polypropylene
or polyethylene/sensor material/polyethylene. The polymeric
material employed is of the type disclosed in the paper entitled "A
Litmus Test for Molecular Recognition Using Artificial Membrane,"
Charych, D. et al. Chemistry and Biology, Vol. 3, No. 2, February
1996, 3:113-120, expressly incorporated herein by reference. The
lower web 806 may be microperforated in the region of the label 812
so that juices from the ground beef 804 can penetrate the web and
contact the label 812. The label 812 will change color in the
presence of E. coli bacteria. The upper surface of the label can
also be treated so that it may be printed with instructions
relating to the E. coli test and/or information relating to the
ground beef 804 or other edible product. A detail of the webs 806
and 808 carrying the litmus test label 812 is shown in FIG. 25.
[0436] Alternatively, as shown in FIGS. 24 and 25 (a cross-section
of FIG. 24 along section line c-c) shows that the container for the
soaker pad 808 can be made of the laminated three-layer web
described above containing as the middle layer the litmus test
sensor material. In this embodiment, the absorbent material 814 in
the soaker pad 802 is encased in an upper web 816 of the tri-layer
test material and a lower web 818 of the same test material. It is
heat sealed around the entire periphery 820 and placed in the
bottom of the tray 800 (FIG. 22). Both webs 816 and 818 are
microperforated so that juices from the red meat 804 can penetrate
to the absorbent layer 814. The presence of E. coli will be shown
by a change in color of the test material in the web 816 and
818.
[0437] FIG. 26 illustrates a tray 800 similar to that shown in FIG.
22. However, this tray carries a plurality of ground beef patties
822 that are interleaved with layers 824 of the test material. In
this manner, the presence of E. coli bacteria can be ascertained at
a variety of locations in the package.
Apparatus and Methods for the Manufacture of Soaker Pads
[0438] Referring to FIGS. 27-30, a side elevation (FIG. 28) and a
plan view (FIG. 29) of an apparatus for manufacture of soaker pads
with the engineered polymerized molecular film of the type that
detects E. coli and indicates its presence by a change of color
[EPMF] attached to an inner surface of a side of the soaker pad is
illustrated. A roll of coextruded transparent, perforated, plastics
material 900, including a rolled length of web 902, is mounted on
an unwind stand 904 and the end of the web is "threaded" around a
series of drive and idler rollers, 906, 908, 910, 912, and 914 such
that when drive rollers 908 and 914 are driven, the web 902 is
pulled over the drive roller 908 so that the inside surface of the
web 902 contacts the surface 922 of the water 918 flowing through
the trough 920. The trough 920 is connected to a conventional
Langmuir-Blodgett water trough in such a manner as to cause water
918 to flow, from the Langmuir-Blodgett water trough, horizontally,
underneath and parallel to web 902 and at a similar rate of flow to
the speed of the forward movement of the web 902 as controlled by
the rate of revolutions of drive roller 908. The Langmuir-Blodgett
water trough is provided to generate sufficient quantities of EPMF
as required by the process. The EPMF floats on the surface 922 of
the water 918 and is carried with the flow of water at a similar
speed. When the web 902 contacts surface 922, the EPMF is
transferred from the water surface to the web 902 and travels
adjacent to a drying section 924 that evaporates any surplus
water.
[0439] The web 902 is transferred from a vertical disposition
across drying section 924 to horizontal by way of movement over the
idler roller 910. Soaker (absorbent) pads 942 are positioned onto
the surface of the web 902 and a further perforated web 930 is
unwound from roll 932 mounted on unwind stand 934. The two webs,
with absorbent pads therebetween, are transferred, between two
drive rollers, 914 and into a heat sealing station 936. The heat
sealing station seals the two webs 902 and 930 together by applying
pressure through two sets of temperature controlled heat sealing
bars 936a, 936b shown in FIG. 30. The pressure applied is
sufficient to distort the EPMF layer 960 and allow direct contact
of the web 902 and 930 surface layer material (SURLYN is a
registered trademark of Dupont), which is an ionomer resin and the
SURLYN readily bonds together. Webs 902 and 903 are composites
which include an outer and inner layer, 962, 964, 966 and 968,
respectively. The longitudinal slitting station 938 slits and
separates the sealed soaker pads into continuous strips and the
lateral cutting station 940 cuts across the webs thereby separating
the complete soaker pads.
Trays with Flaps, Trays with Channels
[0440] Trays with flaps and trays with channels which are
constructed according to the present invention provide sturdier
stackable trays which are able to be evacuated of air and flushed
with inert gasses and additionally provide channels and spaces to
retain any liquids exuded from the purchased goods.
Embodiment 1
[0441] Referring now to FIG. 31, a preferred packaging tray 3000
with flaps, is shown in a three dimensional drawing. The tray and
flaps 3002 can be thermoformed from suitable materials such as
polystyrene, polyester and polypropylene in a solid or foamed
sheet. The tray 3000 is most preferably thermoformed from an
expanded polystyrene sheet of suitable thickness. Tray 3000
includes a base with perforations 3004. Four upwardly extending
sides terminate at a common flange 3006. Flaps 3002, 3050, 3052 and
3054 are attached to flange 3006 at the external edge of flange by
way of hinges at a hinge lines as shown. Flap 3002 is provided with
a profile that mirror images flap 3052, and flap 3050 is provided
with a profile that mirror images flap 3054. Flaps are attached to
the outer edge of flange rim at hinges as shown, such that flaps
3002, 3050, 3052 and 3054 will fold downwardly and intimately
contact outer surfaces of the tray walls. The cross-sectional
profile of flaps 3002, 3050, 3052, 3054 are similar, flap 3002 and
flap 3052 being of substantially similar dimensions, and flap 3050
and flap 3054 being of substantially similar dimensions. Flaps are
formed with a rim 3008 that follows a continuous path around the
perimeter of the flaps. Flaps include a profile which includes a
flap base 3010, a flap flange wall 3012 and external flap vertical
walls 3022. Buttresses 3016 are formed into flap profile and
connect flap flange wall 3012 to flap base 3010. Horizontally
disposed ridges 3018 and 3020 provide horizontal channels that
connect buttresses 3016 with continuous communication to openings
at each end of flaps in flap vertical walls 3022. Apertures 3014
are provided between the ridges. Apertures 3014 thereby provide
communication through flaps at locations between the buttresses.
Apertures 3026 are provided in upwardly extending walls of tray at
points adjacent to buttresses such that when flaps are folded into
a vertically disposed position relative to tray, apertures 3026
provide direct communication through tray walls to buttress
recesses 3024.
[0442] Referring now to FIG. 32, a three dimensional sketch of the
tray 3000 with flaps folded downwardly, is shown. Flaps are folded
to a downwardly position, such that flap flange wall 3012 is in
contact with the underside of flange 3006. In this position, flaps
are located in close proximity and in contact with upwardly
extending tray sides. Flap base 3010 is substantially horizontally
disposed relative to tray and provides an extension to base of tray
such that when tray with flaps folded as shown in FIG. 32 is placed
directly above a similar tray, flap base is adjacent to and resting
on flange 3006. It should be noted that while packaging shown in
FIG. 31 includes a tray with four flaps, any number of flaps from
one to four may be provided according to preference and any
specific requirements of a particular application.
[0443] Referring now to FIG. 33, tray base 3028 is shown with
perforations therein. Perforations 3004 may extend directly through
tray base or partially therethrough from either side. Perforations
can provide absorption of liquids that may accumulate adjacent
thereto, by the open cell structure of the tray base material, such
as when the tray has been thermoformed from expanded polystyrene
sheet which is, at least in part, of open cell structure. A space
3030 is shown which can be provided if desired. Space 3030 can be
provided after tray with flaps is inserted into a pre-formed shrink
bag that is then exposed to elevated temperature that can cause the
shrink bag to shrink around the tray with flaps. Alternatively,
tray with flaps profile can be arranged such that space 3030 is
substantially minimized when the tray base is in direct and
intimate contact with the shrink bag. Shrink bags may be printed as
required with information of interest to any person interested in
purchasing the finished package. Such shrink bags are manufactured
for example by Robbie Manufacturing Inc., and are well known by the
name PromoBag.TM.. Shrink bags can be printed and fabricated from a
clear, biaxially-oriented, heat shrinkable, anti-fog, polyolefin
film material manufactured by E.I. Dupont De Nemours and known as
Clysar AFG anti-fog shrink film. Clysar is a registered trade mark
of Dupont, details of which can be obtained from Dupont or on the
internet at www.clysar.com.
[0444] Referring now to FIG. 34, a finished package is shown. The
finished package may contain perishable goods such as fresh red
meats or fresh ground meats. Apertures 3032 can be provided at
optimized locations and/or as shown, in the outer cover shrink
material 3034 of the finished package 3036. Apertures 3032, which
may be provided in the bag or web of shrink material before or
after package assembly, thereby providing direct communication from
external atmosphere through space 3038, apertures 3032, buttress
recess 3024 and apertures 3036, and into the tray cavity 3040. A
plurality of finished packages can be located inside a barrier
master container as shown in FIG. 35 or any other master
container/bag previously described above. Such barrier master
container may be thermoformed from a substantially gas barrier
plastics material, such as a co-extruded multi-layer sheet of
nylon//PVDC//polyethylene. After inserting finished packages into
the barrier master container, the master container can be located
inside a vacuum chamber and substantially all atmospheric gases can
thereby be evacuated from within the barrier master container, and
within the finished packages. A gas or blend of suitable gases such
as carbon dioxide, nitrogen, oxygen and any other suitable gases,
can be provided into the barrier master container and the finished
packages prior to hermetically sealing a substantially gas barrier
lid to flanges of the barrier master container. A plurality of
barrier master containers can then be positioned into a suitably
sized shipping case as shown in FIG. 35, prior to shipping to
another location.
[0445] Referring to FIGS. 116-117, in yet another preferred
embodiment, the master container 3226, with one or more finished
packages, 3224, contained therein and including a "loaded master
container", may be located inside a pressure vessel that is also
arranged to operate as a vacuum chamber with gas flushing. After
location of the "loaded master container" inside a pressure vessel,
the pressure vessel is closed and sealed from atmospheric air and
substantially all air is evacuated to a desired and predetermined
level. Following evacuation, the pressure vessel can be filled with
a desired gas such as carbon dioxide to a predetermined, controlled
and maintained pressure, above atmospheric pressure, such as 12 psi
or up to 250 psi or higher, and held at a predetermined pressure
for a period of time that will allow sufficient carbon dioxide gas
to dissolve in the perishable goods contained in the finished
packages in the master container. Carbon dioxide gas can be held at
the pressure, for a period of time, as required to prolong the
subsequent storage life of the perishable goods. Following the
period of time, the gas pressure may be lowered to a pressure equal
to that of the prevailing atmospheric pressure and a gas barrier
lid then hermetically sealed to the flanges of the master container
prior to opening the pressure vessel and removing the master
container. The aforementioned process may include the steps of:
[0446] i) Locating a master container, 3226 with finished packages
such as those shown as 3224 contained therein, into a suitable
pressure vessel.
[0447] ii) Closing and sealing the pressure vessel so as to isolate
it from atmospheric air.
[0448] iii) Evacuating substantially all air from within the
pressure vessel.
[0449] iv) Providing a gas such as carbon dioxide in the pressure
vessel at a pressure above atmospheric pressure.
[0450] v) Holding the pressurized carbon dioxide provided in the
pressure vessel for a period of time sufficient to enhance the
keeping qualities of the perishable goods contained in the finished
packages 3224, for an extended period.
[0451] vi) Lowering the gas pressure within the pressure vessel, to
a level equal to the prevailing atmospheric pressure.
[0452] vii) Hermetically heat sealing a gas barrier lid to the
flanges of the master container so as to substantially exclude
oxygen gas from inside the master container.
[0453] viii) Removing the master container from the pressure vessel
automatically.
[0454] ix) Locating another master container in the pressure vessel
by automatically and repeating steps i). to viii). in an automatic
fashion.
[0455] x) Placing and sealing the master container into a finished
shipping case as shown in FIG. 36 which may be constructed of
cardboard material with a crush test rating of 44 lbs. per
inch.
[0456] xi) Shipping the finished container to another location.
[0457] xii) Removing the finished packages from the finished
shipping case and allowing atmospheric air to penetrate through the
apertures in the finished package.
[0458] xiii) Repeating any or all of the above steps as required to
maximize the keeping qualities of the perishable goods.
[0459] Referring again to FIGS. 31 and 32, it can be seen that by
manufacturing packaging in this manner, any liquids that may
accumulate within the tray cavity 3040, such as blood, will be
substantially restricted from escaping through apertures 3032 shown
in FIG. 34. This restriction is provided due to the arrangement of
flaps and apertures therein, and the location of the apertures.
Furthermore, perforations 3004 provide for retention of the liquids
within the package.
Embodiment 2
[0460] An alternate embodiment of a tray with flaps constructed
according to the present invention is shown in FIGS. 37-124. The
tray of FIG. 37 includes four flaps as the tray of FIG. 31, with
modifications as described herein. FIG. 37 shows the
cross-sectional detail of a tray. The tray walls are perforated in
sections shown as incision section 3526 and incision section 3528,
shown in FIG. 39. Perforations may be in the form of small holes or
incisions that extend fully through the tray walls, but may be only
provided within the limits of regions shown as incision sections
3526 and 3528.
[0461] Referring now to FIG. 37, a cross-sectional view of finished
package 3514 is shown. Finished package 3514 includes a packaging
tray 3556 with perishable goods located in tray cavity with an
outer cover 3516. The outer cover 3516 includes an envelope of
material that completely covers and encloses the packaging tray and
the perishable goods and is heat sealed to provide a sealed
package. The outer cover 3516 may be manufactured from a shrink
material such as Clysar, manufactured by DuPont, and can be printed
such that all surfaces are rendered opaque leaving a transparent
window 3522 on the upper surface only, as shown in FIG. 38 of the
finished package. Clysar outer cover shrink material is then heat
shrunk such that the outer cover shrinks, holding the flaps against
the tray walls. Apertures 3518 are provided on the four vertical
faces of the finished package when the base 3520 of tray is
horizontally disposed.
[0462] Referring now to FIG. 39, a detailed section of a packaging
tray 3556 with base 3520, tray wall 3524 and flange rim 3512
attached to flap 3508 at a hinge 3532, is shown. The relative
position of flap 3508 and the section of tray is in the "open
position". Flap 3508 is attached at hinge 3532 to flange rim 3512,
however flap 3508 is not folded downwardly.
[0463] Referring now to the flap portion 3508 of FIG. 39, a
cross-section is shown including a first and second raised peaks
3534 and 3536, respectively, and a flat area shown as face 3538 and
face 3540; also shown are a ridge 3542; and gussets 3544, with
connecting sections therebetween. Packaging tray includes a base
3520, flange rim 3512 with tray wall connecting base of tray to the
flange rim. Tray wall includes recess 3546, a first incision
section 3526, recess 3548 and a second incision section 3528. FIG.
40 shows a view of flap from the direction of arrow 3608. Flap 3508
includes a perimeter 3530 including hinge 3532, face 3538 and end
flanges 3550 that are connected together to provide the continuous
flat perimeter. Referring now to FIG. 126, depressions 3552 may be
provided in the flap section between peak 3534 and ridge 3542 but
do not perforate the section to provide direct communication
therethrough. Apertures 3554 are also provided in face 3540.
[0464] Referring now to FIG. 41, an enlarged view of a tray portion
of FIG. 124 is shown. Flap and the tray wall are in intimate
adjacent contact and ridge 3542 and recess 3546 are engaged. Faces
3538 and 3540 as shown in FIG. 126, are in direct and intimate
contact with the tray wall. Face 3540 is located in recess 3548,
thereby closing apertures 3554 when in this position. Spaces 3560
and 3558 are directly adjacent to first and second incision
sections 3526 and 3528. Shrink film 3516 holds flap firmly and
tightly against the tray wall providing sealed contents within the
finished package. The package may be colorized to prevent
translucency. An adhesive such as a cold seal latex is provided
between the continuous perimeter 3530 of the flap as shown in FIG.
40. The tray wall is inwardly flexible such that when a vacuum is
provided within the tray cavity, the recess 3548 and face 3540 will
separate to provide direct communication from within the tray
cavity via perforations or incisions at first and second incision
sections 3526 and 3528 through apertures 3554, and through
apertures 3518 in outer cover shrink film 3516.
[0465] A plurality of finished packages 3514 of this embodiment
can, as well, be stacked and placed inside a gas barrier master
container inside a vacuum chamber. Substantially all the air may be
evacuated from within the gas barrier container and from inside the
finished packages. Air is evacuated from within the packaging tray
cavity through perforations and/or incisions in the tray wall at
first and second incisions 3526 and 3528 into space 3560 and 3558,
created when the flap is place adjacent the tray wall, the air
flows through apertures 3554 and apertures 3518. A suitable gas or
gas blend such as nitrogen and carbon dioxide can then be provided
into the vacuum chamber. The desired gas can be provided in a
reverse flow direction into the finished packages by way of direct
communication through apertures 3518, apertures 3554 into spaces
3560 and 3558, through perforations at incision sections 3526 and
3528 and thereby fill all free space within the finished packages
and the gas barrier master container. A gas barrier lid can then be
hermetically heat sealed to the opening of the gas barrier master
container and the finished packages in the hermetically sealed
master container can then be stored at a controlled temperature for
a desired period of time prior to opening the master container and
removal of the finished packages for retail sale.
[0466] In this way air and gasses can be removed from the finished
and sealed packages by evacuation and then replaced by gas flushing
with a desired gas, while liquids such as blood cannot readily
escape.
Embodiment 3
[0467] Referring now to FIG. 271, another preferred packaging tray
with flaps constructed according to the present invention is shown
in a three dimensional sketch. The packaging tray of this
embodiment as with the packaging trays of previous embodiments is
similar in operation, but with an alternate configuration of the
channels through which evacuation and flushing is accomplished. The
tray with flaps can be thermoformed from suitable plastics
materials such as polystyrene, polyester and polypropylene in a
solid or foamed sheet. The present packaging tray is preferably
thermoformed from expanded polystyrene (EPS) sheet. The EPS sheet
may include an "open cell" structure with a surfactant added prior
to extrusion of the sheet such that the finished tray will have a
capacity to absorb water and other liquids such as "purge" or
blood. The EPS sheet may be extruded with a "skin" on what will
become the in-side of the finished tray. The "skin" can be arranged
so as not to absorb the liquids. The non absorbent "skin" may be
provided on both surfaces of the extruded sheet.
[0468] The EPS sheet may be a multi-layer extruded sheet including
three layers. The three layers may include two outer layers of
closed cell EPS foam with an inner layer of open celled EPS foam.
The outer layers may be close celled and resistant to liquids such
as blood and/or purge. The inner layer of open celled EPS foam can
be extruded with a suitable surfactant contained therein that will
enhance the liquid absorbing qualities of the open celled EPS
foam.
[0469] The tray with flaps, shown in FIGS. 271-272, is most
preferably thermoformed from expanded polystyrene sheet of suitable
thickness, of preferably from about 0.01'' to about 0.15'', and
most preferably about 0.090'' and including at least two layers
including a "skin" that will not absorb the liquids and an adjacent
layer of open cell structure that will absorb the liquids. FIG. 271
shows detail of the packaging tray with flaps extended and
including a tray with tray cavity and four flaps shown as flap
7002, flap 7004, flap 7006, and flap 7008. Flap 7002 is provided
with a profile that mirror images flap 7006, and flap 7004 is
provided with a profile that mirror images flap 7008. Flaps 7002,
7004, 7006 and 7008 are attached to the outer edge of flange rim
7010 at hinges 7012 as shown, such that flaps 7002, 7004, 7006 and
7008 will fold downwardly and intimately contact outer surfaces of
the tray walls. FIG. 272 shows the packaging tray with flaps folded
downwardly. The cross-sectional profile of flaps 7002, 7004, 7006
and 7008 are similar. Flap 7002 and flap 7006 being of
substantially similar dimensions, and flap 7004 and flap 7008 being
of substantially similar dimensions, but can be longer or shorter
than flaps 7002 and 7006. Referring yet again to FIG. 271, the
packaging tray includes a base with four upwardly extending tray
walls terminating at a continuous flange rim 7010. The tray walls
can be perforated with openings directly therethrough with the
perforations arranged in sections shown as a first incision section
7014 and a second incision section 7016. The perforations may be in
the form of small holes or incisions that extend fully through the
tray walls, but are preferably provided within the limits of
regions shown as first and second incision sections 7014 and 7016,
respectively. Apertures provided in sections 7014 and 7016
preferably extend into spaces between flaps and tray walls.
Apertures 7020 provide a passage for evacuating and flushing the
tray in a master container, as previously described.
Embodiment 4
[0470] In another embodiment shown in FIGS. 45-49, a gap 4126 is
provided between the flap at openings 4128 and the tray wall. The
flap 4106 is in a folded down position and a gap 4126 is arranged
between openings 4128 and the tray side wall. Spaces 4130 and 4132
are directly adjacent to incision sections 4118 and 4116. The
shrink film holds the flap firmly and tightly against the tray
wall. An adhesive such as a cold seal latex, or any other suitable
adhesive may be provided between the flaps and the tray walls so as
to cause sealing and bonding where contact between the flaps and
the tray walls occurs. FIG. 46 provides details of a cross-section
through a section of the tray wall and the flap that are in direct
contact. A "skin" 4134 is shown on the outer surfaces of the
section directly adjacent to EPS foam that is bonded together by
adhesive layer 4146 causing a secure bonding and sealing of the
tray wall and the flap together. The sealing and bonding can be
arranged so as to provide a completely sealed and "liquid tight"
condition such that any liquids contained in the spaces 4130 and
4132 will be retained within the spaces. As shown in FIG. 49, an
adhesive layer 4142 can be provided between base 4138 and outer
cover 4240 so as to bond the outer cover 4240 to the base 4138.
[0471] Referring now to diagram FIG. 47, an elevation of finished
package 4118, is shown. The finished package 4118 includes a
packaging tray as shown in FIG. 45 with perishable goods located in
tray cavity with an outer cover 4120. The outer cover 4120 includes
an envelope of material that completely covers and encloses the
packaging tray and the perishable goods and is heat sealed to
provide a sealed package. The outer cover 4120 may be manufactured
from a shrink material such as Clysar, manufactured by DuPont, or
alternatively a stretch wrapping material such as Mapac-M, a
plasticized polyvinyl chloride web material manufactured by AEP
Industries, Inc. The outer cover 4120 can be printed such that all
surfaces are rendered opaque leaving a transparent window 4122 on
the upper surface as shown in FIG. 47. Clysar outer cover shrink
material is then heat shrunk such that the outer cover shrinks,
holding flaps against the tray walls. Alternatively, if the
Mapac-M, pPVC material is used, heat shrinking may not be required
and the Mapac-M material is stretched over the tray with flaps such
that flaps contact the tray walls. Apertures 4124 are preferably
provided on the four vertical faces of the finished package. The
apertures are conveniently located in such a location so as to
minimize the probability of any liquids, such as blood or "purge",
escaping therethrough.
[0472] The EPS material, which may contain a suitable surfactant,
used in production of the packaging tray may be manufactured so as
to have a capacity to absorb liquids such as blood. Incisions
and/or perforations provided in sections of the packaging tray can
enhance the capacity of the EPS material to absorb the liquids such
as blood.
[0473] Referring now to FIG. 48, an enlarged view of a cross
section of the tray of FIG. 45 is shown. The flap and the tray wall
are in intimate contact and a gap 4126 is arranged between openings
4128 and the tray side wall. Spaces 4130 and 4132 are directly
adjacent to incision sections 4118 and 4116. A suitable adhesive
can be applied between the flap and the tray at all direct points
of contact therebetween causing a secure bonding and sealing of the
tray wall and the flap together. The sealing and bonding can be
arranged so as to provide a substantially sealed and "liquid tight"
condition such that any liquids contained in spaces 4130 and 4132
will be retained. The shrink film, outer cover 4120 holds the flap
firmly and tightly against the tray wall. Referring now to FIG. 49,
a cross-section of the tray base portion and outer cover 4120 are
shown to be in adjacent disposition. An adhesive layer 4142 can be
provided so as to completely bond the outer cover 4120 to the base
of tray 4138.
[0474] Furthermore, when the outside-surface of foam is arranged to
have a capacity to absorb liquids, such liquids can be retained and
substantially prevented from escaping from within the finished
package. Additionally, a suitable adhesive can be provided between
the tray flange rim 4144 and the outer cover 4120 where the
continuous flange rim 4144 is in contact with the outer cover 4120
so as to cause bonding in a substantially liquid tight fashion
therebetween. The openings at sections 4116 and 4118 in the tray
wall, openings 4128 in the flaps and apertures 4124 in the outer
cover 4120 provide a passage and direct communication from the tray
cavity to the outside of the finished package such that when the
finished package is exposed to a vacuum, air and gasses can be
removed from within the package and replaced with a desired gas or
mixture of gasses through the passage.
Embodiment 5
[0475] FIGS. 50-53 show yet another embodiment of a tray with flaps
constructed according to the present invention. The tray 4808 of
this embodiment is similar in operation to the trays described
above. Referring to FIG. 50, a tray is shown whereby flaps 4802 and
4806 can be arranged so as to have no openings therein, and flaps
4800 and 4804 can be arranged to have openings 4810 therein. Tray
4808 as shown in FIGS. 50-56 can be over wrapped with a web of pPVC
to produce a finished package. The web of pPVC can be printed on
the inner surface with a heat activated coating that can provide a
method of bonding the web of pPVC to faces 4812 on flaps 4802 and
4806 and face 4814 on flaps 4800 and 4804. The heat activated
coating can be applied to the web of pPVC by typical offset
printing process and applied in those areas of pPVC that will come
into contact with the faces 4806 and 4814 after over wrapping the
tray 4808 with the web of pPVC in such a manner that when heat is
applied to the pPVC in contact with the faces 4812 and 4814 the web
of pPVC will become bonded to the faces 4812 and 4814. The web of
pPVC will thereby cover recess 4816 and recess 4818 in flaps 4800
and 4804 but will not fully enclose and isolate the recesses
leaving openings at openings 4820. The web of pPVC can also thereby
cover recess 4822 and recess 4824 in flaps 4806 and 4802 but will
not fully enclose and isolate the recesses leaving openings at
openings 4826. In this way a path of direct communication from
internal space of the tray to external atmosphere is provided
through apertures 4828 into space 4830 shown in FIG. 274 through
apertures 4810 in flaps 4806 and 4802 only into recessed 4822 and
recesses 4824 and through openings 4826 into space between the pPVC
outer cover and tray through space 4830 and therefrom through
openings 4820 into recesses 4816 and 4818 and finally through
apertures that are provided in the outer cover pPVC adjacent to the
recesses 4818 in flaps 4800 and 4804 to external atmosphere.
[0476] The tray 4808 may be thermoformed from any suitable material
such as expanded polystyrene EPS materials as shown in FIGS.
242-246 and FIGS. 71-72. The EPS materials may include several
layers of co-extruded material that are arranged so as to allow any
liquids that may enter space 4830 of FIG. 274 through apertures
4828 to be absorbed into the open cell structure of EPS materials
through surface perforations 4850 that can be provided into the
surface of the EPS materials that are adjacent to space 4830 only.
Liquids can thereby be concealed within the layers 4502 or 4508 as
shown in FIG. 173.
[0477] The pPVC outer cover can be bonded to the underside of the
tray 4808 by any suitable method, such as heat sealing or adhesive
bonding, so as to follow contours of recess 4832 shown in FIG. 173.
The pPVC outer cover can also be bonded, by any suitable method,
such as heat sealing or adhesive bonding, to flange rim 4834 along
the full length and perimeter thereof so as to inhibit liquids from
passing between the flange rim 4834 and the pPVC over wrapping web
of material after the bonding.
[0478] In this way liquids that may accumulate in internal space of
tray are restricted from escaping from within the finished package,
while providing a path to allow extraction and injection of
suitable gasses into and out of the internal space of tray.
[0479] In another preferred embodiment the flaps may be extended as
shown in FIG. 54, flap 5056 to provide additional cushioning around
the perimeter. The additional cushioning can provide protection of
the package and the package contents during shipping from the point
of production of the finished packages and a point of sale to
consumers such as a supermarket. FIG. 273 shows a tray flap with a
space wherein substances 4850 may be added, such as wax-coated iron
particles. FIG. 274 shows a cross section of a tray with flaps,
wherein the flaps form a plurality of spaces between the tray wall
and the flap (outer wall).
Embodiment 6
[0480] Referring now to FIG. 55, yet another preferred packaging
tray 5200 with flaps, is shown. The flaps are shown folded into a
desired position and bonded to the tray base and/or walls. The
packaging tray with flaps can be thermoformed from suitable plastic
materials such as polystyrene, polyester and polypropylene in a
solid or foamed sheet. The present packaging tray is preferably
thermoformed from expanded polystyrene (EPS) sheet. The EPS sheet
may include a single or multi-layer construction as shown in FIG.
59. Any suitable sheet of EPS material may be used but most
preferably the sheet includes 3 layers 5204, 5206, and 5208. The
layer 5204 preferably includes a layer of solid plastic material
such as polystyrene sheet with any suitable thickness, preferably
about 0.001'' and is laminated to layer 5206. Layers 5206 and 5208
preferably include "closed" or "open cell" structures either with
or without a surfactant added prior to extrusion of the sheet such
that the finished tray may have a capacity to absorb water and
other liquids such as "purge" or blood. The EPS sheet may be
extruded with a "skin" covering on a surface that will become the
in-side of the finished tray. The "skin" can be arranged so as not
to absorb the liquids. The non-absorbent "skin" may be provided on
both surfaces of the extruded sheet. The layer 5204 may contain a
white or other suitable pigment, such as white titanium dioxide in
such a quantity so as to prevent visibility of any discoloration
that may be caused by blood or purge absorbed by layers 5206 or
5208. In this way the layer 5204, which will be visible, will not
show substantial discoloration as a result of blood or purge that
has been absorbed by any of the other layers.
[0481] Tray 5200 with flaps is most preferably thermoformed from
sheet material of suitable thickness, preferably about 0.01'' to
about 0.15'' but preferably about 0.090'' and includes a tray with
tray cavity and four flaps. Two flaps are shown as flap 5210 and
flap 5212. Flap 5210 is an end flap and flap 5212 is a side flap.
The construction of tray 5200 with folded and bonded flaps, allows
for production of suitably rigid finished trays even though the
thickness of the sheet material from which the tray is formed, is
substantially thinner than would otherwise be required in
conventionally formed packaging trays that do not have "flaps".
[0482] Flap 5210 can be provided with a profile that is a mirror
image of 5214 (not shown), and flap 5212 can be provided with a
profile that is a mirror image of flap 5216. Flaps 5210, 5212, 5214
and 5216 are attached to the outer edge of flange 5218 at hinges as
shown by the hinge lines, such that flaps 5210, 5212, 5214 and 5216
can be folded downwardly and intimately contact outer surfaces of
the tray walls at locations as required. One or more flaps may be
provided and folded to provide an enclosed space 5222 and/or cavity
5220 shown in FIG. 58. The cross-sectional profile of flaps 5210
and 5214 are similar. The cross-sectional profile of flaps 5212,
and 5216 can be similar.
[0483] Referring again to FIG. 55, the packaging tray includes a
base with four upwardly extending tray walls terminating at a
continuous flange 5218. Tray walls can be perforated with openings
5224 directly therethrough with the perforations arranged so as to
communicate between the tray cavity and space 5222. The apertures
5224 can be located so as to allow any purge that may be present in
the tray cavity 5226 to pass therethrough and into space 5222. The
perforations 5224, may include small holes, slots or incisions that
extend fully through the tray walls. The flaps can be bonded to the
tray walls so as to retain any liquids that enter therebetween and
into space 5222. Any suitable liquid absorbing medium may be
attached to one or more of the flaps so that when the flaps are
folded and bonded the liquid absorbing material will be enclosed
within space 5222. The liquid absorbing material could therefore
absorb any liquids that may enter the space 5222 during use of the
tray.
[0484] Referring again to FIG. 55, recesses 5228 and 5230 are shown
in flap 5212. Slots 5232 are shown in flap 5212 and are located in
recess 5228. Perforations 5234 are provided in flap 5212 and are
located in recess 5228. Recesses 5238 and 5240 are shown in flap
5210. A suitable adhesive is provided at the interface between
flaps and tray walls so as to provide a bonding of flaps to tray
walls. Bonding of flaps and tray walls is provided in such a manner
so as to ensure complete bonding of flaps to the tray wall along
strips that follow a path close to what will become a perimeter of
the flaps. FIG. 58 shows a cross-section through flap 5212 and tray
wall showing enclosed space 5222. Space 5222 is enclosed between
the flap and the tray wall in a substantially liquid tight manner.
Iron powder deposits 5244 can be applied to locations on the tray
walls and flaps adjacent to space 5222 and also to the underside
surface of the tray base. The iron powder deposits 5244 may include
iron powder particles that have been fully coated with a special
coating material, such as wax. The coating can be arranged to
prevent direct contact of the iron particles with ambient air or
any gas that may be present, until such direct contact with the air
or gas is required. The coating may have physical and/or chemical
properties that can be activated by exposure to microwaves, radio
waves or a magnetic field. For example, when using wax as a
coating, microwaves will cause the iron particles to heat up,
thereby melting the wax and exposing the iron particles. The
coating may also contain an adhesive that is heat activated and
otherwise does not bond with other matter until activated and/or
heated by exposure to any suitable microwaves, radio waves,
magnetic field or any suitable electrically or sonically induced
waves or field. The coated iron particles 5244 can be deposited on
the surfaces by apparatus shown in FIG. 140 herein. The coated
particles can be coated with a substantially gas barrier substance
that is altered when exposed to suitable microwaves or an
electrically induced magnetic field. Exposure to the waves, field
or microwave can cause the coating gas barrier substance to
physically or chemically alter and become gas permeable, in such a
manner that will cause the iron particles to immediately or
subsequently react with any gases such as oxygen that may be
present. The quantity of iron particles 5244 provided and attached
to the tray and flap selected surfaces can be measured and
controlled in an amount having an equal or greater capacity that
may be required to absorb substantially all oxygen gas that may be
present and/or become present by permeating into the finished
package.
[0485] Referring now to FIGS. 55-209, a plurality of finished
packages that may be conveniently stacked as shown in FIG. 62 may
be placed in a gas barrier master container which can then be
evacuated of substantially all air. Ambient air that may be present
within the finished package tray cavities and spaces such as 5222
shown in FIG. 58 will be evacuated through apertures 5306 and
replaced with a suitable gas. The air can be replaced or displaced
with any suitable gas prior to hermetically sealing the master
container to provide a single container with finished packages
enclosed and sealed therein. At a convenient time after sealing the
sealed master containers may be exposed to a suitable level of
microwaves or magnetic field or other suitable source of energy
that will selectively alter the gas barrier coating on the iron
particles so as to render it permeable and further activate iron
particles to oxidize with any residual oxygen that may remain
within the master container. The substance "IPD" 5244 may include
any suitable substance that can be applied in any convenient manner
to the trays 5200 so as to remain inactivated until exposed to the
microwave and/or magnetic field in such a manner as to render the
IPD activated. When the IPD is selectively activated by any
suitable source of energy that is applied before or after the trays
are loaded with goods, the IPD can react with and thereby absorb
any residual oxygen gas remaining within the finished packages, in
such a manner so as to inhibit the formation of metmyoglobin that
may otherwise be formed as a result of available oxygen that has
been released during reduction of any oxymyoglobin that may be
present in the finished package after sealing the master
container.
[0486] The IPD can be applied in any suitable manner to selected
surfaces of the tray and/or flaps so as to not directly contact but
to be in close proximity to goods that is subsequently loaded into
the cavities of trays. Ground or sliced red meats may have been
exposed to ambient oxygen, after grinding or slicing and prior to
packaging, for such a period of time that deoxymyoglobin present in
freshly cut red meats has reacted with ambient atmospheric oxygen
to form oxymyoglobin. Fresh meat with oxymyoglobin may be then
packaged in a substantially oxygen free gas package such as a
barrier master container that has been evacuated and filled with
any suitable gas that may contain less than 500 PPM oxygen. After
packaging, the oxymyoglobin will reduce to deoxymyoglobin thereby
releasing oxygen gas into the spaces in the master container. The
released oxygen can then react with the deoxymyoglobin to form
metmyoglobin. The metmyoglobin is brown in color and is undesirable
and consumers are unlikely to purchase meat that is brown in color.
The IPD substance can be provided within the finished packages in
such a manner so as to substantially absorb, and thereby render
inactive, the oxygen that has been released by reduction of the
oxymyoglobin to deoxymyoglobin, after hermetically sealing the
finished packages. In this way the formation of undesirable
metmyoglobin can be inhibited and/or minimized. In order to enhance
the absorption of oxygen gas by the substance IPD, any suitable
method to cause circulation and movement of any gas inside the
finished package can be incorporated. Such methods may include
shaking or suitable movement of the finished and sealed master
containers in such a manner so as to cause gas to circulate through
apertures 5306 from the spaces in the tray cavities and more
particularly near and over the exposed surfaces of the goods.
[0487] In another alternate embodiment, the present invention
provides capsules of suitable size but most preferably having a
diameter or widest/longest/deepest dimension of less than 0.25'',
wherein capsules have a generally rounded, spherical or oval
profile with a continuous capsule wall of any suitable thickness
but most preferably approximately 00.060'' thickness, with a cavity
enclosed within the continuous capsule wall and wherein each
enclosed capsule cavity contains a suitable quantity of any
selected agent, substance or material, such as, for example, a
bactericide, a water absorbing gel, a CO.sub.2 generating agent.
The capsule wall may be manufactured from a material such as wax or
a flexible waxy plastics material that is affected by micro waves,
RF (radio frequency) or a magnetic field that is generated from a
controlled source and with such an intensity that it can cause the
capsule walls to rupture or soften or dissolve and to such an
extent that the contents of the capsule cavities will be expelled
or allowed to escape from within the enclosed capsule cavity. A
suitable quantity of capsules or combination of capsules containing
separate quantities of several agents, with any selected agent(s)
contained therein may be enclosed, for example, within the
cavity(ies) of any suitable packaging tray prior to use in a
packaging application. At any time during or after assembly of such
a tray with capsules contained therein, it may be exposed to the
appropriate source and intensity of micro waves, RF (radio
frequency) and/or a magnetic field and in such a way so as to cause
the release of any agents contained within the cavity of the
capsules. In this way, for example, a bactericide may be held until
required for use within the package walls or base and after
assembly of the package such as a tray containing fresh red meat,
at which time the bactericide can be released and thereby made
available to substantially kill bacteria, fungi, virus or any
undesirable life form that may be dangerous to human or animal
life.
[0488] Referring now to FIG. 64, a finished package 5300 is shown
with a seal 5324, that extends continuously around a horizontally
disposed perimeter of the finished package. Seal 5324 is provided
so as to bond an over wrap 5326, which is positioned above the seal
5324, to an over wrap 5328 which is located below the seal 5324.
The seal 5324 can be provided by any suitable method such as by
heating and is arranged to be a complete and continuous and gas
tight seal along the full length of the seal 5324. The over wraps
5326 and 5328 may be either both clear and transparent or
alternatively printed but most preferably the 5328 will be printed
as desired. 5326 and 5328 may be produced from a substantially gas
barrier material such that when sealed along seal 5324 a
hermetically sealed finished package is produced. Alternatively gas
permeable plastic materials may be used to produce the over wraps.
The profile of over wrap 5326 and 5328 may be provided by a
thermoforming method prior to assembly of the finished package
whereby a loaded tray 5300 is located into a thermoformed over wrap
5328 prior to sealing a thermoformed over wrap 5326 thereto at seal
5324. Alternatively, both over wraps 5326 and 5328 may be produced
from a web of "stretched" material such as pPVC. The web of pPVC
may be held taught above a depression where the depression is
similar in profile to the lower section of tray 5300 but slightly
larger so as to allow a neat location of tray 5300 therein. A
vacuum can be applied in the depression so as to stretch the pPVC
web therein and thereby provide a lower over wrap 5328. Tray 5300
can be located into the stretched pPVC depression and heat sealed
at 5324 to an over wrap 5326 that can be formed in a similar manner
by stretching into an inverted depression, of suitable size, that
is located directly above and aligned therewith so as to allow such
sealing at seal 5324. Apertures 5306 may be provided in the over
wrap 5328 or alternatively, over wrap 5328 may be maintained
without apertures so as to provide a complete finished and
substantially gas barrier package.
[0489] In another preferred embodiment, iron powder that has been
completely coated with a substance, such as a special type of wax,
can be included in one or more layers of a tray thermoformed from a
one, two, three or more layer sheet of co-extruded EPS foam. The
special type of wax coating can be arranged so as to prevent
contact of undesirable substances such as water, with the powdered
iron that is completely covered by the special type of wax coating,
until a suitable time. The special type of wax coating can be
arranged so as to melt or otherwise change when exposed to an
electromagnetic field, microwaves or other suitable medium. The
melting or change to the special type of wax coating can allow the
powdered iron to become exposed and thereby react with oxygen gas
that may be present, after exposure to the electromagnetic field,
microwave or suitable medium. In this way trays, formed from the
EPS foam with coated iron powder contained therein, can be used to
package perishable goods and when the tray with perishable goods
has been over wrapped with a gas permeable web of plastics
materials, can be located in a master container with a suitable
gas, and all hermetically sealed so that the master container
contains the over wrapped tray with perishable goods and a suitable
gas. Immediately after hermetically sealing the master container,
the master container can be exposed to an electromagnetic field,
microwave or other suitable medium, so as to change the coating and
thereby expose the iron powder and allow reaction of the iron
powder with any oxygen gas that may be generated within the master
container as a result of reduction of oxymyoglobin.
[0490] Immediately prior to or after loading goods such as ground
or sliced meats into the tray cavities, the trays 5320 can be
exposed to a suitable level of microwaves or a magnetic field
sufficient to cause coating SCM to be altered and thereby allowing
the IPD to react with any oxygen that is present and in contact
with the IPD. In this way and due to the close proximity of the IPD
to the oxymyoglobin, the oxygen that is released by reduction of
the oxymyoglobin, can be quickly absorbed by the iron powder IPD as
soon as it contacts therewith.
[0491] Pre-conditioning of the goods, prior to loading into the
trays can reduce the quantity of oxymyoglobin formed immediately
after slicing or grinding of the goods but before packaging and
sealing in the master container. The pre-conditioning can include
the process of exposing the goods to carbon dioxide or any suitable
gas at any suitable pressure or high pressure immediately after
and/or during slicing and/or grinding. The goods can be exposed to
the gas at high pressure in such a manner that the gas becomes
highly soluble in liquids and oils present in the goods, and
dissolves in the liquids and oils. The goods can be exposed to high
pressure gas for an adequate period of time to allow saturation of
the liquids with soluble gas. Saturation of liquids and oils will
therefore occur at the high pressure. Therefore, when goods are
removed from exposure to high pressure gas and returned to exposure
to normal ambient atmosphere for subsequent packaging into finished
package and/or master container, gas (or gases) that have dissolved
in the liquids and oils will be then exposed to a lower gas
pressure. Gas that has dissolved under the high pressure into
liquids will be "released" and return to a gaseous condition. The
release of gas will occur at the surface of goods and during this
event, any oxygen that is present in atmospheric air will be
inhibited from contacting the surface of the goods. This procedure
can therefore provide a method to slice and package goods while
reducing and minimizing the formation of oxymyoglobin immediately
prior to packaging and consequently minimizing the otherwise
corresponding formation of metmyoglobin after packaging in the
manner described herein. The pre-conditioning process can also
include the method of lowering the temperature of the goods to any
suitable "pre-conditioning" temperature that may be 28 degrees F.
prior to slicing and/or subsequent immersion in high pressure gas
with exposure thereto. After removal of the goods from immersion in
and exposure to high pressure gas at a lower temperature the goods
will be exposed to ambient atmospheric conditions which will be at
a higher temperature and lower gas pressure. After packaging the
goods in the finished package and/or master container, the packaged
goods can be stored and maintained within a suitable temperature
range that may be higher than the "pre-conditioning" temperature.
The pre-conditioning temperature may be maintained within a range
of approximately 29 to 32 degrees F. The suitable post conditioning
temperature range may be maintained between 33 to 36 degrees F. The
difference between the pre-conditioning temperature and the post
conditioning temperature may be less than 15 degrees F. Goods may
be pre-conditioned by passing through a first tube at a suitable
pressure where the first tube has a diameter of `X` and is
centrally located within a second tube that has a diameter of `X`+1
inch or more and thereby providing a space between the outer
surface of the first tube and the inner surface of the second tube.
A temperature controlled liquid such as brine or glycol can be
provided in the space between the first and second tubes and
thereby provide a cooling or heating devices that will allow
temperature controlling of goods that are present in the first
tube. A specified and controlled quantity of any suitable gas at
any suitable temperature and pressure can also be provided in the
first tube with goods so as to provide a controlled devices of
dissolving suitable gasses into the goods. The goods with the gas
can be held in the first tube for a suitable period of time so as
to allow the gas to dissolve into the liquids and oils in the goods
at a suitable temperature. The first tube can be filled with
compacted goods in such a manner so as to restrict any gas, that is
provided therein, from escaping or leaking there from. The first
tube may be provided with mixer therein to allow mixing of goods
contained therein. The first tube may be fitted with scraper and
substantially remove any solids, such as frozen liquids, ice and/or
solids that may accumulate on the internal surfaces thereof.
[0492] Referring now to FIG. 56, a cross-sectional view through
tray wall and flap 5212 is shown. For illustration purposes, a
section of web material 5246 is shown bonded to plane 5248.
Recesses 5236, and 5230 are therefore shown as enclosed channels.
Cavity 5220 is fully enclosed and sealed from external
communication save through perforations 5234 by bonding at
interface 5242. Gases can therefore communicate through the
perforations 5234 and into the cavity 5220 and recess 5236. The
gases can therefore come into direct contact with deposits 5244.
The deposits 5244 are preferably applied to tray and flap surfaces
that will not come into contact with any goods that are
subsequently located in the tray cavity.
[0493] Referring again to FIGS. 57-58, a cross-sectional view
through crest 5250 is detailed in FIG. 57 with hinge 5252 between
the flap 5210 and flange 5218. In FIG. 58, tray 5200 is shown in a
horizontal disposition with the opening in tray cavity facing
upwardly. The tray base is profiled so as to be higher at the
center of the tray base than at the lowest point of the tray cavity
(at a radius connecting the tray base to the upwardly extending
tray wall) and a clearance, designated by arrow 5254 is shown. The
clearance 5254 is the distance (clearance) measured from the lowest
point of the tray 5200, at the side flaps and the highest point of
the under surface of the tray base. The clearance 5254 is arranged
so as to suitably accommodate and "mate" with the crest 5250 when
another tray (not shown) is located above and placed onto a lower
tray 5200. In another alternate, the clearance 5254 may be enclosed
by over wrap material to provide a cavity into which purge may
enter through suitably located apertures in the tray. Suitable
liquid absorbing material with a suitable capacity may be provided
between the over wrap and underside of the tray base. The crest
5260 and clearance 5254 prevent the base of a stacked tray from
contact with an overwrap on the bottom tray. In this manner, the
goods are prevented from touching the base of an adjacent tray.
Embodiment 7
[0494] Referring now to FIGS. 60-61, another preferred embodiment
of a tray 5300 with flaps is shown. Tray 5300 has similar features
to tray 5200; therefore, those features ill be alluded to by the
same reference numerals. Tray 5300 with depression therein is shown
after over wrapping with overwrap web 5302. Web 5302 may include a
plastic web of material such as pPVC. The depression may be
substantially filled with goods such as ground beef prior to over
wrapping with the over wrap 5302. Over wrap 5302 may be stretched
in such a manner as to contact the goods in the depression. The web
of material 5302 may be printed with information that gives detail
of the contents of the over wrapped tray. Further more the inner
surface of the over wrap 5302 may have been processed and a heat
activated coating applied thereto, by any suitable method, and in
those areas that will come into contact with planes 5258 and 5256
as shown in FIG. 55. A suitable heat source can be provided to
activate the heat activated coating so as to cause bonding of the
web 5302 to flaps 5212 and 5210 at planes 5256 and 5258 and at
locations shown as shaded sections 5304. Alternatively, the areas
shown as 5258 and 5256 may be coated, by any suitable method, such
as by "ink-jet", with any suitable bonding material such as a heat
activated coating. Apertures 5306 may be provided as shown.
Apertures 5306 can be provided after bonding of the web to plane
5256 such that communication directly into recess 5238 is provided.
A cross-sectional view is shown in FIG. 61 through where web 5302
has been bonded to plane 5256 thereby providing space 5308 and
recess 5310. Apertures 5312 in flap, apertures 5314 in wall of tray
and apertures 5306 in web 5302 are provided. In this way a
communication is provided between the tray cavity to the outside of
the over wrapped tray following a path that will readily allow
gases to communicate therethrough but will restrict escape of
liquids such as purge. The communication follows a path through
aperture 5314 into space 5316, through aperture 5312 into recess
5310, through recess 5310 to space 5308, through space 5308 to
recess 5318, through recess 5318 to recess 5238 and through
aperture 5306.
[0495] Referring now to FIG. 62, a stack of 4 finished packages of
the tray shown in FIG. 60 is shown. A cross-sectional view is shown
in FIG. 63, through the stack of packages. It can be seen that with
this arrangement an upper tray is in contact and rests on the
flange of a lower tray. As can also be seen, clearance provided in
the underside of the base of tray mates with the upper profile of a
lower tray whereby the contents of a lower tray are located in
close proximity to the upper tray but are not in contact with the
underside of the upper tray.
Embodiment 8
[0496] Referring now to FIG. 65, a preferred packaging tray 3200
with flaps, is shown. FIG. 65 shows a flap 3202 attached to a tray
3200 by a hinge 3204 to flange 3206. Tray can also be provided with
similar flaps attached by hinges to all four sides of the tray at
hinge lines between flaps and flanges. However, FIG. 65 shows a
tray that has two flaps, on opposing sides, where one only flap can
be seen.
[0497] Packaging tray 3200 includes a substantially flat base that
may have depressions, ridges, apertures and/or penetrations
provided therein, with upwardly extending walls terminating at a
continuous flange 3206. A ledge 3208 is provided in two of the four
walls in a horizontally disposed position and level, across the
face of the side wall and between the flange and the base of tray.
The other two walls have flaps 3202 attached thereto, at a hinge
connecting the flaps to the flange. Apertures 3210 provided are
provided in ledge 3208. Tray 3200 with flaps 3202 may be
thermoformed from a suitable material such as solid or foamed
polystyrene (EPS), polyester, polypropylene or other suitable
material. Apertures 3212 are provided in flaps at optimized
locations that will restrict passage of solid or liquid matter
therethrough. An alternative aperture construction is also shown as
slot 3234 cut through a compressed section 3240 of tray in
cross-section FIG. 68 and in an enlarged view, FIG. 69, showing
details of the slot 3234 provided in a section of the flap along
ridge 3214. Slots may also be located at other locations. The
region surrounding the slot is compressed to provide a section of
thinner cross-sectional thickness. Slot 3234 includes an incision
in the compressed section of the ridge and may be provided with an
"H" profile. The slot with "H" profile provides two adjacent flaps,
3236 and 3238, respectively, that can open when a differential in
gas pressure is provided on opposite sides of the flap, however,
when the gas pressure differential has equalized the two adjacent
flaps shown as "H" flaps, can close to the former condition before
opening.
[0498] Flaps 3202 are folded downwardly, against the upwardly
extending adjacent tray walls 3216 as shown in end view of flap in
FIG. 66, prior to over wrapping. Flaps 3202 can be provided with a
fastening lug 3242 that is profiled so as to "mate" with a
corresponding fastening recess 3244 provided in tray 3200. The
fastening lug 3242 and fastening recess 3244 holds flap 3202 in a
downwardly located position in convenient readiness to be inserted
into a bag prior to sealing and shrinking. Flaps 3202 may otherwise
prevent automated loading of the tray with perishable goods
therein, into the bag.
[0499] Perishable goods such as fresh ground beef can be placed in
the tray cavity prior to tray and perishable goods being over
wrapped and shrink wrapped with a material such as Clysar AFG Anti
Fog Polyolefin Shrink Film. Shrink film may be in the form of a
preformed fabricated printed pouch (or bag) or alternatively,
unrolled from a continuous web of rolled material that is formed
into a tube on a machine such as a flow overwrapper, and cut into
convenient sized sections that can be heat sealed (or cold sealed),
so as to completely cover the assembled packaging tray and
contents, prior to heat shrinking. The assembled tray with flaps,
perishable goods and sealed overwrap are then passed through a heat
shrink tunnel that causes the overwrap material to shrink and
provide a taut and relatively tight cover over the packaging tray
and goods. Flap 3202 is provided with a continuous rim 3246. The
continuous rim 3246 is provided in such a manner so as to contact
the inner surface of the outer cover 3218. Rim is in continuous
contact around the perimeter of the flap and substantially
restricts passage of matter between the rim and the outer cover
3218 as shown in FIG. 112.
[0500] Referring now to FIG. 112, a cross-section through the tray
with flaps is shown after outer cover 3218 has been heat shrunk
into a finished position. Apertures 3220 are provided in the outer
cover. A space 3222 is provided between the flap and the outer
cover such that apertures 3220 provide direct communication between
the space 3222 and external atmosphere. A finished package 3224 is
shown in FIG. 113. A plurality of finished packages can be
assembled in a group that may include a total of twelve finished
packages in three adjacent stacks of four finished packages. The
group of twelve packages can be transferred by automatically into a
thermoformed, substantially gas barrier, outer master container as
shown in FIGS. 35-36. The barrier master container 3226 containing
the finished packages may be located within a vacuum chamber and
substantially all air evacuated from the vacuum chamber and from
within the finished packages and the barrier master container. In
this way, substantially all atmospheric air can be removed from
within the finished packages via a route that follows a path
through apertures 3210 (FIG. 65) into space 3228 (FIG. 66), through
apertures 3212 (FIG. 65) into space 3222 (FIG. 112) and through
apertures 3220 (FIG. 112). The vacuum chamber may then be filled
with a desired gas such as any single, oxygen free or oxygen
enriched blend of gases including nitrogen, carbon dioxide and/or
any other suitable gases. The gases will therefore substantially
fill all voids and spaces within the barrier master container and
the finished packages contained therein, by following the reverse
route of the path along which atmospheric gases had previously been
evacuated. In this way, finished package 3224 provides a suitable
package with space therein that can be filled with desired gases as
required, while restricting the escape of liquid or solid matter,
from within the finished package, to external atmosphere.
[0501] Referring again to FIG. 112 and FIG. 113, it can be
understood that when a plurality of finished packages are assembled
in a stack, the base of tray 3230 with adjacent flaps will be in
intimate contact with the upper surface of the finished packages.
The flaps will be in adjacent contact with the flange regions of
the lower package, thereby supporting the weight of packages
stacked above. Therefore, the perishable goods contained in any
package located beneath a package stacked above, will be protected
from damage.
Embodiment 9
[0502] Referring now to FIG. 88 an isometric projection of a
finished package 2500 constructed according to the present
invention is shown and a cross-section through an empty package
2500 is shown in FIG. 116. Tray 2502 is thermoformed from a
suitable material such as expanded polystyrene. Flaps 2504 are
connected to the tray by way of hinges 2506. Flaps can rotate about
the hinges such that upper surface of flanges 2508 can contact
directly and in alignment with flanges 2510 of the flaps.
[0503] Referring now to FIG. 115, a perishable goods 2600 such as
ground meat is located in tray 2502 and a web 2512 is positioned
directly above and over the tray and perishable goods. Web 2512
includes a transparent sheet of a suitable material such as
plasticized PVC that has been coated with a heat activated adhesive
covering the areas of the web that will come into contact with
flange 2508 thereby providing a method of sealing web 2512 to the
flanges 2508. After the web has been heat sealed to the flanges
2508, it is severed along the perimeter of flanges 2508. The web is
hermetically sealed around the full flange extending around the
perimeter of the tray. Flaps 2514 and 2504 can then be rotated
about hinges 2506 and flanges 2510 of flaps are sealed to flanges
2508 of the tray as shown in FIG. 114.
[0504] Referring again to FIG. 115, flanges 2516 and 2518 are
conveniently formed into a portion of the end walls of the tray.
Web 2512 can be sealed to the flanges 2516 and 2518 as shown.
Aperture 2520 can be provided in the location shown such that
direct communication between the gas contained between the tray and
the web 2512 and external atmosphere is enabled. The location of
aperture 2520 inhibits the egress of any liquids that may
accumulate within the package from escaping therethrough.
Additionally or alternatively, aperture 2522 is also shown. A
plurality of finished packages can be stacked together such that
face 2524 engages with face 2526. Such engagement of faces provides
a secure method of stacking finished packages.
Embodiment 10
[0505] Referring now to FIG. 117, another preferred embodiment of a
finished package constructed in accordance with the present
invention is shown. The package 2544 includes a tray 2526 and a
tray cover 2528. Tray and cover can be formed from suitable
materials such as expanded polystyrene (EPS). Cover 2528 has a
window 2530 cut therein as shown and web 2532 is stretched taut and
heat sealed to flanges 2534. Tray 2526 and tray cover 2528 are
hermetically sealed together at flanges 2536 and 2538. Walls of
tray and the cover can be printed directly thereon with information
describing the contents of the package with all legally required
information, pricing, weight of contents and cost per unit weight.
Recesses 2540 (four) in ridge 2542 are conveniently provided to
allow for evacuation of air from between stacked packages. Recesses
2540 can also provide for location of bands of printed paper that
may provide further information and details of package
contents.
[0506] Referring now to FIG. 118, a cross-section through the end
section of two stacked and finished packages 2544 of FIG. 117 is
shown. The perishable goods contents of the packages have been
omitted for clarity. Faces 2546 and 2548 engage between the stacked
finished packages. Engagement of the faces causes the outward
urging of ridge 2550 of the lower package. The weight of the upper
package is thereby transferred through the walls of the lower tray
cover while inhibiting the inward displacement of flange 2552. Such
an arrangement minimizes the likelihood of undesirable pressure
being applied to the perishable goods contents of the lower tray by
depressing the flange 2552 downwardly.
[0507] FIGS. 119-121 show an enlarged section of flange 2552,
including side elevation, FIG. 120, and a plan view FIG. 119, of
the underside of FIG. 120, and a further end view, FIG. 121, is
shown with grooves and slots that allow direct communication
between the inside of the finished package and atmospheric gases on
the outside. Web 2554 is heat sealed along a continuous seal path
2556 and intermittent seals 2562 are shown with slots 2558
therebetween. Slot 2560 is therefore in direct communication with
slots 2558 and 2564 and grooves 2566. Apertures 2568 are located
adjacent to slot 2560 and directly between continuous seal 2556 and
intermittent seals 2562. Web 2554 can include a sheet of
plasticized PVC and is tensioned prior to sealing as shown thereby
providing a transparent cover across the window. In this way direct
communication from within the package to atmosphere is provided
through apertures 2568, slot 2560, slots 2558, slot 2564, and
grooves 2566, while minimizing the possibility of any accumulated
liquids escaping that may be present within the package.
[0508] Referring now to FIG. 122, three empty packages 9608 with
web sealed thereto, are shown stacked together. A section through a
finished package 9610 is shown in FIG. 124, and a section through
an individual package is shown in FIG. 123.
[0509] Referring now to FIG. 125 three finished packages 2570 are
stacked together within a flexible gas barrier container 2572. A
gas barrier lid 2574 is hermetically heat sealed to gas barrier
container 2572 after substantially all air has been evacuated and
replaced with a suitable gas that may be substantially oxygen
free.
Embodiment 11
[0510] Referring now to FIG. 126, another alternative embodiment of
a tray with flaps constructed according to the present invention is
shown. Tray 2578 includes a first 2576 and second flap (not shown).
Flap 2576 is attached to tray 2578 by hinge 2580. Ridges 2582 are
formed in flap and corresponding ridges 2584 are formed in tray
such that when flanges of flap and tray are in contact, portions of
ridges are also in contact. Web 2586 is heat sealed to flanges 2588
and 2590. Apertures 2592 and 2594 are provided in the web such that
when flanges of the flap and tray are parallel to each other and in
closest proximity, apertures are in alignment providing direct
communication therethrough. Concentric depressions 2596 are shown
in FIG. 126 and in the detail of cross-section FIG. 127. Tray 2578
may be formed from a three layer construction of expanded
polystyrene where the inner layer includes an "open" cell structure
that will absorb liquids such as water and blood. Depressions are
provided on the inner surface of the tray, to allow contact of
liquids, that may be present in the tray, with the inner cells of
the tray and allowing absorption of liquids by the open cell
structure.
Embodiment 12
[0511] Referring now to FIGS. 128-130, another preferred embodiment
of a tray with flaps constructed according to the present invention
is shown. FIG. 130 shows a cross-section through a tray 2400, FIG.
129 shows a cross-section through a tray 2402 that contains ground
meat with a web 2404 stretched over the ground meat and sealed to
flanges 2406, 2408 and edge portion 2410. FIG. 128 shows a
cross-section through a portion of a master container 2412 with
finished packages 2414 stacked therein. A flap 2415 is shown that
has been severed from tray 2402 and web 2404 is also sealed to flap
2416. A space 2418 is provided between web 2404 and inner surface
of the flap 2416 providing direct communication between recess 2420
and aperture 2422. Flap 2416 and tray 2402 are therefore attached
together by web 2404 and a gap 2424 is provided between flap 2416
and the tray 2402. An aperture 2422 is provided in web 2404 at flap
2416 portion and an aperture 2426 is also provided in web 2404 at
tray portion. Recesses 2420 are provided in the flap 2416 such that
when web 2404 is sealed thereto recess 2420 provides direct
communication therethrough from atmosphere to the space between the
flap 2416 and web 2404. Recesses 2420 are conveniently located in
wall of flap 2416 between flange 2406 and horizontal edge portion
2410 shown in FIG. 129. Severing of flap 2416 is optional and
alternatively a hinge may be provided by compressing flange 2428
with a profile so as to facilitate easy hinging of flap 2416 and
tray 2402 relative to each other.
[0512] Flap 2416 is arranged such that it can be "hinged" about the
gap 2424 such that flanges 2406 and 2408 contact directly with web
2404 material therebetween. Flanges can then be sealed together
through web 2404 such that web 2404 material seals together in a
desired manner. The apertures 2422 and 2426 are positioned such
that they become aligned after sealing of the flanges. Web 2404
material is then most likely to become lightly bonded together
around the perimeter of apertures 2422 and 2426. An adhesive may
also be applied to the contacting surfaces of web 2404 around the
perimeters so as to cause substantial bonding and providing a
substantially liquid `tight` seal there around so as to inhibit
escape of any liquids therebetween. This arrangement provides a
direct communication from space 2418 to any atmosphere external of
the package, via apertures 2422 and 2426, space 2430 and recesses
2420. The location of apertures 2422 and 2426, space 2430 and
recesses 2420 are arranged such that any liquids (or solid matter)
that may accumulate within the package are inhibited from escaping
from space 2418. With this arrangement, gasses can communicate
directly between space 2418 and while liquids and other solid
matter is substantially restricted and held within space 2430 or
2418.
[0513] Tray can be formed from foamed polyester or from expanded
polystyrene foam (EPS). Web 2404 may include a suitable grade of
plasticized PVC (pPVC) which may be printed with various colors and
graphics and a heat activated, or pressure sensitive adhesive may
also be applied during the printing process or separately as
desired and required to provide sealed finished packages.
[0514] Completed packages 2434 can be stacked into master container
2412 until it is filled. A lid including a gas barrier web can be
then sealed to the flanges of 2412 as described in U.S. patent
application Ser. No. 09/039,150. Packages 2434 are stacked such
that the ridges 2436 on the base of a first package "nest" adjacent
to ridges 2438 of a second package. A space can therefore be
maintained between the bottom of the second package and the web and
contents of the first package.
[0515] In a further embodiment, 2412 can be located within a
chamber such as is shown in diagram 5100 prior to sealing the gas
barrier web to the flanges of `MC`.
Embodiment 13
[0516] Referring now to FIG. 70, another embodiment of a tray with
flaps constructed according to the present invention is shown. FIG.
70 shows a cross-sectional through tray detailing a preferred
profile. Rib 4420 is formed in flap 4422 adjacent to recess 4424.
Rib 4420 is formed so as to contact wall of tray as shown when flap
is folded into position. Recess 4426 is formed in the flap 4422
with an aperture or slot therein but does not contact the outer
surface of the wall of tray and is provided with space 4428
therebetween. A suitable adhesive such as a solvent is applied to
the surfaces of the flap 4422 and the wall of tray such that when
flap 4422 contacts the wall of tray, both parts bond together. The
bond between the flap 4422 and the wall of tray can be arranged to
follow a continuous path close to the perimeter of the flap 4422
and thereby provide a substantially liquid "tight" seal around
space 4428. Each flap (4) can be applied with adhesive in a similar
manner to that described for flap 4422 then, in like fashion,
bonded to walls of tray to produce a finished tray. Apertures 4430
can be provided in the lower section of the wall of tray such that
liquids that may accumulate within the tray can pass through
apertures 4430 and enter space 4428. Slots, slits or holes can be
provided in recess 4424 such that direct communication through
recess 4424 into space 4428 and through apertures 4430 can be
provided. The surface of the flap and the wall of tray in direct
contact with space 4428 can be treated so as to absorb liquids such
as water, purge and blood.
[0517] Referring now to FIGS. 71-72, an enlarged cross-section
through a portion of EPS sheet is shown and an enlarged
cross-section through EPS sheet, after thermoforming and assembly
of tray and flaps in finished and bonded position, are detailed. In
FIG. 71, a cross-section through a portion of sheet EPS foam with
skin 4432 and skin 4434 is shown. EPS sheet, as shown in FIG. 71
can be extruded in normal production such that skin 4432 and skin
4434 is substantially nonporous and will resist absorption of
liquids, while the inner layer of EPS foam 4436 can be produced so
as to absorb liquids. In a preferred embodiment, the EPS sheet with
skin 4432 and skin 4434 can be extruded and wound onto rolls in
readiness for use in thermoforming and production of trays with
flaps as shown in FIG. 52. In another preferred embodiment, the EPS
sheet material may include three layers of expanded polystyrene
sheet where an inner layer of open celled foam, that has been
arranged to absorb desired liquids, is "sandwiched" between two
outer layers of closed cell expanded polystyrene sheet that will
resist absorbing of the liquids. After thermoforming the trays with
flaps, from the three layer material or alternatively from material
with outer skin 4432 and 4434 a solvent or other suitable agent,
can be applied by spraying, or any other suitable method, to
selected areas of flap(s) and wall(s) of tray such that only those
selected surface areas, that will become enclosed between the flaps
and the trays, after folding and sealing into the required
position, will have the solvent applied thereto. The solvent, or
other suitable agent, can be applied in sufficient quantities to
the selected surface areas, so as to dissolve the skin 4432 or 4434
at surfaces 4438 and 4440, shown in FIG. 72 thereby exposing the
inner, liquid and water absorbing EPS foam, for subsequent contact
with any liquids that may enter space 4428. In this way a finished
tray, with flaps folded and sealed into the desired configuration,
can be produced so that only the surfaces adjacent to and in
contact with the space 4428 will be substantially liquid and water
absorbing. It can be seen that any liquids that may be present on
the inside of the tray can pass through apertures 4430 and into
space 4428. Liquids can then be absorbed by the exposed EPS foam in
contact with the space 4428 however, due to the liquid absorbing
resistance of skin 4432 and 4434, the liquids may not be visible to
any person looking at the tray with flaps from outside the space
4428.
Embodiment 14
[0518] Referring now to FIGS. 73 and 74, another embodiment of a
tray with flaps constructed according to the present invention is
shown. A cross-section through a finished package in shown in FIG.
730 and a three dimensional view of a finished package 3400, is
shown in FIG. 74. The finished package 3400 includes a tray 3402
with perishable goods contained therein and an outer cover of a
substantially gas barrier shrink material 3404. Apertures 3406 are
provided in the gas barrier outer cover and a peelable, gas barrier
label 3408 is hermetically sealed over the apertures 3406. The
finished package 3400 has spaces 3410 and 3412 and other space
contained within the outer cover 3404. A substantially oxygen free
gas including any suitable gas, selected to extend the keeping
qualities of the perishable goods, such as a blend of carbon
dioxide and nitrogen, can be provided in the spaces inside the
package 3400 after evacuating other gasses contained therein, such
that all the spaces are filled with oxygen free gas. The finished
package can be stored for a period of time and then the gas barrier
label 3408 on the tab 3414 can be removed by peeling, thereby
allowing atmospheric gas to enter through the apertures 3406 and
3416 and into the spaces around the perishable goods and contact
the perishable goods.
Embodiment 15
[0519] Referring now to FIG. 76, another embodiment of a finished
package constructed according to the present invention is shown. A
cross-sectional view with details of a preferred configuration
including a tray with flaps that are folded into the finished
position and extend below the base of tray is shown in FIG. 75. As
described in earlier embodiments of this present specification, a
tray with flaps may include a rectangular flat base with radiused
corners and upwardly extended walls that terminate at a flat
horizontally disposed, common flange. A space or cavity is
therefore defined between the walls. Flaps are connected directly
to the peripheral edge of the common flange at a hinge along a
hinge line. A single flap may be attached to a single wall or
alternatively up to four flaps may be attached, one to each wall.
The packaging tray with flaps can be thermoformed from suitable
plastics materials such as expanded polystyrene (EPS) sheet. Flaps
of various configurations have been described herein with apertures
conveniently provided to allow gas or air exchange therethrough
while inhibiting and restricting the escape of other matter such as
liquids including blood therethrough. Such apertures and
configurations allowing gas exchange therethrough can be provided
in this present embodiment if desired, however, the purpose of the
description of this present embodiment is to disclose an improved
packaging that will also protect the perishable goods contents of
the finished package when stacked together in a master container as
shown in FIG. 16.
[0520] Referring now to FIG. 75, a loaded tray 3700 with flaps 3702
is completely covered with an outer cover 3704 and it can be seen
that the outer cover 3704 is domed upwardly and is stretched over
the upper surface of the perishable goods 3706 such that the
uppermost part of the perishable goods 3706 is extended above the
common flange 3708 under the outer cover 3704. In this manner the
perishable goods 3700 are held firmly to the base 3710 of tray 3700
by applying tension on the outer cover material. An adhesive 3712
may be provided between the outer cover 3704 and the common flange
3708 so as to seal, hermetically or otherwise, the outer cover 3704
to the common flange 3708 along a path that will become an outer
edge of the finished package. Additionally and as shown, adhesive
3712 may be provided between the flaps 3702 and the tray walls 3714
so as to seal the flaps 3702 in position to the walls as may be
desired, hermetically or otherwise. Adhesive 3712 may also be
provided between the underside of the base 3710 and between the
base and the inner surface of the outer cover 3704. Outer cover
3704 may include a suitably printed, heat shrinkable, stretchable,
sealable, transparent, oxygen and gas permeable web of material
with a "memory" that may be applied after loading the perishable
goods into the tray cavity. The outer cover 3704 may be applied
directly from a continuous web or roll of the material or
alternatively may be fabricated into suitably sized bags, such as
those supplied by Robbie Manufacturing, Inc., prior to sealing over
the loaded tray with flaps. The outer cover 3704 may be suitably
perforated with apertures to allow gas and/or air exchange
therethrough and can be heat shrunk after sealing over the loaded
tray with flaps by passing through a suitably adjusted heat tunnel.
Alternatively, the outer cover 3704 may be applied from a
continuous web and stretched during application thereof and then
sealed to provide a sealed outer cover 3704 that is stretched
taught around and over the loaded tray with flaps as shown in FIG.
75.
[0521] FIG. 77 shows a cross-section of a tray after the
application of the outer cover 3704, that may be manufactured from
any transparent suitable material, but before stretching by
depressing the outer cover 3704 into the recess 3716 as shown in
FIG. 78. FIG. 78 shows the same cross-section as in FIG. 134 after
outer cover has been depressed so as to contact the adhesive
between the base of tray and the inner surface of the outer cover
3704. By a mechanical device, the outer cover 3704, that is located
adjacent to the underside of the base 3710 of tray, can be
depressed and stretched so as to contact the adhesive 3712 located
between the inner surface of the outer cover 3704 and the under
surface of the base 3710 of tray so as to provide bonding
therebetween. A recess 3716 can therefore be provided as shown. In
this way, the outer cover 3704 can be stretched over the entire
surface of the tray 3700 with perishable goods contained therein.
Therefore, when another finished package of similar configuration
is located and stacked above and onto a similar lower package, the
underside of the finished package will not contact the upper
surface of the dome of the lower package. In this way the lower
packages are protected from damage when stacked and transported or
when displayed in stacks at a point of sale to consumers.
[0522] Referring now to FIG. 79, a cross-sectional view through an
assembled and finished master container 3722 is shown inside a
closed and sealed corrugated cardboard carton 3724. Two finished
packages 3726 and 3728 are shown inside the master container 3722.
As can be seen, the extended flaps of the upper finished package
provide a recess to accommodate the upper surface dome of the lower
finished package thereby providing protection to the perishable
goods contained therein. The master container 3722 may be
thermoformed from a web of flexible, substantially gas barrier,
plastics material such as Curlon Grade 9315-II as manufactured by
Curwood of Oshkosh, Wis. and can be provided so as to tightly hold
the finished packages. A substantially gas barrier lid 3732 that is
provided from a web of plastics material such as Curlam Grade
2500-K as manufactured by Curwood of Oshkosh, Wis., is shown heat
sealed to the flange of the master container 3722. The seal 3734
between the lid and the master container will, most desirably, be a
peelable seal that can be peeled with relative ease by any person
wishing to open the sealed master container. A desired gas 3736 is
contained within the hermetically sealed master container and an
oxygen scavenger 3730 is located therein. Further, the lid of a
master container may contain a relief valve to allow escape of any
excess gas that may be released from solution in the meat and to
accommodate for an expansion of the master container.
[0523] The sealed, gas barrier, master container 3722 is located in
a corrugated cardboard carton 3724. The corrugated cardboard carton
3724 may be manufactured by the Weyerhaeuser Corporation, of
Tacoma, Wash. from 69140/69, 5100 flute corrugated cardboard and
such a construction will withstand substantial loading.
[0524] An enlarged view of the seal arrangement is shown in FIG. 80
and an alternative configuration showing flange of container in
position after folding inwardly is shown in FIG. 81. In this
embodiment the corrugated cardboard carton is just large enough to
contain the master container but the flange of the master container
is folded inwardly to allow the sides of the master container to be
in close contact with the inner surface of the carton, thereby
reducing the size of the carton to a minimum.
[0525] The size of the master container and the corresponding size
of the carton can be suitably arranged to contain one or more
finished packages.
Embodiment 16
[0526] FIG. 131 shows another embodiment of a tray constructed
according to the present invention. The tray 1900 includes flap
1900. Flap 1900 is attached to tray 1902 along an outer edge 1904
of tray flange 1906 and a further flap (not shown) can be attached
to the outer edge along the opposite side of the tray which is
parallel with the first flap and is similar in operation thereto.
After sealing of second and third webs to flanges 1906 and 1908,
flap 1900 can be folded downwardly so that radius 1910 in FIG. 132
engages with recess 1912. Flap 1900 includes a hinge that can be
folded along a hinge line through an arc shown more clearly in FIG.
132. Radius 1910 and recess 1912 "mate" and can be arranged so that
they "snap" into a matingly engaged position, thereby holding the
flap 1900 firmly. Referring now to a cross-sectional view of the
stacked trays in FIG. 65, flap base 1918 is shaped so as to
correspond with profile of flanges 1906 and 1908 and a ridge 1926
is located along the external edge of flap base 1900 such that when
a finished package is stacked above another similar package they
will "nest" together and the upper tray is prevented from
contacting the contents of the lower tray. The base of the tray can
be formed with a profile providing an upwardly extending depression
that extends above the highest point of the contents in the lower
tray. In this fashion, the finished packages can be stacked within
cartons for distribution and shipped long distances without causing
damage to contents of the trays in the lower position. First web
tray 1920 has recessed base to clear goods in the tray below. Lip
1928 can be heat sealed after folding of the flap by heat seal bars
1930 to ensure that flap 1900 is retained in folded position as
shown in the stacked finished packages FIG. 133. Ridges 1932 can be
formed into flaps to improve rigidity and stability of the finished
pack.
Embodiment 17
[0527] Referring to FIG. 82, another embodiment of a tray, 3100,
with flaps is shown. A cross-section is shown in FIG. 83, where
both flaps are folded inwardly and the package has been inserted
into a Clysar AFG shrink bag 3114. The tray can be
"stretch-wrapped" with PPVC as an alternate to a PP bag as shown in
FIG. 83.
[0528] Tray 3100 includes a base with four upwardly extending
walls, terminating at flanges 3104. Two flaps 3102, 3103 are
provided such that they can fold inwardly. Recesses 3106 are
provided in the flaps to allow communication of gasses
therethrough. Tray 3100 further includes a base rim 3108 that
extends around the perimeter of the base. Depressions 3110 and
perforations 3112 can be provided at the tray base 3126. Apertures
3116 are provided in shrink bag 3114. Tray 3100 may be thermoformed
from any suitable material. Apertures 3116 provide direct
communication from external atmosphere through space 3118 and
recesses 3118 to tray cavity. Perishable goods can be located into
tray cavity and flaps 3102 folded inwardly. Assembled tray and
perishable goods can then be located within a polypropylene shrink
bag, such as Clysar AFG shrink bag 3114 which is then heat sealed
and heat shrunk around the tray and goods to form a finished
package. A plurality of finished packages may be assembled and
stacked together to provide a group of assembled finished trays
which is then hermetically sealed within a substantially gas
barrier master container as described in U.S. patent application
Ser. No. 09/039,150 with a gas barrier lid. When the finished
packages are stacked, the base rim 3108 of one pack will rest
directly above flaps 3102. In this way, finished packages can be
stacked together without causing undesirable damage to the contents
of the package. Perforations 3112 absorb liquids as described
herein.
[0529] Alternatively, in a preferred embodiment, the Clysar AFG
shrink bag 3114, may be replaced with a stretch wrap material such
as plasticized PVC.
[0530] Referring now to FIG. 135 wherein a view of a section of
tray 3100, after folding and bonding of the flaps to the tray wall,
is shown. A plan view of the scrap view section, prior to folding
and bonding of the flaps, is shown in FIG. 134. A preferred method
for production of trays with flaps includes a thermoforming process
and a "cut in place" procedure. The term "cut in place" is a common
term used by those skilled in the art of tooling manufacture and
use of thermoforming equipment. This term describes a thermoforming
production method including the use of a thermoforming tool with a
cutting devices incorporated into the tool so as to permit cutting
of the subject thermoformed component from a web of plastics
material immediately after forming and before ejection and removal
of the component(s) from the thermoforming tool. The scrap view
section shown in FIGS. 134-135 details a single corner section of a
four cornered tray such as the tray of FIG. 55, however, all four
corners of the tray with flaps are similar. Referring again to
FIGS. 134-135, flaps 5268 and 5270 are shown attached to a tray
5272 at a hinge 5274. The tray with flaps is shown in FIG. 134
prior to folding flaps and bonding. The tray with flaps is shown in
FIG. 135 after folding of flaps and bonding. The flaps can be
printed by ink jet devices, prior to folding and bonding in the
manner disclosed above with reference to FIG. 55. Adhesives can
also be applied by ink jet printers to the flaps and tray. Hinge
lines 5276 and cut lines 5278 are all parallel and in the same
plane. The cut lines 5278 and hinge line 5276 terminate at points
5280 and 5282. If desired a further hinge line 5284 provides
devices to fold sections 5286, which can be folded and bonded to
the base of tray. Panels 5288 and 5290 can be printed with any
information or graphics as may be desired and are arranged to be
elevated and angled so as to be more easily visible by an intending
purchaser of the tray with goods therein.
[0531] Referring now to FIG. 136, a cross-sectional view through a
corner of the tray with flaps, after the flaps have been folded and
bonded, is shown. The "cut in place" forming method allows a method
to provide walls 5292 and 5294 that can contact each other, as
shown, and be bonded together after folding the flaps into the
finished position. In this way, a substantially more rigid tray
structure can be provided that would otherwise require a heavier
wall section for trays that have not been provided with flaps as
herein disclosed. With ink jet application of adhesives, as
described herein, an efficient devices of economically applying the
minimum quantity of adhesives is provided. In this way, adhesives
can be applied in a pattern that allows for maximum surface area
bonding of trays and flaps while minimizing the quantity of
adhesive material required.
[0532] In yet another preferred embodiment, packaging including a
combination of features disclosed in any of the trays above may be
combined to construct a finished package. For example, a package
including a tray with any of the flaps disclosed herein may be
constructed to provide desired features and inserted into either a
Clysar AFG shrink bag or alternatively a stretch wrapped in a pPVC
stretch film over wrap or shrink wrapped with printed Clysar AFG
anti fog shrink film.
[0533] In yet another preferred embodiment, packaging including a
combination of features disclosed above may be combined to
construct a finished package. However, perforations may be provided
in depressions to allow any free liquids to pass therethrough to a
space between the base of tray and the outer shrink bag.
Indentations may be provided in the under (or outer) surface of the
tray that can allow open cells, that may be present in the EPS
structure of the tray, to absorb the liquids.
[0534] Any of the foregoing trays with flaps will be used in a
method to automatically or manually performing the following
steps:
[0535] Providing a tray with flaps, that has been thermoformed from
expanded polystyrene (EPS). The tray having dimensions that will
provide for the efficient use of the internal dimensions and
capacity of typical, refrigerated road and rail transport
vehicles.
[0536] Trays will retain a substantially oxygen free gas within
cell structure of the tray and/or exposing the tray and/or the tray
material prior to and/or during thermoforming and production of the
tray, to a gas that excludes oxygen and allowing the gas to
exchange with any gasses contained within the cells of the EPS
thereby substantially displacing any atmospheric oxygen from the
cells or otherwise ensuring that gasses contained in the cell
structure substantially excludes oxygen.
[0537] Providing perishable goods onto the base of the tray. The
perishable goods having been treated and processed to enhance the
keeping qualities thereof.
[0538] Over wrapping the tray with goods therein with a web of gas
permeable material such as pPVC, to produce a finished package and
then seal the over wrapping web of gas permeable material to
portions of the tray by a heat sealer or other suitable adhesives
and then perforate the over wrapping web of gas permeable material
at desired locations.
[0539] Placing the finished package or a plurality of similar
finished packages into a gas barrier master container.
[0540] Displacing substantially all atmospheric gas, and
particularly atmospheric oxygen, from within the master container,
with a suitable gas or blend of suitable gasses.
[0541] Sealing a lid over the opening in the master container to
form a hermetically sealed package containing the trays with
perishable goods and suitable gas.
[0542] Placing the master container inside a carton such as can be
manufactured from corrugated cardboard and enclosing the master
container.
[0543] Locating a plurality of closed cartons onto a standard (GMA
specified) pallet (Dimensions of 40''.times.48'') so as to maximize
the efficient use of the upper surface area provided by the pallet
thereby producing a loaded pallet.
[0544] Storing the loaded pallet for a period of time in
refrigerated space.
[0545] Delivering the finished pallets to a point of sale such as a
supermarket.
[0546] Performing all aspects of the process in temperature
controlled conditions
Embodiment 18
[0547] Referring first to FIG. 88, a tray 1000 is shown in a three
dimensional disposition. The tray is arranged with a base 303 and
four upwardly extending walls terminating at a flange 901 with a
cavity 110 surrounded by the walls. Each of the walls may be
rigidly fabricated by bonding together, two or more layers (shown
as 100, 101 and 102 in FIG. 89). Each layer is attached directly
together or in series to the flange 901, of the tray, via hinges
that allow folding of each layer together and against each other,
prior to bonding the layers together, to provide rigid wall(s). In
this way the tray walls can be rigidly constructed with higher
compression resistance and at a lower cost than would otherwise be
incurred for a single layer wall of a similar compression resistant
rigidity.
[0548] Referring to FIG. 90, a plan view of a thermoformed pre-form
is shown which can be manufactured from any suitable material, of
any suitable thickness but is most preferably thermoformed from
extruded polypropylene sheet with a thickness of approximately
0.018''. The polypropylene sheet is then thermoformed to produce a
pre-form, which is constructed so that it can then be folded and
bonded into a stackable tray profile. The pre-form consists of a
cavity 110, with a series of semi-rigid flaps, all connected by at
least a single hinge to the flange 901. Cavity 110 has a base 303
with four upwardly extending walls terminating at a continuous
flange 901. Flange 901 may be arranged with four straight sections
connected via rounded corners but the other packaging tray
configurations may be fabricated. At the outer perimeter of flange
901, adjacent flange flaps, 100, 301, 300 and 400 are attached via
hinges shown as 88, 90, 89 and 87 respectively. Located at each
corner of flange 901, and between each adjacent pair of adjacent
flange flaps, additional flaps are provided. Between adjacent
flange flaps 100 and 301 a pair of generally triangular adjacent
flaps 101 and 99 are located but severed completely from direct
attachment together by cut 200. Flap 101 is attached to adjacent
flange flap 100 via hinge 91 and flap 99 is attached to adjacent
flange flap 301 via hinge 98. Similarly, flap 104 is attached to
adjacent flange flap 301 via hinge 96 and flap 206 is attached to
adjacent flange flap 400 via hinge 94. Additionally, flap 205 is
attached to adjacent flange flap 400 via hinge 93 and flap 105 is
attached to adjacent flange flap 300 via hinge 202. Finally, flap
106 is attached to adjacent flange flap 100 via hinge 97 and flap
204 is attached to adjacent flange flap 100 via hinge 73. The pair
of flaps 204 and 106 are severed along cut 203, the pair of flaps
101 and 99 are severed along cut 200, the pair of flaps 104 and 206
are severed along a cut 201 and the pair of flaps 205 and 105 are
severed along cut 202. Said flaps 101 and 204 can be folded toward
each other until they contact what becomes the inner surface of
adjacent flange flap 100, and adjacent flange flap 100 can then be
folded toward adjacent tray cavity wall 102 until the surfaces of
flaps 101 and 204 contact a surface of adjacent cavity wall 102.
This can be repeated simultaneously, separately or in
correspondingly opposite, adjacent flange flaps such that all flaps
are folded and held together for bonding at any and all contact
points between the corresponding flaps and generally as detailed in
FIG. 89.
[0549] Referring now to FIG. 89, a side wall of packaging tray
shown in FIG. 88 is detailed, after folding of flaps shown therein
which can be bonded, by any suitable bonding means, at contact
points 405, 406, 407, 408 and 409. Bonding can be arranged to
follow a path near what becomes a perimeter of adjacent flange flap
100 so as to hermetically seal space 900 therein.
[0550] Referring now to FIG. 91, a cross section through flange
901, cavity wall 102 and adjacent flange flap 100, details a
preferred embodiment wherein hinge 88 is located parallel to hinge
902 with an additional flap section 905 between hinges 88 and 902.
Adjacent flange flap 100 is bonded to wall 102 at 904.
[0551] Referring again to FIG. 90 in a preferred embodiment, an
additional flap 701 is shown attached to adjacent flange flap 301
via hinge 85 and additional flap 700 is shown attached to adjacent
flange flap 300 via hinge 86. Flaps may also be similarly attached
via hinges to adjacent flange flaps 100 and 400 if so desired. In
this arrangement pairs of flaps 104 and 206, 99 and 101, 204 and
106, 205 and 105 can be deleted, allowing flaps 701 and 700 to be
folded respectively against what become internal surfaces of
adjacent flange flaps 301 and 300 prior to bonding there together
to provide a structure generally similar to that shown in FIG.
89.
[0552] Referring now to FIG. 92, a plan view of a preferred
pre-form is shown, wherein a centrally located cavity 12 is
connected via hinges 17, 19, 23 and 18, to flaps 11, 13, 14 and 16
respectively. Additional flaps 10 and 15 are attached via hinges to
flaps 11 and 14. Ribs can be provided to all parts of the tray
cavity, walls and flaps and can be arranged in any suitable profile
so as to maximize rigidity of the finished tray but are shown only
in flaps 10 and 15.
[0553] Referring now to FIG. 93, two pre-forms are shown stacked
and nested together. In this way pre-forms can be manufactured and
then conveniently stacked in a nesting configuration, minimizing
the volume of space required during storage and shipping thereof.
Pre-forms can then be fabricated at the point of use for packaging
goods.
[0554] Referring now to FIG. 94, a cross section through a tray
assembly fixture arranged to fold and bond pre-forms in an enclosed
chamber is shown. Only one view of the assembly fixture is shown
which is rigidly constructed from suitable materials wherein a base
frame 38 is connected to a platen 37. Base frame 38 and platen 37
can be securely connected there together by any suitable means but
most preferably by way of a quick release arrangement so as to
allow the rapid separation of the two components. In a preferred
embodiment, several similar assembly fixtures can be attached to a
horizontally disposed continuous conveyor and arranged to operate
automatically as a complete machine and this will be generally
described in a later part of this disclosure. Platen 37 is securely
attached to a profiled fixture 39, which is shaped to correspond
with the internal, cavity surface profile of a pre-form such as
shown in FIG. 92. A pre-form 35 is shown in position and mated with
fixture 39. Part 36 is hinged at 151 and part 33 is hinged at 150.
Parts 36 and 33 are arranged to dimensionally correspond to the
flaps of pre-form 35, and can be attached to a suitable driving
arrangement such as pneumatic cylinders that will drive each part
to close in a sequence as required. Part 36 is shown in an open
disposition whereas part 33 is shown in a closed position and
firmly holding a flap of pre-form 35 against a wall thereof. A
source of vacuum may be attached to fixture 39 or single chamber
(32 and 31) so as to assist in securely holding the pre-form in
place during folding and bonding of flaps. After flaps have been
bonded into position the vacuum may be released to allow easy
removal of the folded and bonded tray. Additional hinged parts (not
shown), similar to 36 and 33, may be attached to other sides to
fixture 39 as may be required to correspond with additional flaps
that may be attached via hinges to pre-form 35. A typical pre-form
is shown in FIGS. 92 and 93. All hinged parts 36, 33 and any others
can be arranged to fold flaps against the side walls of pre-form 35
and to hold there against securely during bonding of flaps to
correspondingly adjacent side walls. A single chamber is shown in
two parts, 31 and 32, that can be opened and closed as required to
allow pre-forms such as 35 to be located on fixture 39 and
sequentially unloaded by any suitable means in an automated and
continuous process. The single chamber (31 and 32) is attached to a
shaft 30, which in turn is attached to a drive such as a pneumatic
cylinder, which can provide alternating opening and closing of the
chamber. Ports can be provided in the single chamber with valves
arranged to allow any suitable gas at any suitable pressure therein
and connection to a suitable source of vacuum. The single chamber
can be arranged to close over fixture 39 after locating a pre-form
(35) thereon and a seal such as `O` ring 34, can be installed along
the contacting face between the single chamber (31 and 32) and
platen 37. In this way, an enclosed and substantially gas tight
enclosed space 46 can be provided. Prior to closing the single
chamber against platen 37, hinged parts 36 and 33 can be activated
by driving air driven cylinders. After closing the single chamber,
space 46 can be substantially filled with any suitable gas at any
suitable pressure via valves and ports (not shown) and to ensure
that cavities between flaps and cavity walls are filled with the
selected gas and thereby substantially excluding atmospheric
oxygen. Hinged parts 36 and 33 can be arranged to carry any
suitable sealing mechanism, such as RF welding and arranged to bond
flaps to side walls of pre-form 35 directly. In this way cavities
such as space 900 described above and in association with FIG. 89
can be filled with any suitable gas at any suitable pressure. In
summary, a preferred sequence of apparatus operation, as shown in
FIG. 94 can be as follows:
[0555] A. Provide a pre-form 35, locate on fixture 39, and apply a
vacuum source to hold the pre-form securely to fixture 39.
[0556] B. Apply any suitable adhesive to selected surfaces of flaps
of pre-form and fold hinged parts such as 36 and 33 so as to fold
and close flaps against the side walls of the pre-form. [Hinged
parts 36 and 33 may be arranged with a means to partially close and
thereby allow substantially complete evacuation of air or gas
therefrom prior to bonding].
[0557] C. Close single chamber over pre-form and seal chamber
against platen 37.
[0558] D. Evacuate space 46 and provide any suitable gas at any
suitable pressure therein.
[0559] E. Seal flaps to side walls of pre-form.
[0560] F. Open chamber and allow removal of pre-form with flaps
bonded to side walls.
[0561] Referring again to FIG. 94, assembly fixture detailed
therein can be arranged in groups wherein each assembly fixture is
attached, via quick release connection, to a pair of parallel
horizontally disposed, continuous chains, with a driving motor such
as a servo electric motor, horizontally disposed to provide a
conveyor. In this way a complete machine can be arranged with the
upper section thereof, enclosed and a suitable gas provided in
enclosure, such that when pre-forms are located on fixtures (39),
if so desired, the gas in contact with pre-forms is oxygen
free.
[0562] Referring now to FIG. 95, a side view and end view of two
finished packaging trays 40 and 41 stacked together are shown. Ribs
43 and 42 locate interlock with the base of the upper tray.
[0563] Referring now to FIG. 97 and FIG. 98, another preferred
packaging tray (190) embodiment is shown with a cross sectional
view 2-2 therethrough. Tray 190 may be manufactured from any
suitable material but in this instance a material such as
polyethylene is preferable. A cavity 61 is surrounded by upwardly
extended side walls 64, 67, 68 and 60 all terminating at flange 60.
Flaps 67 and 64 are visible and ribs 65 and 67 are shown in flap 67
and ribs 62 and 63 are shown in flap 64. Flaps, 67 and 64
(including those not visible), have been hermetically bonded to
side walls of tray. Referring now to section 2-2 in FIG. 98, a
cross section through ribs 65 and 66 is shown. Hinges 70 and 71 are
arranged to allow folding of flap 67 against wall 80. Hermetic
seals are shown at 72, 75 and 78. Hermetic seals shown as 72 and 75
follow a path completely around the perimeter of rib 65 and
hermetic seals shown as 75 and 78 follow a path completely around
the perimeter of rib 66. In this way a spaces 73 and 76 can be
completely enclosed and hermetically sealed separately from each
other. However, prior to bonding ribs so as to enclose and
hermetically seal spaces 73 and 76, any suitable gas such as carbon
dioxide at any suitable pressure but most preferably at a relative
high pressure, such as 80 psi, can be provided therein. In this way
a rigid tray can be manufactured with reduced material content and
therefore at relatively lower cost.
[0564] Referring now to FIG. 99, a tray 180 with lateral ribs
arranged in a similar manner to those (62, 63, 65 and 66) disclosed
in FIG. 7 is shown. Section 3-3 shows spaces 86 and 87, enclosed
and hermetically sealed within ribs 94 and 98, along seals 84, 88
and 89 which can be filled with high pressure gas such as CO.sub.2.
Hinges 82 and 83 are located so as to provide an outwardly
extending flange, after folding flap against wall 85, and to which
a web of material shown as lid 81 can be hermetically sealed so as
to fully enclose cavity 181. Apertures such as 99 can be provided
to allow liquids to enter cavity 90 and seal at 91 prevents escape
of such liquids from space 90. Ribs such as 93 can be provided.
[0565] Referring now to FIG. 84, two thermoformed trays 200 and 201
are shown in a partially nesting disposition. The profile of tray
200 is arranged with upwardly extending walls terminating at flange
196 with ribs 199 and 184, formed into the walls. Ribs formed in
tray 200 such as 199 and 184 extend inward toward the center of
cavity 210 and ribs such as 198 and 183 in tray 201 extend
outwardly away from a centrally disposed cavity.
[0566] Referring now to FIG. 85, the two trays 200 and 201 in FIG.
84 are shown sealed together to form a single tray 1001. Flanges
196 and 197 are hermetically sealed together around the full length
of what has become a path close to the tray perimeter. FIGS. 86-87
show details of enclosed spaces such as 188, 187 and 189. Ribs are
also hermetically sealed such that ribs formed in the walls of the
inner tray are sealed against the corresponding rib in the outer
tray to provide fully enclosed spaces such as 187 shown in FIG. 87,
that can be filled with high pressure gas. Seal paths 190 and 191
are shown as examples of hermetic sealing and enclosing of spaces
such as 187. FIG. 87 shows rib 184 hermetically sealed to rib 187,
at 186 and 185 enclosing space 187.
[0567] Referring now to FIG. 101 a cross section through a tray
similar to tray 200 shown in FIG. 84 is detailed in a preferred
embodiment wherein a tray with a base 1100, and upwardly extending
walls 1102 terminating at flange 1103 is provided with rib 1102
formed therein. A separately formed rib 1101 is shown adjacent to
rib 1102 in a position prior to bonding and also after bonding to
tray wall along seal path 1105. A hermetically sealed and enclosed
space 1106 can be filled with high pressure such as CO.sub.2. In
FIG. 102, a cross section through ribs 1105 and 1102 is shown with
space 1106 enclosed therein.
[0568] Referring now to FIG. 103, a thermoformed tray, 12102 is
shown in a three dimensional view located above a form cut blank,
12100. Ribs are provided in the base 12104 and walls, 12108, 12107,
12106 and 12105 in a vertically disposed arrangement. Any suitable
rib configuration may be provided in the walls and base of any
suitable size tray, but most preferably rigid ribs such as 12103,
as shown in FIG. 103, are provided with the recess accessible from
the outer side of each wall, with the ridge extending inwardly.
Trays 12102 and blanks 12100 can be manufactured in any required
size, from any suitable material but most preferably would be
produced from mono-layer extruded polyethylene terephthalate (PET)
sheet. PET sheet may be extruded with multiple layers and both or a
single outer layer may be provided with enhanced heat or RF (radio
frequency (RF) or micro wave) sealable properties. Enhanced RF
sealability may be provided by including any suitable additive such
as suitable metallic elements or compounds in the outer layers, by
blending into the polymer prior to extrusion.
[0569] Hinges shown at 1204, 1208, 1209 and 1207 are arranged so
that flap portions 1200, 1201, 1202 and 1205 are all attached,
thereby, to central rectangular portion 1203. In this way flap
portions can be folded upwardly about hinges so as to contact the
walls of tray 12103. Flap and base portions of blank 12100 can then
be sealed to the walls of tray 12102 so as to provide a hermetic
seal around the perimeter of each rib after providing gas such as
CO.sub.2 at an elevated pressure in the recess of each rib. In this
way a rigid tray can be manufactured with substantially less
material content than would otherwise be required for a tray
manufactured from a single component.
Embodiment 20
[0570] Referring now to FIGS. 268-270, a preferred tray with flaps
is shown. Tray 7202 includes a crest 7200 constructed on the
perimeter of the tray opening on a wall of the tray 7202. A similar
crest is also constructed on opposite sidewall so as to form two
convex areas having a first radius. Referring now to FIG. 269, a
flap is shown with a flap base 7204 having a concave indentation
7204 of a second radius. When folded, as in a finished package,
flap base 7204 is substantially level with the tray base 7216.
Preferably, two such flap bases are provided, each in opposing
sides from the other. Referring now to FIG. 270, a plurality of
finished stacked packages using the trays of FIG. 268 is shown.
Preferably, the flap base concave indentation radius is smaller
than the radius of tray crest, so that when stacked, flap base of
upper tray 7212 makes contact with tray crest of lower tray 7214 at
two locations 7208 and 7210. In this manner, trays are prevented
from rocking back and forth if only one contact point is provided.
Preferably, a space is provided between upper tray 7212 and lower
tray 7214 which is also shown in FIG. 270. In this manner, the
underside of tray base 7216 is prevented from touching the sealed
or overwrapping web on lower tray. The sealed or overwrapped web
material substantially holds the fresh meat portions to the tray
base. Preferably, the web material is oxygen permeable. Finished
packages can thus be stored and packaged in any of the master
containers disclosed herein. The disclosed tray profile allows
stacking of several layers of trays in a vertical stack, wherein
each loaded and over wrapped tray is located directly above and in
contact with a lower tray to maximize density of a finished master
container. Preferably, the profile of the flaps is an upwardly
arched base that corresponds with the profile of the tray upper
flange profile. Preferably, ground meat is extruded with a profile
that corresponds to the inner profile of the cross section across
the length of the tray such that when loaded into the tray, the
upper surface of the extruded grinds portion is in firm contact
with the tray over wrap so that it holds it in place and slightly
below the upper edge of the flanges. The end flanges are arched to
match the arched base and end flap profile of the lower tray
profile. Continuous bonding of each flap around it's perimeter to
ensure that the end edge butts up and contacts the adjacent flaps
provides for maximum structural stability and minimum twist after
fabrication and bonding. Thus, the double walls (inner cavity and
outer flap) improve crush resistance.
Trays with Iron Powder
[0571] Powdered iron is often used as an agent for scavenging free,
residual oxygen gas in packaged perishable, foods; for example
Keplon Co., Ltd. of Kanagawa, Japan have manufactured deoxidizers
such as Keplon-TY for this purpose. As exemplary of the application
of the method to the present invention, reference will be made with
regard to FIG. 49, but it should be readily apparent that the
method herein described can be easily applied to any of the trays
made from the present invention. Powdered iron may be applied to
the inner surface of the outer cover 4140, in such a manner so as
to become activated by water that may be provided in the adhesive
layer 4136. Furthermore when the outside-surface of foam 4142 (see
detail in FIG. 49) is arranged to have a capacity to absorb
liquids, such liquids can be retained and substantially prevented
from escaping from within the finished package. Additionally, a
suitable adhesive can be provided between the tray flange rim 4144
and the outer cover 4140 where the continuous flange rim 4144 is in
contact with the outer cover.
[0572] Powdered iron can be used as an oxidizing agent and removal
of oxygen gas from within a hermetically sealed, gas barrier
package. Powdered iron may be applied, in combination with other
suitable sealing substances and agents, to the surface and most
preferably to an inner surface, of the outer cover 4140 at
locations that will become in direct contact with underside of the
base of tray. The iron powder can be applied to outer cover 4140 in
such a manner so as to allow subsequent activation by water that
may be contained in the adhesive layer 4136 when applied to the
under surface of the base of tray, at the time of over wrapping the
tray with perishable goods therein, and when cover 4140 contacts
the base of tray.
[0573] Prior to application to the inner surface of the outer cover
4140, the powdered iron particles may be coated with a suitable
coating including a suitable protecting substance or blend of
protecting substances, that can provide a protecting layer over the
complete outer surface of the iron powder particles thereby
protecting and isolating the iron powder particles from direct
contact with water or other substances that may cause the iron
powder to oxidize. The protecting layer can thereby remain in the
protecting condition until the coating is altered to allow water to
permeate therethrough or otherwise contact the iron particles. The
coating may be altered at, for example, a convenient time after
complete or partial assembly of the finished packages by exposing
to an electromagnetic field of such intensity or in such a manner
as to induce generation of heat in the particles of iron.
Generation of heat in the iron particles by, for example, exposure
to an electromagnetic field, may be induced by a suitable frequency
of alternating electric current. Generation of heat in this manner
may cause the protecting coating to release water or allow water
from adhesive layer to contact and thereby activate the powdered
iron to oxidize. Oxidation of iron powder in this way can result in
absorption of residual oxygen that may be present inside the master
package. Any suitable coating that possesses the required chemical
and physical properties may be used to coat the iron powder. In
this way the iron powder particles can be maintained in a protected
and "dormant" condition until required to absorb oxygen such as
after sealing of the package and when enclosed within a master
container.
[0574] In this way air and gasses can be removed from the finished
and sealed packages by evacuation and then replaced by gas flushing
with a desired gas, while liquids such as blood cannot readily
escape. Furthermore, gasses can readily flow through the
communicating passage from inside to outside of the package (but
still inside the master container) to enable rapid equilibration of
gasses when oxygen gas is released by reduction of oxymyoglobin
after sealing of the master container. Any residual oxygen that may
remain present in the sealed master container can be absorbed by
the oxidizing iron particles after activation with the
electromagnetic field, causing release of water or other suitable
substances and direct contact with the iron particles.
[0575] Referring now to FIGS. 137-139 three cross-sectional views
of selected sections of EPS trays with flaps are detailed. FIG. 137
shows a section of a tray with a flap attached at a hinge and where
the flap is "open" and not folded so as to be in contact with tray
3500. FIG. 138 shows a flap folded into a finished position and
contacting tray 3500. The flap may be formed with a recess 5506
that can be a arranged to be a continuous recess that follows a
path close to the perimeter of the flap. The tray can be arranged
to have a ridge 5508 that follows a path corresponding to the
recess 5506 such that when the flap is folded about the hinge so as
to intimately contact the tray wall and base, the ridge 5508 will
mate with the recess 5506, as shown in enlarged view of FIG. 139.
Accordingly, the flaps with heat activated adhesive applied in
recesses 5506 can be folded, as shown in FIG. 138, so as to cause
intimate contact with the tray base 5512 and/or walls 5514 thereby
providing a tray with folded flaps. The tray with folded flaps can
be held in such a folded condition so as to hold ridges 5508 firmly
against adhesive and in continuos contact with 5516 along the full
length of the ridge and recess. The tray with folded flaps can be
transferred automatically into and through a microwave oven source
of heat such that adhesive 5516 is activated by exposure to a
suitable level of microwave heat source and thereby bond the flap
and tray together at ridge 5508 and recess 5506. The bond can be
arranged along a continuous path and enclose the space between the
flaps and the tray so as to provide a substantially liquid tight
seal. Selective heating of adhesive 5516 can be provided by
microwave or magnetic field devices so as to cause bonding without
application of excessive heat that could otherwise cause
undesirable distortion to the EPS tray. Any suitable heat activated
adhesive may be provided by any suitable device. In another
preferred embodiment the heat activated adhesive may be provided in
the recess 5506 by computer controlled robots such as in the form
of a heated and softened continuous extruded bead that may be
subsequently heated so as to provide good bonding in the recess,
followed by cooling thereof to provide hardening of the heat
activated adhesive. Heat activated adhesives may be applied to the
tray with flaps or any other suitable packaging materials by any
suitable method prior to bonding. Subsequent exposure to microwave
or other suitable source of heating, that can be selectively
applied in such a manner so as not to cause undesirable damage or
distortion to the packaging materials, can produce a package
according to the present invention. A suitable device for adhesive
application to selected surfaces of packaging may be provided by
the known process of ink jet printing.
[0576] Any suitable substances for enhancing the keeping qualities
of goods can be provided into the spaces between the flaps and the
tray walls. Water, liquid and purge absorbing substances can be
provided in those spaces which may be arranged so as to be non
absorbing prior to exposure to and capable of absorbing liquids
only after exposure to microwaves or a magnetic field.
Apparatus for Applying Adhesives and Iron Powder to Trays
[0577] Trays constructed according to the present invention may
have one or more features which lends itself to be stackable or
allows the channeling of gases, while retaining liquids. Trays with
flaps are preferably constructed with adhesives to form the
finished tray. This description therefore provides a method and
apparatus for applying adhesives and other substances to the
trays.
[0578] Referring now to FIGS. 140-142, an apparatus constructed
according to the present invention that can be used to apply
substances to the surface of packaging materials, such as EPS
trays, for bonding thereto is shown.
[0579] In FIG. 140 a cross-sectional view through a
diagrammatically represented apparatus is shown where a
horizontally disposed motor driven conveyor 5400, can be
intermittently indexed by driving for a set distance or movement.
Magnets 5402 can be located in the conveyor 5400 in convenient
positions. A web of tray 5404 impressions can be arranged to mate
with the conveyor 5400 and can thereby be carried by the conveyor.
The distance traveled by the conveyor in each movement or index is
equal and can be arranged so as to carry a single tray impression a
distance equal to the machine direction length of each consecutive
tray impression. Such an arrangement can therefore position each
tray impression adjacent to a station or processing device for a
desired period of time followed by further movement of the tray
impression to a subsequent station to allow further processing.
FIG. 140 shows a first, second, and third station which are marked
5406, 5408 and 5410, respectively. Station 5406 is arranged to
apply an adhesive 5412 by a nozzle spray device 5412 to an exposed
surface of the tray impressions. Station 2 is arranged to dispense
iron powder 5410 or other suitable substance, from a conveniently
located hopper 5418 with valve 5420, directly above an exposed
surface of a tray impression that has had adhesive applied thereto.
Magnets 5402 which may be arranged as permanent or as electrically
induced (electromagnets) magnets, are conveniently located in the
conveyor such that when iron powder 5416 is dispensed from hopper
5418, it will be attracted toward the magnets 5402 and be deposited
in a pattern on the exposed surface of the tray impressions. The
pattern of iron powder deposits can be determined by the
profile/shape of the magnets 5402 which can be adjusted as required
to provide a suitable pattern. The powder 5416 may be then bonded
by adhesive to the tray impression 5424. Third station 5410 can be
arranged to apply drying or curing, such as a radiant heater 5422,
to the adhesive sprayed and tray impressions 5424 and thereby cause
setting and/or drying of the adhesive applied at the first station
5406 with iron powder 5416 thereto. The iron powder applied at
second station 5408 can thereby be suitably bonded to the tray
impression 5424. Additional stations may be arranged, adjacent to
the conveyor 5400 so as to apply additional layers of adhesive
and/or additional substances as may be required.
[0580] Referring now to FIG. 141, a cross-sectional view through a
section of a diagrammatically represented apparatus is detailed and
showing a profiled vacuum plate mating with a section of an EPS
tray that is located between a manifold 5426 and a vacuum plate
5428. Manifold and the vacuum plate can be attached to moving
devices such as pneumatic cylinders that can be operated as desired
to move the vacuum plate and the manifold toward and away from each
other in an automated cycling and repetitive sequence. The vacuum
plate and the manifold can be closed together so as to conveniently
clamp an EPS tray (or other material) therebetween for a period of
time. The EPS tray can be arranged with perforations 5430 therein.
The perforations can be located in a recess shown as 5432 in the
enlarged view in FIG. 141. The vacuum plate can be provided with
vacuum ports 5434 therein and located so as to provide connection
between the under surface of EPS tray and a suitable vacuum source
5436. In this fashion a vacuum source can be applied to the under
surface of the EPS tray with communication through the perforations
5430. The manifold can be provided and arranged with suitable
openings that connect selected exposed sections, such as sections
5440 and 5442, on the exposed surface of the tray to a source of
powdered substances "ADSP". In this way powdered substances, such
as heat activated adhesives, can be provided into the manifold
openings and by applying a vacuum source to the underside of the
tray, the powdered substances can be deposited onto the exposed
surfaces of the tray and/or in recesses such as recess 5432. After
the powder 5414 has been deposited into the recesses 5432 the
manifold and vacuum plate can be opened pneumatically allowing the
EPS tray to be removed therefrom and subsequently passed into and
through a suitable heat and/or suitable energy source, such as a
microwave oven. The powder 5414 can be arranged to contain
substances such as water or suitable metal elements, so that when
the tray with powder 5414, 5444 is exposed to a microwave, magnetic
field or other suitable source of heating energy, the powder will
be heat activated and bond together and to the surface of the tray
and in the recess 5432. The powder 5414, 5444 can thereby be
securely bonded to the EPS tray at selected locations on the
exposed surfaces of the EPS tray. This method of using a magnetic
field, microwave or other suitable source of heating energy can
selectively heat the powder 5414, 5444 without application of
excessive heat to the EPS tray. Powder application apparatus
including the vacuum plate and the manifold material clamping
devices with all required driving and controlling apparatus can be
integrated into a typical thermoforming equipment, such as an Irwin
Magnum or a Commodore 730-12 MM continuous thermoformer (as
manufactured by Commodore Machine Company of Bloomfield, N.Y. The
disclosed powder application with selective microwave heating of
the powder 5414, 5444 can be located between a thermoforming
station and a trim press of the thermoforming equipment. In this
way, a heat activated adhesive can be applied to specific locations
of any suitable material such as the flaps and/or tray walls of EPS
trays such as a tray with flaps described above.
Apparatus for Applying Adhesives and Iron Powder to Outer Cover
[0581] Referring now to FIG. 143 an embodiment of apparatus
constructed according to the present invention to apply adhesive
materials and powdered iron to a web of material such as stretch or
shrink wrapping materials is shown.
[0582] The description disclosed herein provides details of a
method and apparatus for producing stretch or shrink wrapping
material that can be used in the production of those packages
disclosed above, having an outer cover web material. The stretch or
shrink wrapping material with powdered iron attached thereto
absorbs any residual oxygen that may be present within the master
container and also the cell structure of EPS materials used in the
production of the finished package.
[0583] The apparatus shown in FIG. 143 includes a series of
rollers, a hopper containing powdered iron, a tray containing
solvent based adhesive, an oven and a continuous web of outer cover
material 4300 that is arranged to follow a path over rollers,
through oven and onto a web winder assembly as shown. The sketch
includes a cross-section through the apparatus.
[0584] A suitable tension is applied to web outer cover material
4300 which is arranged to follow a path over idler roller 4302 and
then to contact imprint roller 4304, over roller 4306, between oven
segments 4310 and onto a roll 4310 at a web winder assembly 4312.
Web 4300 is wound onto roll 4310 by web winder assembly 4312 at a
suitable tension and speed. In this manner, imprint roller 4304 is
arranged to apply a suitable adhesive, which may be solvent based,
onto web 4300 in a registered print pattern and in rectangular
areas 4314 as shown in FIG. 144 where a section of finished web
material 4316 is detailed in plan view, with a cross-sectional view
shown in FIG. 145, after processing through the apparatus shown in
FIG. 143. The method includes transferring the adhesive 4318 from
the tray 4320 via contact with roller 4322 which in turn transfers
the adhesive to transfer roller 4324 which in turn transfers the
adhesive onto the imprint roller 4304. Transfer of the adhesive
from the transfer roller 4324 to imprint roller 4304 occurs only at
selected areas on the roller 4304 that correspond with the
rectangular areas 4314 such that areas 4314 only are imprinted with
the adhesive applied thereto and leaving other sections of the
outer cover 4300 free of adhesive. The outer cover web material
4300 can be printed with information and graphics as required on
the opposite side of the web to the applied solvent based adhesive
in rectangular areas 4314 and in registered relationship to the
rectangular areas 4314, such that when the web 4300 is cut by
slitting along the length of the outer cover web, and wound
conveniently onto rolls, the web 4300 can be applied, in an earlier
described manner to cover the finished packages and with the
rectangular area 4314 adjacent to and in direct contact with the
base of trays.
[0585] Referring again to FIG. 143, powdered iron is dispensed from
the hopper evenly across the web, so as to fall directly downward
toward web 4300 above roller 4306. Roller 4306 includes a tube
manufactured, most preferably, from a nonmetallic material such as
fiberglass and is cylindrically ground on both internal and
external surfaces to provide a finished tube of specified internal
and external diameters. External diameter is arranged so as to have
a circumference equal to two (.times.3 across the web) consecutive
imprints (6 imprints in total) of rectangular areas 4314 per single
revolution of the roller 4306. Correspondingly, during a single,
full revolution of the roller 4306, 2 times 3 imprints (6) are
applied to the web 4300. Corresponding to the imprint areas 4314,
magnets 4305 are located and fixed to the internal surfaces of
roller 4306 in a pattern that corresponds with the rectangular
areas 4314 in positions such that when the powdered iron is
dispensed from the hopper it is drawn by the magnets so as to be
deposited substantially within the specified rectangular areas
4314. When the powdered iron contacts the areas 4314, on the web
4300, the powdered iron bonds to the solvent based adhesive applied
by imprint roller 4304. The powdered iron thereby becomes fixed to
the web 4300 by adhering to the solvent based adhesive. The web
4300 then passes between the oven segments 4308 that are arranged
to have sufficient capacity to cure and dry the solvent based
adhesive prior to further processing and/or winding of web 4300
onto the roll 4310 by web winder assembly 4312.
[0586] Web 4310 may be further processed by applying solvent based
adhesive onto rectangular areas 4314 after the powdered iron has
been applied and cured together therewith by passing through the
oven segments. This process may be repeated several times and as
may be required to produce the most effective finished outer cover
web 4304 materials.
[0587] In yet another preferred embodiment other web materials such
as perforated polyethylene and polyester may be laminated to web
4300 and over the powdered iron. Most preferably the powdered iron
will thereby be applied and retained between the outer cover 4300
and the polyethylene and/or polyester webs in such a manner so as
to allow oxygen to transmit through the outer webs and contact the
powdered iron and after reacting therewith, inhibiting the escape
of any odor that may be produced as a result of oxygen reacting
with the powdered iron, and/or other substances contained therein.
Solvent based adhesive can also allow transmission of oxygen
therethrough while inhibiting transmission of odors
therethrough.
[0588] Alternative oxygen absorbing materials that are suitable for
the application may be applied with the iron powder or in place
thereof.
[0589] The finished web material 4316 can be slit and wound onto
conveniently sized rolls for subsequent use as the outer cover of
packages similar to the finished packages described above.
Tray Sealing Apparatus
[0590] Webs suitable for use as trays and covers have thus far been
disclosed. A method for sealing a cover to a tray web now
follows.
[0591] Referring now to FIG. 146, a tray sealing apparatus is shown
to produce packages, including a tray, a web and perishable goods
contents shown as ground meat. The perishable goods may be portions
of beef, pork, or any other suitable perishable goods. A
horizontally disposed, continuous conveyor 2326 including a number
of carrier plates 2302 suitably attached to chains is arranged
adjacent and below a series of stations. The conveyor 2326 is
driven by a driver that intermittently indexes in a forward
direction indicated by arrow 2328, at a rate of one carrier plate
per index. Trays 2300, as described in any of the previous
embodiments, are dispensed into apertures in the carrier plates
2302 at a first station generally denoted by the number 2330. With
each progressive forward indexing movement of the conveyor,
stations will perform a function. Cutting devices at a second
station generally denoted by 2304 severs flaps. Product such as
portions of ground beef is loaded into the tray at a product
loading station 2306, and a web of material 2308 is heat sealed to
flanges at a heat sealer station 2312. Scrap material from web 2308
is wound onto scrap roll 2310. Preferably, tray apertures are
provided by heated pin devices at station 2314. Flaps are turned
over by rotating about hinge so as to then locate flanges adjacent
to tray 2300, at flap turning station 2316. Preferably flanges of
flaps are then sealed to flanges of tray at station 2318 and flange
trimming is performed as may be required at station 2320. Labeling
is done with a tray labeler at station 2322. The finished tray with
perishable goods packaged therein is ejected from the conveyor at
an ejector station 2324.
[0592] Referring now to FIG. 14, a preferred tray constructed
according to the present invention is shown in an inverted
position. The tray 2402 includes those apertures made by the
apparatus of FIG. 83.
Method and Apparatus for Evacuating Master Containers
[0593] Trays constructed according to the present invention
provided structures which allowed the evacuation of ambient
atmosphere and flushing with inert gases. Trays according to the
present invention are also stackable atop one another to allow
placement within a master container. Therefore, a method for
evacuating a master container appropriately follows.
[0594] Referring now to FIG. 148, details of a vacuum and modified
atmosphere packaging and sealing apparatus is shown. The apparatus
3564 can be used to hermetically seal a web of material over the
open end of a plastic bag or pouch. The web of material and pouch
may include substantially gas barrier materials and the
hermetically sealed pouch and web can be used for any useful
purpose, such as vacuum packaging meat primal portions or to
contain one or more retail packages, thereby providing a master
package which can be subsequently packaged inside a suitably sized
shipping carton.
[0595] The apparatus 3564 includes a lower vacuum chamber 3566,
that is suitably mounted with a driver (not shown) attached to a
shaft 3568, an upper vacuum chamber 3570 with a moveable heat bank
3572, attached to a driver (not shown) via shaft 3574 and suitably
mounted between the upper and lower vacuum chambers, and a web
unwinding assembly 3576 arranged to allow controlled unwinding of
web material 3578 from roll 3584. A conduit 3582 is connected to
upper vacuum chamber 3570 and a conduit 3584 is connected to lower
member 3566. Both conduits 3582 and 3584 can be connected to a
suitable source of vacuum and/or supply of suitable gas. The upper
vacuum chamber 3570 is fitted with a suitable rubberized sealing
member 3586 which is attached to the rim of the vacuum chamber 3570
and a corresponding and matching sealing member 3588 is mounted, in
similar fashion, to a rim of member 3566, so that when the upper
and lower vacuum chambers are closed and held together, members
3586 and 3588 are in intimate contact with each other, thereby
providing an enclosed vacuum chamber that is sealed from ambient
atmosphere with space 3590 contained therein. Web unwind assembly
3576 is arranged to unwind material 3578 from roll of material
3580, as required, and locate the web between the upper and lower
vacuum chambers. In this way suitable portions of the material 3578
can be automatically unwound by web unwind assembly and clamped
between sealing members 3586 and 3588. Referring now to FIG. 150,
it can be seen that rim at 3588 is extended beyond rim at 3592 such
that when web 3578 is clamped between members 3566 and 3570 a space
3594 between the web 3578 and the rim at 3592 is provided. Sealing
members 3588 and 3586 are parallel and follow adjacent paths at
parallel perimeters of the respective members 3570 and 3570 along
corresponding rims at 3586 and 3588, such that when the vacuum
chambers 3570 and 3566 are closed together a completely sealed and
defined space 3590 is provided therein. In this way space 3590 can
be evacuated and substantially all air contained therein removed,
as required, and then space 3590 can be filled with suitable gas
such as nitrogen, CO.sub.2 or any other suitable blend of gases, at
a suitable pressure, via conduits 3582 and 3584.
[0596] Referring now to FIG. 149, a three dimensional sketch is
shown of the lower vacuum chamber with a portion of the lower
vacuum chamber shown in FIG. 150. The vacuum chamber can be
manufactured from any suitable material such as stainless steel. It
can be seen that vacuum chamber 3566 includes a rectangular
profiled component with vertical walls and a rectangular depression
3596 provided therein; two parallel and continuous rims, an inner
rim 3592 and an outer rim 3598 are provided with a recess 3600
between the parallel rims. A suitably sized pouch 3602 can be
located into the depression 3596 and the "mouth" 3604 of the pouch
can be cuffed over the rim 3592 such that the mouth of the pouch is
tensioned around and over the external and upper surface of rim
3592. A vacuum source can be provided to recess 3596, via conduit
3584, such that the pouch can be drawn against the internal walls
of the depression 3596, prior to closing the upper and lower vacuum
chambers together. In this way the mouth portion of the suitable
pouch 3602 can be tensioned across the rim 3592 in such a manner so
as to ensure that no creases are present in the pouch mouth section
that is located directly adjacent (and above) the rim 3592. Any
suitable stretching devices may be provided that will stretch the
mouth section of the pouch and ensure that no creases are present,
thereby allowing subsequent and effective sealing of the web 3578
to the pouch when required. Following loading of goods into the
pouch 3602, heat bank member 3572 can be activated so as to provide
heating and sealing of a section of web 3578 to the mouth of the
pouch around the full continuous length of rim 3592. An automatic
cutting device 3606, can be arranged so as to provide suitable
cutting and severing of the web 3578 after sealing to the pouch. In
this way web 3578 can be hermetically sealed to the mouth section
of the pouch 3602 so as to completely seal and enclose any space
and goods that may be located in the pouch prior to sealing of web
3578 thereto.
[0597] Any suitable method of manufacturing a suitable pouch with
adequate gas barrier properties may be employed to manufacture the
pouches. For example the pouch may include a suitably sized,
multi-layer plastics tube, extruded from an annular die with
specified layers of material that provide all gas barrier and
sealing properties and features required. Such a tube may be
extruded and cut into suitable lengths and then heat sealed to
close one end of each length of tube, in any suitable fashion, to
produce pouches and, if required, a valve may be fitted to the wall
of the pouches. The valve can be arranged to allow excess gas such
as carbon dioxide, that may be generated in the pouches after
sealing with goods, such as carbonized retail packaged ground meat,
therein.
[0598] Referring again to FIG. 149, a grouping of several identical
such members 3564 may be arranged by attaching to the upper surface
of a suitable conveying device such as a horizontally disposed
carousel style, circular table, of suitable size arranged with
suitable driver to intermittently rotate the carousel. In this way,
pouches could be automatically loaded into each lower vacuum
chamber 3566, consecutively and immediately prior to loading goods
into the pouch. After loading the goods, the carousel can rotate so
as to locate the loaded member 3566 directly under upper vacuum
chamber 3570 and web unwind assembly so as to allow sealing of a
section of web 3578 thereto. In this way, an automatic and
semi-continuous packaging process can be arranged to automatically
open the pouches, load into member 3566, fill the pouch with goods,
evacuate and gas fill the pouch with goods therein and then heat
seal a web of material 3578 over and to the mouth of the pouch. An
automatic ejection device can be provided that may include a method
of relaxing tension in the pouch mouth and lifting the sealed and
finished pouch (with goods therein) from member 3566 and then
locating the finished pouch into a carton prior to closing the
carton closed and sealing the finished pouch therein.
[0599] Referring to FIG. 213, yet another preferred embodiment f an
apparatus 7200 for producing a master container with finished
packages is shown. Equipment 7200 includes an upper chamber 7206
and a lower chamber 7210. A master container 7216 with finished
packages 7208 is contained within lower chamber 7210. The operation
of this apparatus is in many respects similar to the previous
embodiments. Master container 7216 is loaded with finished packages
7208, and located in the lower vacuum chamber. A web 7214 is passed
through the chamber to cover the opening in the master container
7216. The upper 7206 and lower 7210 chambers close, providing a
substantially air tight seal. Air is evacuated through any number
of ports 7204 and 7212. a suitable gas is flushed into the
chambers. The cycle can be repeated any number of times to expel
the air and/or oxygen from the master container 7216 and packages
7208. The master container is then sealed with web 7214. The vacuum
chambers separate, and a new master container is evacuated, flushed
and sealed.
[0600] In yet another preferred embodiment, the packages need not
have apertures, but rather are sealed or wrapped with a web that
expands to fill the voids in the master container to expel the air.
This is possible because the web preferably has memory, to contract
to its relaxed state. The packages need not be evacuated because
packages can be wrapped in a low oxygen atmosphere according to the
invention, thus eliminating the need for values.
Method and Apparatus for Packaging, Labeling and Weighing
[0601] Trays containing perishable goods are preferably weighed and
labeling prior to sealing. Therefore, it is appropriate to describe
a method and apparatus of the invention for such a task.
[0602] FIG. 151 shows a packaging machine constructed according to
the present invention to apply label(s) to the second web and also
an alternative printing device to print directly onto the second
web. Reference is also made to patent application PCT/AU93/00484,
which is herein incorporated by reference. FIG. 151 shows a side
elevation of the packaging apparatus and FIG. 152 shows a plan view
of the upper side of the packaging machine of FIG. 151. Packaging
machine 1800 is arranged in two sections to provide a space so as
to allow a sufficiently clear area to install a scale 1802 with
load cells 1828. Packaging machine 1800 is mounted and attached to
the floor (also shown) independently of scale 1802 such that they
are not in contact with each other. Second web unwind roll 1806 is
provided with braking devices attached thereto. Drive 1804 is
arranged to unwind second web from roll 1806 of second web 1812.
Printer 1808 is located between second web roll 1806 and third web
roll. Printer 1808 is attached to driver to move in X, Y and Z axis
in horizontal and vertical planes. Printer 1808 includes a
mechanism to print onto labels and then apply labels to second web
or alternatively print directly onto second web. Third web roll
1810 is located above second web 1812 and is fitted with braking
devices as well to maintain tautness of the web as it is unrolled.
Packaging apparatus 1800 includes a vacuum chamber assembly. The
assembly includes a number of components including a lower 1816 and
upper 1824 vacuum chamber, a lower 1820 and upper 1822 plate and a
sealing plate 1818.
[0603] FIG. 154 shows a cross-section through the vacuum assembly
constructed according to the present invention. Sealing plates 1818
are arranged in a conveyor which is driven by a motor as required
providing intermittent movements of the conveyor 1826. Lower vacuum
chamber 1816 is independently moved by pneumatic driver (not shown)
so as to apply pressure to underside of sealing plate 1818. Plate
1820 is located between sealing plate 1810 and plate 1822. Plate
1822 has vacuum port 1830 provided therein. Upper vacuum chamber
1824 is located above plate 1822. All components are in vertical
alignment and when lower chamber 1816 and upper chamber 1824 are
retracted and moved in the vertical plane away from each other,
plates 1818, 1820 and 1822 which can be spring loaded also "expand"
away from each other so as to allow free movement of first 1836 and
second 1832 webs between plate 1820 and plate 1827 or between plate
1818 and plate 1820 as may be selected according to requirements or
preferred operation of apparatus. As is shown in FIG. 154, third
web 1834 enters the vacuum chamber assembly between plates 1822 and
1824 and exits the vacuum chamber assembly between plates 1820 and
1822. Also it can be seen that second web 1832 enters vacuum
chamber assembly between plates 1820 and 1822. A space 1838 is
shown between the second 1832 and third 1834 webs with port 1830
opening into space 1838. During the operation of the packaging
apparatus, after closing of lower vacuum chamber 1816 and upper
vacuum chamber toward each other thereby providing a closed and
sealed vacuum chamber, a vacuum source can be applied to port 1830
and thereby evacuate substantially all air from the space 1838.
Evacuation of air from space 1838 can cause second 1832 and third
1834 webs to become laminated together after removing substantially
all air from the space 1838. Slots shown as 1840 are provided
between the faces of plates 1816 and 1818, 1818 and 1820, 1820 and
1822, and 1822 and 1824. These slots provide spaces between each of
the components also, "O" rings are fitted along the outer edges of
each slot to provide a seal when the components are in contact with
each adjacent component. A vacuum source can be applied to each of
these spaces, simultaneously, thereby providing a method to hold
them together with a force equal to that provided by the ambient
atmospheric air pressure prevailing at the time. The holding force
that urges the components together is therefore approximately equal
to the width of the slots between each component, times the length
of the slot, multiplied the difference of the prevailing
atmospheric air pressure minus the air pressure within the slots
defined by the equation: F=WL(P.sub.a-P.sub.s)wherein,
[0604] F is the force,
[0605] W is the width of the slot,
[0606] L is the length of the slot,
[0607] P.sub.a is the atmospheric pressure, and
[0608] P.sub.s is the pressure inside the slot.
[0609] The width of each slot can be arranged, by enlarging (or
decreasing) so as to provide a level of force that exceeds the
desired and opposing force of gas pressure within the closed
chamber. A pair of "O" rings are also provided around all shafts
that penetrate the chamber and spaces provided between each pair of
"O" rings can also be evacuated.
[0610] Referring again to FIG. 151, printer 1808 is equipped so as
to either apply a label or print desired information onto second
web 1812. Load cells 1828 are located along a beam 1854 that
extends across and under the full width of sealing plates 1818.
Beam 1854 can be elevated and lowered. Scale 1802 and beam 1854 is
arranged to elevate load cells 1828 upwardly so as to contact
underside of trays in apertures of sealing plates 1818 and lift the
trays from apertures in sealing plates 1818 in conveyor. Trays are
lifted to an extent that prevents any contact with anything else
apart from the load cells 1828. The weight of each separate tray
can thereby be determined and this information is transferred to a
printer 1808. Printer 1808 prints information onto labels (prior to
application of label onto second web) or directly onto the second
web 1812. Second 1812 and third web 1856 are then laminated
together before heat sealing to flanges of first web trays.
[0611] FIG. 153 shows one embodiment of a single register detail of
second web. The single register detail includes a frame 1842 of
heat activated adhesive that can be printed directly onto web. The
frame is arranged with dimensions that correspond to the flange of
third web tray such that the frame 1842 covers flanges and located
above third web tray. Other details of package contents are also
shown and boxes 1846 provide areas onto which information can be
printed at the time of packaging. Barcode 1847 contains product
information, such as date of packaging and weight, which can later
be used to determine price at the point of sale.
[0612] FIG. 155 shows a cross-section view through a laminating
assembly including a first 1848 and second 1850 driven rubber
coated roller arranged in horizontal disposition and with devices
(not shown) to be urged toward each other so as to press and
laminate the second 1832 and third 1834 webs when the webs are
passed between the rollers. Rollers are driven by a variable speed
motor (not shown). Laminating assembly can be located between the
third web roll 1810 and the vacuum chamber assembly and provide a
method to laminate second 1832 and third 1834 webs together before
entering the vacuum chamber assembly.
Method and Apparatus for Packaging Trays
[0613] Trays with flaps constructed according to the present
invention can be sealed by a first and second web. Webs are sealed
to the flap in the non-folded state in two or one heat sealing
stations. Upon bending of the flaps, the webs are stretched, thus,
providing a taut appearance and protection for the perishable goods
inside.
[0614] The following description provides apparatus and methods for
production of a package of the type shown in FIG. 158, with a
pre-stretched second web 1004. The preferred use of this embodiment
is for the packaging of shallow products such as boneless pork loin
chops, butterfly steaks, thick-cut bone in pork chops and New York
Strip, super trim beef and pork cuts that are generally not
displayed in the package by shingling but are laid flat and
adjacent to each other and spaced apart so that a consumer can
inspect carefully.
[0615] FIG. 168 shows a sketch of a side elevation of a preferred
packaging machine constructed according to the present invention
that can be used to produce packages of types described herein in
this disclosure. The packaging machine includes a frame supporting
a driven conveyor with two roller chains located one on each side
the packaging machine and engaged with a first 1044 and second 1128
set of sprockets, each pair of the sprockets is located at opposite
ends of the frame. Sealing plates, 1012, as shown in FIGS. 159-162
are attached to the roller chains via attachment points. First and
second stations, generally denoted by 1014 and 1016, respectively,
are located on the upper side of the packaging machine with web
unwind arrangements rolls 1130 and 1132 and scrap web wind-up
arrangements at 1120 and 1138. Continuous conveyor 1010 carries
sealing plates 1012 in the direction indicated by arrow 1126.
Details of a preferred sealing plate 1012 can be seen in FIGS.
159-162. Preferably, first and second stations 1014 and station
1016 are mounted onto the upper side of the packaging machine frame
adjacent to the upper section of the conveyor 1010. A loading
section 1018 is preferably located adjacent to and down stream of
station 1014. Conveyor 1010 is supported within the frame and is
attached to a powered indexing device for moving the conveyor 1010
and sealing plates 1012, intermittently and in a direction from
loading section 1018 toward first station 1014. Preferably, each
intermittent movement of conveyor 1010 travels one pitch which is
equal to at least the distance required to move a sealing plate
1012 the full distance of the length of the sealing plate.
Preferably, with each movement of the conveyor, a sealing plate is
located directly between the lower vacuum chamber 1020 and the
lower clamp plate 1022 shown in FIG. 167. Preferably, a sealing
plate is also located directly beneath heat bank 1024, as shown in
FIG. 156. Preferably, this arrangement transfers a package that has
been sealed in first station 1014, to a subsequent location at
second station 1016. Preferably, the driving devices for the
packaging machine, machine components and conveyor are a pneumatic
cylinder and electrically powered driving motors of suitable size
and capacity. The pneumatic cylinders are attached to shafts 1030
(attached to heat bank 1024), 1032 and 1028 (attached to
water-coded clamp 1036) and, 1034 and 1026 (attached to cutting
device 1038), and provide independent reciprocating movements to
each shaft and attachments generally in the directions shown in the
diagrams by arrows drawn adjacent to each attachment. Similarly,
pneumatic cylinders (not shown) are attached to upper 1056 and
lower 1020 chambers to provide reciprocating movements parallel
with shafts 1030, 1028, 1032, 1026, and 1034 to provide movement
and apply pressure as required. Preferably, an electrically powered
drive motor 1042 is attached to conveyor sprocket 1044 so as to
intermittently drive the conveyor 1010 as required such that the
upper section 1046 of the conveyor travels in a direction from
right to left.
First Heat Sealing and Vacuum Chamber
[0616] FIG. 167 shows a cross-sectional view through a first
station vacuum chamber assembly 1014 constructed according to the
present invention which details the first 1002, second 1004 and
third 1006 webs prior to sealing the webs together. This vacuum
chamber has a plate, separating to second and third webs, unlike
the chamber of FIG. 154. Meat is loaded into tray (first web 1002)
and then each loaded tray is placed into apertures in sealing plate
1050. The conveyor indexes forward such that a loaded tray is
located at first station 1014. During indexing, third web 1006 and
second web 1004 are also indexed forward and a longitudinally
disposed tension can be applied to third and second webs and in a
direction parallel with the conveyor. Preferably, lateral
stretching can also be applied to second web 1004 such that it is
stretched taut. Upper clamp member 1052 and lower clamp member 1022
then close against the middle clamping plate 1054 thereby clamping
and firmly holding third and second webs 1006 and 1004,
respectively. Preferably, lower vacuum chamber 1020 and upper
vacuum chamber 1056 are closed against the clamping plate assembly
such that a substantially "airtight" seal is provided and the
upward movement of lower vacuum chamber 1020 lifts sealing plate
1050 and holds it firmly against the underside of the lower clamp
1022 thereby providing substantially "airtight" seals around the
perimeter of the upper and lower vacuum chambers 1056 and 1020.
Closing the upper and lower chambers thereby defines a single
enclosed chamber that is substantially isolated from atmospheric
gasses. During the procedure of closing the upper and lower
chambers, the lower vacuum chamber 1020 lifts the sealing plate
1050 upwardly and tray (first web 1002) is carried upward. The
upper rim portion of sealing plate 1050 and 1058 contacts the
underside of second web 1004 stretching second web upwardly until
sealing plate 1050 contacts the underside of lower clamp 1022 at
surface thereby stopping the upward movement in a closed and
substantially "airtight" condition. Preferably, the second web 1004
is now stretched taut across the opening of the ring 1058 and
distanced preferably about 1/64'' to about 1/2, and most preferably
about 1/8'' above flange 1072 (FIG. 158) and preferably about
1/64'' to about 1/2, and most preferably about 1/8'' below third
web 1006.
[0617] Preferably, atmospheric air contained within the enclosed
chamber is then substantially evacuated through evacuation ports
1008, to a pressure of less than 5 torr. Preferably, immediately
after evacuation, the chamber can be filled with carbon dioxide
gas, or a blend of carbon dioxide and nitrogen gasses, to a
pressure of up to 2 bar (28 psi) or more, by injection through
ports 1064 and optionally 1008, and held at pressure for a period
of 1 to 5 seconds or more and most preferably until water and goods
in the tray have become substantially saturated with dissolved
carbon dioxide. The gas pressure within the chamber assembly can
then be lowered to a pressure equal to that of the prevailing
ambient atmospheric pressure prior to sealing. Evacuation and
gassing of the chamber assembly in accordance with the invention,
provides a method of filling packages with a chosen gas such that
the residual atmospheric oxygen that remains within the package
does not exceed an amount about 0.05% by volume of the gas that
remains within the package after sealing the first 1002, second
1004, and third 1006 webs together.
[0618] Referring now to FIG. 158, a clamping member 1036, that is
preferably water cooled, can now be moved and positioned so as to
clamp third web 1006 against second web 1004 and in turn against
the inner edge portion of flange 1072 on first web tray 1002.
Preferably, heat bank 1024 can then clamp and heat seal second and
third webs 1004 and 1006 to flange of first web 1002, under
pressure. Preferably, heat bank 1024 can now be retracted followed
by cutting of second and third webs with cutting member 1040
attached to cutting device 1038. The cutting member is withdrawn
from the cutting position followed by release of clamp 1036.
Preferably, enclosed vacuum chamber assembly can then be opened
allowing conveyor to move forward a single pitch followed by
closing the enclosed chamber assembly, followed by evacuation,
gassing and heat sealing. Preferably, this cycle can be repeated in
an automatic and continuous mode. Vacuum chamber assembly
constructed according to the present invention and frame to which
it is attached is built in a manner that will allow continued
cycling of the packaging process and pressurization without
sustaining excessive damage other than normal wear and tear.
[0619] An optional method of using the apparatus whereby a gas is
not provided in the space between third web 1006, the upper barrier
web, and second web 1004 (so as to subsequently facilitate urging
of the second 1004 and third 1006 webs together), before sealing
the third web 1006, second web 1004 and first web 1002 (shown as
tray) together at a path near what will be a perimeter of the
package. The tray 1002 is elevated so as to urge second web 1004
toward the underside of third web 1006 thereby providing stretching
means to second web 1004 to sealing webs together to form a
package. Apparatus for evacuation of substantially all air from the
space between the third 1004 and the second 1004 webs, through
ports 1008 is optionally provided.
[0620] Preferably, packages are then transferred from the vacuum
chamber at first station 1014 via the conveyor to the secondary
sealing apparatus located at second station 1016.
Second Heat Sealing Chamber
[0621] Referring now to FIG. 156, a cross-sectional view of second
station 1016, constructed according to the present invention is
shown in a partially closed position.
[0622] Referring to FIGS. 157-158 a cross-sectional view through a
finished and sealed package constructed by second station 1016 is
shown. Package 1092 includes a flange with second web 1004 and
third web 1006 attached thereto. Shown is first web, tray 1002,
formed with two flange portions 1072 and 1074. Preferably, flange
portions 1072 and 1074 are adjacent and concentric to each other,
with flange 1074 located on the inner side of flange 1072.
[0623] Referring now to FIG. 156, an assembled package is
positioned in the sealing plate which is located beneath heat bank
1070. It can be seen that lip 1080 has a profile that corresponds
and follows the path and plan profile of flange portion 1074. A
section of flange 1074 can be clearly seen in the enlarged
cross-section in FIG. 157. Preferably, flange portion 1074 is
parallel and concentric to flange portion 1072 but follows a path
on the inner side of flange portion 1072 and at a plane shown to be
at a distance 1076, about 1/8'', below flange portion 1072.
Preferably, heat bank 1070 is pneumatically operated and can extend
downwardly and be retracted upwardly as required to exert a force
such as to provide pressure onto the lip 1080 and when engaged with
flange portion 1074, simultaneously depressing third and second
webs that are then held, under pressure (sealing pressure), between
the surface of flange portion 1074 and lip 1080 for a set period of
time (set time). Preferably, the temperature of heat bank 1070, and
correspondingly lip 1080, can be controlled and is set at a
suitable temperature (set temperature). Preferably, the temperature
of heat bank 1070 is less than temperature of heat bank 1024
located in first station 1014. Preferably, pressure is applied at
lip 1080 and can be set at sealing pressure. The suitable time of
contact and clamping of third and second webs to flange portion
1074 can be varied. Time of contact is defined as the length of
time during each cycle from the first instant of first contacting
between lip 1080 and flange portion 1074 through the third and
second webs, to the first instant of no contacting after retraction
of heat bank 1070. Thereby, when the set temperature, sealing
pressure and set time of heat bank 1070 are adjusted as required,
the selective heat sealing of second web to flange portion 1074 can
be achieved while third web does not heat seal to second web. This
can preferably be achieved when first, second and third webs
include materials as shown in FIGS. 43 and 44.
[0624] Referring now to FIGS. 43 and 44 a representation of an
enlarged view of a section through a flange portion of an assembled
package is shown. FIG. 43 shows heat sealing bars and a section of
a rubber seal mounted on sealing plates around the perimeter of the
apertures in the sealing plates. Details of materials that can be
used in the first, second and third webs are also shown and
described in detail below: Preferably, third web 1006 is a
co-extruded web including at least two layers with a first layer
1082 of Eastman PET 9921 and a second layer 1084 of material on the
underside of the third web including a blend of 2 grades of Eastman
polyesters in amounts of about 50% Eastobond 6763 and about 50%
Eastobond 9921 or alternatively the layer on the underside may be
about 100% Eastman PM 15086. Preferably, third web can be about
0.006'' thick, about equally divided between first and second
layer. Preferably, second web 1004 is a web of pPVC with a
thickness of about 0.0008''. Preferably, first web 1002 includes a
thermoformed tray produced from a multilayer co-extruded web with
an outer layer 1088 of Eastman 9921 and an inner layer 1086
including a blend of about 50% Eastman PETG 6763 and about 50%
Eastman 5116 (or Eastman PM14458 or equivalent). Preferably, first
web has a thickness of about 0.012'' where the inner layer 1086 is
about 0.004'' thick and the outer layer 1088 is about 0.008''
thick. Preferably, under such conditions the heat transferred
through third web is insufficient to cause bonding between the
third and second webs but sufficient to cause bonding between the
second and first webs at flange portion 1074. Preferably, such
arrangement provides stretching of second web, after sealing of
third and second webs to first web at first station 1014.
Preferably, applying gas pressure to the upper surface of the third
web, when located at second station 1016, so as to cause the second
and third webs to depress downwardly and substantially conform to
the contours of flange portion 1074 prior to providing heat seal
1090 provides an alternative step in the method.
[0625] Preferably, second web 1004, will have a feature known as a
"memory". The term "memory", in this context, is known in the
packaging industry and is characterized as a material that will
substantially return to its original shape after distortion has
occurred due to, for example, a consumer "feeling" the goods
contained within the package while the package remains intact, with
second web sealed to the tray flanges. This can cause finger marks
and depressions in the second web as prospective purchasers of the
package examine it prior to purchase during retail display of the
package. After excessive handling by consumers the package can
become unattractive to an intending purchaser and financial losses
can result therefrom. Materials such as polyethylene substantially
do not have "memory". However, plasticized PVC (pPVC) web
materials, such as are made by Borden do provide this important
feature. Second web constructed from pPVC may be perforated by
perforating apparatus to improve gas transmission therethrough.
[0626] Preferably, perforations can be provided in second web 1004.
The perforations can allow gas to permeate into a space between
second web and third web. Preferably, when the gas pressure inside
the sealed package is at a pressure slightly above ambient air
pressure, third web will be stretched outwardly into a dome shaped
condition thereby providing a gas buffer between third web and the
surface of goods beneath the second web. Second web may be in
contact with the surface of package goods, alternatively a space
can be provided therebetween. Preferably, the seal between second
web and first web may be arranged such that it is not a continuous
seal along the full path of flange portion 1074 and may be arranged
as an intermittent sealing, completely along one or more sides only
or parts thereof.
[0627] In yet another embodiment heat bank 1070 may be mounted at
first station 1014, concentrically with and on the inside of heat
bank 1024 within the same chamber but with separate moving shafts.
Such an embodiment would allow sealing at flange portion 1072 and
flange portion 1074 without the need to transfer the package from
first station 1014 to second station 1016 for sealing of flange
portion 1074. Preferably, web cutting devices are located at second
station 1016 to separate the sealed and finished package 1092 from
webs.
[0628] After passing through stations 1014 and 1016 on packaging
machine, the finished packages are ejected from the machine.
[0629] In yet a further embodiment, the tray evacuation arrangement
can be set up to transfer trays containing goods to a vacuum
chamber, evacuate any ambient atmosphere from the trays and then
transfer the trays into an enclosure excluding air. However, the
trays have not been sealed with a lid at the vacuum chamber.
Sealing Plates
[0630] Sealing plates constructed according to the present
invention are members attached to conveyors to carry trays in the
packaging system.
[0631] FIGS. 163-166 show the use of sealing plates with trays of
the present invention. Package 1224 contains goods 1214 shown in
FIG. 163. In FIG. 163, the first web 1200, second web 1202, and the
third web 1204 are shown sealed together to form a complete package
1224. FIG. 164 shows a cross-section through the tray (the first
web). Dotted lines are shown in FIGS. 164-166. The dotted lines in
FIGS. 164-166 show the position of the side walls before insertion
of the tray into the aperture 1206 in the sealing plate member
1208. Dotted lines in FIG. 166 show the relative position of the
edge of the flange prior to the tray insertion into the aperture.
The aperture is sized to suit and is slightly smaller than the
tray. The aperture is located in member 1208 which includes a plate
means with the aperture therein with the aperture having dimensions
slightly smaller than the external dimensions of the side walls of
the third web tray such that when the tray is inserted into the
aperture, the side walls are distorted and urged inwardly. The
solid lines show the side walls after the inward distortion and the
dotted lines show the relative position of the tray prior to
insertion into the aperture. FIG. 164 shows a plan view of a
section of a conveyor such as may be installed in a packaging
machine. Sealing plate 1208 may have a plurality of apertures, all
of a suitable size and arranged to hold a plurality of the trays in
like distorted condition as herein described.
[0632] Referring to FIGS. 159-162, a cross-section of a preferred
sealing plate 1050 constructed according to the present invention
is shown with a plan view shown in FIG. 160. Sealing plate includes
attachment points 1094. Preferably, attachment points 1094 attach
the sealing plates to a pair of continuous roller chains that
engage with sprockets 1044 and 1128 and are located, one at each
relative side of conveyor. Preferably, sealing plate 1050 has a
depth dimension that is about equal to or deeper than the depth of
depressions in first web. Preferably, a rubber seal 1100 is
attached to the sealing plate 1050 by an adhesive and is profiled
to provide flanges 1096 and 1098 that correspond to flange portion
1072 and flange portion 1074 of first web tray. Preferably, a space
between the rubber seal 1100 and rim 1078 is provided to allow
clearance for cutting member 1040 during the cutting of the third
and second webs after sealing to flange portions 1072 and 1074.
[0633] Referring now to FIG. 162, a cross-sectional view of the
details of sealing plate 1050 are provided. As an example, a
preferred embodiment with three apertures 1150 and rubber seals
1100 located around the perimeter of each aperture is shown.
However, sealing plates may have more or less apertures and
corresponding rubber seals. Preferably, rubber seals are made
optional. Preferably, sealing plates are machined from aluminum or
other metals or any suitable plastic plate, for example, about
0.75'' thick polypropylene with upper 1152 and lower 1154
faces.
[0634] Referring again to FIG. 164, wherein the arrangement of
first web 1200 (tray) with a flange 1210 extending continuously
around the perimeter of tray 1200 to provide a flat ledge to which
second web 1202 is sealed. Preferably, tray 1200 has been distorted
such that side walls are urged inwardly and held in position by the
limiting size of aperture 1206 located in sealing plate 1208 of
FIG. 165. Preferably, second web 1202 is a gas permeable material
such as pPVC of about 0.0008 inches thickness and first web 1200 is
constructed of a substantially gas impermeable material such as a
co-extruded multilayer sheet of Eastobond APET 9921 and a blend of
about 16% Eastobond PETG 6763 and about 84% Eastobond 9921. A third
web 1204 is sealed to second web 1202 adjacent to seal 1212 of the
second web to the first web.
[0635] Alternatively, the tray 1200 can be formed from a web of
polystyrene foam that has been previously laminated to a web of gas
barrier material. A second web of material can be sealed to the web
of gas impermeable material laminated to the upper side (inside) of
foam tray. Trays according to the present invention are
substantially impermeable to gases.
[0636] Referring to FIG. 163, webs are shown sealed together by a
strip-like seal 1212 on flange 1210 that follows a path that
continues around the flange near the perimeter of the package
thereby providing a substantially hermetically sealed package.
Preferably, goods 1214 are contained within the sealed package and
a suitable gas blend such as may include about 40% carbon dioxide
and about 60% nitrogen is provided within the package. Preferably,
sealing of the package is effected while side walls of the tray are
urged inwardly. Preferably, side walls thereby retain a tension and
desire to return to their original relative position thereby
exerting a substantially outwardly disposed urging around the
perimeter of the depression in the tray but which is retained and
held captive by the combined tensile strength of third and second
webs sealed to the flange. Preferably, third web is sealed to the
package in such a manner as to allow peeling from the package,
without rupturing second web and thereby leaving second web
attached to the flange. Preferably, when third web is peeled from
the package the tensile strength of the second web is insufficient
to restrain outwardly urging of the side walls, thereby releasing
urging and providing a means to stretch the second web into a
substantially flat condition. The extent of the urging can be
controlled such that it will maintain a tension in second web.
[0637] FIG. 163 shows a finished package that has been produced by
the method herein described and, after heat sealing of first 1200
and second 1202 webs together, has been removed from aperture 1206
in sealing plate 1208.
Method and Apparatus for Producing Laminated Webs
[0638] Having discussed the advantage obtained by packaging trays
having second and third webs, another embodiment of producing
bilayer coverings is herein described. Referring to FIG. 169, an
apparatus for producing a pre-stretched second web of flexible gas
permeable material laminated to a substantially more rigid gas
barrier material is schematically illustrated.
[0639] First 1400 and second 1402 roll of web material including a
second web 1404 and a third web 1406 are preferably unwound
simultaneously and laminated by passing the webs through a pair of
"nip" rollers 1408 that apply pressure against each other and to
the webs as they pass through nip rollers 1408. Preferably, nip
rollers 1408 are driven by any suitably powered driver to rotate at
a suitable speed. Preferably, the laminated web 1412 is rewound
onto a single roll 1410 together to produce a laminated web 1412.
Third web 1406 may include a semi rigid polyester material, of
about 0.005'' to about 0.007'' thick. The construction of this
material is such that it can be used in a packaging machine to
produce packages as described herein whereby laminated webs are
sealed to a first web of gas barrier material (tray). First web may
have a depression formed therein into which goods such as red meat
can be placed before heat sealing the third and second webs to the
first web. Goods will typically not completely fill the depression
and space will remain in the depression in addition to the goods. A
blend of gases or a single gas such as CO.sub.2 can be provided in
the space with goods and thereby can contact the goods. The gas
substantially eliminates the presence of oxygen and any red color
present in the red meat may be transformed to a purple color. This
is caused in part by the reduction of oxymyoglobin to
deoxymyoglobin. After storage of perhaps a period of 14-28 days
from packaging but prior to retail display at an intended point of
sale to consumers, the third web can be peeled from the package
allowing atmospheric oxygen to permeate the second web of gas
permeable material and to contact the goods. Atmospheric oxygen can
then generate a bright red colored substance such as oxymyoglobin.
Such use involves the sealing of the laminated webs to the first
web of gas barrier material such as a two-layer co-extrusion where
the outer layer includes Eastman APET 9921 of about 0.0035''
thickness, and the inner layer may is a blend of Eastman polyester
materials including about 16% of 6763 and about 84% of 9921. The
thickness of blended layer 1412 can be about 0.0015''. Second web
1404 includes a roll of monolayer pPVC with a thickness of about
0.0008'' to about 0.0012''. Preferably, as second web 1404 is
unwound it can be passed through a perforator 1414 that perforates
the second web by creating small apertures therethrough.
Preferably, second web 1404 can be tensioned in a controlled manner
by retarding the rate of unwinding of second web 1404 from roll
1400 relative to the unwinding rate of third web 1406 from roll
1402. Tension is thereby applied to second web 1404 of material
prior to passing through the nip rollers 1408 at which point
substantially all of the air between the two layers of material is
forced out by the nip rollers 1408. The consistency and texture of
elasticized PVC material including second web 1404 is such that it
adheres lightly to third web 1406 unwound from roll 1402 forming a
very light seal that excludes all air from between the webs. Second
web 1404 is applied to the inner, blended layer of third web 1406,
preferably a substantially more rigid material unwound from roll
1402. Preferably, an anti-blocking agent, such as very fine sand,
can be added to the third web upper (outer) layer of the
co-extrusion so as to preferentially inhibit sticking of second web
to what will be upper layer such that second web will remain in
close contact with what will be the underside of third web during
storage in a roll 1410 condition and during unwinding from roll
1410 in normal operation on a packaging machine.
[0640] Second 1404 and third 1406 webs, having been laminated to
produce a lamination and subsequently wound onto the finished roll
1410 can be stored and when required for use in packaging can be
loaded onto packaging machine as shown in FIG. 170.
[0641] Referring now to FIG. 170, a process to laminate two webs of
material together is shown. The two webs include the third and
second webs. The apparatus is suited to produce any packages herein
described. First web 1416, preferably of a substantially gas
barrier material is located into an aperture (not shown) in sealing
plate 1418 mounted on the conveyor 1420. Preferably, sealing plate
1418 being similar to sealing plate member 1208 shown in FIG. 159.
Preferably, first web has a cup-shaped depression formed therein
and similar to that shown in FIG. 171. Red meat or other perishable
goods is loaded into first web tray 1416 and a plurality of trays
are located into the apertures in each sealing plate 1418 mounted
to conveyor 1420. The conveyor indexes forward such that a loaded
tray is located between upper vacuum chamber 1422 and lower vacuum
chamber 1424. During indexing of the conveyor the third web tray is
also indexed in a direction parallel with the conveyor and placed
into position between upper and lower vacuum chambers. Upper 1422
and lower 1424 vacuum chambers are closed together such that
sealing plate is clamped therebetween to provide a substantially
sealed and enclosed chamber assembly. Air is evacuated from the
chamber assembly to a pressure level of approximately 5 torr and a
selected gas is injected into the chamber assembly. The gas being
chosen for its properties of enhancing the keeping qualities of
goods, in first web tray 1416, such as carbon dioxide or a blend of
carbon dioxide and nitrogen is suitable. First, second and third
webs are then sealed together to produce a package. Upper 1422 and
lower 1424 vacuum chambers are then opened so that conveyor 1420
can carry sealed package to an ejection point. The package may be
trimmed by a cutting devices located within the chamber assembly
such that a skeletal scrap web can then be wound onto a single
wind-up spool, or alternatively, could be separated by
de-laminating the third web scrap from second web scrap onto scrap
wind-up 1426 and 1428 as shown in FIG. 48. The package may be
trimmed within vacuum chamber in one machine cycle or alternatively
the package may be trimmed from the web in a secondary operation
immediately after the vacuum chamber.
[0642] Preferably tray construction may be thermoformed from
co-extruded polyester plastic materials as shown in FIG. 171.
Co-extruded material may include two layers of a total thickness of
about 0.015''. The outer layer 1430 is about 0.0135'' thick and the
inner layer 1432 is about 0.0015'' thick. The outer layer 1430
includes Eastman APET 9921 and the inner layer 1432 is about a
50%/50% blend of Eastman 13162 and Eastman 6763.
Method and Apparatus for Packaging Perishable Goods
[0643] Having described laminated webs, it is now appropriate to
describe a method to package perishable goods using a laminated
web. Although the description preferably applies to laminated webs,
one or more non-laminated webs can also be used with the method
with apparent modification.
[0644] FIG. 172 shows a schematic representation of a side
elevation of a preferred packaging apparatus including a conveyor
with a plurality of sealing plates generally denoted 1436 attached
thereto. Preferably, a drive motor 1438 is connected to conveyor
sprockets 1440a, and b and arranged so as to provide intermittent
driving of the conveyor as required. Trays with goods therein are
loaded into apertures in sealing plates at the loading section and
the conveyor is driven forward in the conveyor direction shown in
intermittent increments of one pitch which is equal to the distance
of a single sealing plate. The conveyor is otherwise stationary
except during each movement of one pitch. A scale 1442 can be
positioned under the upper section of the conveyor and is attached
to a driver such that when the conveyor is stationery the scale can
be elevated and lift the tray from sealing plate 1436, and weigh
the tray and goods. Preferably, scale can be interfaced with a
label printing device. Preferably label will include information
such as price, weight and time of packaging and then label printing
device will apply the label to the upper surface of the second (or
third web) in a label position. Label position can be predetermined
such that when first, second and third webs are sealed together the
self adhesive label is in a desired location which can be easily
seen by any prospective purchaser of the finished package after
removal of the third web. Alternatively, if the label is located on
the third web and if the third web is not removed before retail
display then the label can be viewed. A roll of material 1444 is
mounted above the conveyor adjacent to a first station 1446 to
facilitate unwinding of the material 1443. The material may include
a single web of material or alternatively the material may include
a roll of two laminated webs such as described above. Packages
produced with material according to the present invention would be
similar to packages shown in FIG. 173, whereas packages produced
with web conventional material would be similar to the conventional
package in FIG. 174. First station 1446 includes an upper vacuum
chamber 1448 and lower vacuum chamber 1450 and both are mounted to
the packaging machine and pneumatic drivers. Pneumatic drivers are
arranged to move the upper 1448 and lower 1450 vacuum chamber in a
reciprocating upward and downward motion.
[0645] Preferably, vacuum chambers operate such that they move
simultaneously but in opposing directions such that when they are
moved toward each other a sealing plate 1436 is clamped
therebetween to provide a completely enclosed chamber that is
isolated from ambient atmosphere. Preferably, each vacuum chamber
has ports 1452 and is attached to a vacuum pump (not shown) and
sources of gases via ports 1452. Preferably, the gas sources can be
several in number but typically can include: 100% carbon dioxide
and a blend of carbon dioxide and nitrogen in any concentration.
Sources of gas can be switched from one to the other such that a
selected gas can be injected into the chamber as required and at
will. For example after evacuation of the vacuum chambers, a gas,
such as 100% carbon dioxide, can be provided in the vacuum chamber
at a gas pressure above ambient atmospheric pressure, for example
about 25 psi. Gas pressure may then be reduced to any pressure
between about 0 and about 25 psi before then providing a gas, such
as 100% nitrogen, in the vacuum chambers. A heat bank sealer 1454
is located within the upper vacuum chamber 1448. Sealing device is
also attached to a pneumatic cylinder that provides motion in an
upward and downward fashion. Sealing device is profiled to provide
a flat strip like surface, horizontally disposed, that corresponds
to the flange of the tray and can apply pressure downwardly onto
the flange. Preferably, second station 1456 includes lower clamp
1458 and upper clamp 1460. Preferably, clamps 1485 and 1460 are
attached to pneumatic cylinder and can be operated such that when
moved toward each other a single sealing plate 1436 is clamped
therebetween. Preferably, a sealing device is located within the
upper clamp 1460 with pneumatic cylinders attached thereto and a
cutting device 1462 is located on the outer perimeter of heat bank
1464 and on the inside of 1460. Preferably, members 1462, 1460,
1464, and 1458 can be moved independently and in vertical
directions. A winding arrangement 1466 is mounted above the
conveyor and is powered by an electric driver to wind skeletal
scrap. The preferred sequence of operation of the packaging machine
is as follows. Sealing plate 1436, attached to the conveyor with a
loaded tray contained therein is indexed into position in first
station 1446. Lid material 1443 is unwound from 1444 and located
above tray 1436. Chambers 1450 and 1448 are clamped together with
1436 clamped therebetween. Air is substantially evacuated from the
vacuum chambers which are then filled with carbon dioxide gas or a
blend of carbon dioxide and nitrogen. The gases are pressurized to
a pressure above atmospheric pressure to about 25 psi and held for
a period exceeding about one second. Pressure of the gas in the
chambers is reduced to about atmospheric pressure and sealer 1454
is lowered so as to clamp the lid material against the flange
portion of the tray. The lid material is then sealed thereto along
the complete path of tray flange. Vacuum chambers 1448 and 1450
open and the conveyor indexes forward until sealing plate 1436 is
located at second station 1468, between upper clamp 1464 and lower
clamp 1458. Clamps 1464 and 1458 close together thereby clamping
sealing plate 1436 between the clamps. Sealing device 1464 is
lowered to seal the lid material to tray at flange and cutting
device 1462 is also lowered and retracted thereby severing the tray
and package from web while the tray still located in the sealing
plate 1436. Skeletal scrap is wound onto scrap winding spool 1466.
Conveyor indexes forward and packages are ejected therefrom.
[0646] Cross-sections through the package shown in FIG. 173 and a
conventional pack of FIG. 174 are shown alongside for comparison.
The conventional package shows the absence of second web. The tray
constructed according to the present invention include a second and
third web sealed to a tray flange around the upper periphery of the
tray. A tray constructed according to the present invention
provides a peelable lib to introduce oxygen at a predetermined
time, thus extending the shelf life of the perishable good stored
therein.
Method and Apparatus for Packaging Finished Packages
[0647] Now that trays, webs, and methods have been described, it is
appropriate to consider master packs and their methods for
making.
[0648] Referring now to FIG. 175, details of a packaging apparatus
constructed according to the present invention for producing
substantially gas barrier master containers and heat sealing a
substantially gas barrier lid material to the master containers to
produce hermetically sealed containers is shown. The following
description discloses a method and apparatus for producing the
hermetically sealed containers for providing a vacuum and/or
selected gases in the containers at selected and variable
pressures, so as to accelerate the dissolving of selected gasses
into perishable goods such as red meat that may be contained
therein and then exchanging the selected free gases with other
suitable gases for the purpose of enhancing the keeping qualities
of the perishable goods. Furthermore, the method provides methods
of removing residual oxygen gas that may be retained within the
cell structure of packaging materials such as EPS, that may be
contained in the hermetically sealed master.
[0649] FIG. 176 shows a cross-section through an apparatus intended
to produce master packs thermoformed from a continuous web of
plastics material. The dimensions of the master containers are
arranged so that they can be filled with preferably an exact number
of finished packages containing perishable goods such as any of the
finished packages herein described. The apparatus preferably
includes a horizontal thermoforming, reel fed packing machine,
similar to Model R530 packing machine manufactured by Multivac Sepp
Haggenmuller GmbH & Co. of Germany.
[0650] Preferably, the apparatus includes a frame (not shown) that
is arranged with two horizontally disposed and parallel continuous
gripper chains generally denoted as 4400 in FIGS. 176, 177 and 178
that run almost the full length of the frame and are retained in
tracks that are located on each side of the frame. Gripper chains
4400 are arranged to grip the two opposing edges of the lower web
4402 and apply suitable lateral and longitudinal tension thereto.
The machine direction is shown by arrow 4444 and the chain is
preferably powered by an electrical motor (not shown) that is
controlled electronically to carry the lower web 4402 in the
machine direction in intermittent movements. The distance traveled
by the gripper chains, carrying the lower web, is controlled so as
to carry the formed master packs 4402 forward and simultaneously
locate a suitable area of the lower web material 4402 between the
upper and lower sections of the thermoforming section. Each
intermittent movement, during each machine cycle, of the gripper
chains is equal in distance traveled and the apparatus can be
arranged to automatically operate at a machine speed of a set
number of cycles per minute which may be, preferably about 4 cycles
per minute.
[0651] During a single machine cycle the following functions
preferably occur. After the gripper chains cycle forward carrying a
section of lower web material 4402 into position between the upper
and lower sections of the thermoforming section 4406 the upper and
lower sections close together and thermoform master packs
including, in the present case, three containers. A hole punch 4466
is arranged to provide apertures 4452 in the lower web located
between the containers as shown in FIG. 176 and in an enlarged
cross-sectional view in FIG. 178. Finished packages are then loaded
into the master packs (containers) in the loading section 4446 and
with each machine cycle the lower web travels forward an equal
distance. The gripper chain carries the lower web 4402 in the
machine direction a distance of a single pitch for each machine
cycle until the loaded master packs are located between upper
chambers, generally denoted by 4410 and lower chambers, generally
denoted by 4412. Preferably, a total of five upper chambers and
five corresponding lower chambers are arranged such that the upper
chambers 4414, 4416, 4418, 4420 and 4422 can be elevated and
lowered as required. Lower chambers 4424, 4426, 4428, 4430 and
4432, are located directly below the upper chambers and arranged
with powered drivers (not shown) to elevate and lower the lower
chambers as required. A cross-section is shown in FIG. 176 and is
typical for upper chambers 4414, 4416, 4418, and 4420 with
corresponding lower chambers 4424, 4426, 4428, and 4430. Upper
chamber assembly 4410 and the lower chamber assembly 4412 operate
simultaneously so as to close toward each other and open away from
each other, as required. During a single machine cycle upper
chambers and lower chambers close and open once. After upper
chambers and lower chambers open, gripper chains 4400 carrying the
lower web 4402 move and carry the master packs forward for one
single pitch. A roll 4434 of upper web material is located as shown
and upper web material 4444 is unwound, as required, during each
machine cycle, providing a length of upper web material equal to
the distance of the lower web forward movement. A side web sealer
4436 is located one on either side of the machine in a position
that allows sealing of the upper web to the lower web, forming a
single and continuous heat seal between the upper web and the lower
web, along the outer edges of the upper web, along path 4438 and
4440 shown in FIG. 176. A gassing member 4442 is located between
the upper web and the lower web such that the upper web and the
lower web can be heat sealed together at paths 4438 and 4440,
thereby encapsulating the gassing member 4442 with the upper web
4444 and the lower web 4402, in close and touching proximity to the
gassing member 4442. The gassing member 4442 is attached and fixed
to the machine at the entry end to the upper and lower chambers
assembly and otherwise floats along its entire length. Gas ports
4446 and vacuum recesses 4448 are machined in the gassing member,
such that the gas ports 4446 provide direct communication from a
suitable gas source separately to each lower chamber location 4424,
4426, 4428, and 4430, thereby introducing into the master
containers chosen gases separately and during each cycle of the
machine. Vacuum recesses 4448 provide communication between the
master containers and a vacuum source via apertures 4452 in lower
web and vacuum ports 4450.
[0652] Preferably, during each machine cycle, upper chamber
assembly 4410 and lower chamber assembly 4412 close toward each
other with a clamping force, and clamping the upper web and lower
web with gassing member therebetween, such that master packs in
lower web are enclosed in the cavities in the lower chamber. As can
be seen in FIG. 178, the upper chamber 4414 is clamped against the
upper web 4444 and the lower chamber 4424 is clamped against the
lower web 4402 with the gassing member 4442 between the upper web
4444 and the lower web 4402, which are sealed along path 4440.
Seals 4468 are provided as required and as can be seen in this
closed position, the upper chamber 4414 and the lower chamber 4424
provide a substantially airtight assembly. Preferably, after
closing of the upper and lower chambers together, a vacuum source
is connected to vacuum ports 4450, which substantially evacuates
all air from within the master packs. Preferably after evacuation
of the master packs, a suitable gas which may be selected from
those gases listed herein, is provided through gas port 4446 and
into the master packs 4404. The suitable gas is provided at a
pressure that exceeds ambient atmospheric pressure and may be
provided at a pressure preferably between about 0 psi and about 200
psi or more. The gas can be retained at the desired pressure for a
set period of time preferably equal to about one or more seconds.
Preferably, after the set period, suitable gas pressure is reduced
to slightly above ambient atmospheric pressure so as to maintain a
positive pressure within the master containers but not at such a
high pressure that may cause rupturing of the seal between the
upper and lower webs at seal paths 4438 and 4440, after opening of
the upper and lower chambers.
[0653] The upper and lower chambers assembly is then opened and the
master packs move forward one pitch so as to be located directly
between upper chamber 4416 and lower chamber 4426. The upper and
lower chambers assembly is then closed and the evacuation and
gassing sequence as described for upper chamber 4414 and lower
chamber 4424 is repeated, however, the gas provided through the gas
port into the closed upper and lower chambers may be a different
gas. This sequence of evacuation and pressurized gassing is
repeated during each machine cycle in upper chambers 4418 and 4420
with corresponding lower chambers 4428 and 4430.
[0654] FIG. 177 shows a cross-sectional view through upper chamber
4422 and lower chamber 4432 with heat bank. Upper chamber 4422 and
lower chamber 4432 close against each other and heat bank 4458 heat
seals the upper web 4444 to the lower web 4402, at a path that
follows the perimeter fully around each master container, so as to
hermetically heat seal the upper web 4444 to the lower web 4402
with suitable gas contained therein. Upper chamber 4422 and lower
chamber 4432 open to allow the hermetically sealed master packs
4456 to be carried forward toward the exit end of the machine. The
master packs 4456 are slit longitudinally with a slitter 4462 and
cut laterally with a knife 4464 as shown in FIG. 157, prior to the
ejection of finished master packs from the machine.
[0655] In this way residual oxygen that is retained in the cell
structure of the EPS foam trays, contained in the mater packs, can
be exchanged with other suitable gasses. Preferably, gasses such as
carbon dioxide can be provided under pressure so as to dissolve in
any free liquids such as water and oils contained in the perishable
goods such as red meat.
Modified and Controlled Atmosphere Packaging
[0656] Before disclosure of the preferred methods for conditioning
meats prior to packaging, the inventor, without intending to be
bound to the particular theory, now wishes to advance the theory
for the formation of metmyoglobin in packaged red meats and
solutions to the problems of metmyoglobin formation, with reference
to FIG. 179.
[0657] Fresh meats that have been chilled during an adequate
storage period will contain large quantities of purple colored,
de-oxymyoglobin which is unattractive to typical consumers. When
the chilled meat is sliced in ambient atmosphere the
de-oxymyoglobin that consequently comes into contact with
atmospheric oxygen, will then, by oxidation, convert into
oxymyoglobin (referred to as "bloom") displaying a bright red color
that is attractive to consumers. However, if the sliced meat (or
ground meat) is intended to be stored in a low oxygen gas
atmosphere, case ready condition, as a way of extending storage
life prior to retail display, the oxymyoglobin that has formed
after slicing and/or grinding (but before subsequent packaging in
the low oxygen atmosphere), may provide for undesirable transfer of
oxygen gas into the sealed environment of the master container.
Even though the quantity of oxygen transferred by the
de-oxymyoglobin, is relatively small it can lead to the formation
of undesirable metmyoglobin on the visible surface of the retail
packaged red meat. Metmyoglobin is brown in color and is
unattractive to consumers. It is therefore desirable to prevent
and/or minimize the extent of such deleterious formation of the
metmyoglobin. The apparatus disclosed in the following subject
matter details preventative methods. In order to provide a more
detailed description of the conditions under which the undesirable
metmyoglobin may form, the following known laws of physics and
natural processes are referenced:
Normal Conditions for Oxymyoglobin Formation
[0658] After storage under commercially normal refrigerated
conditions in carcass or vacuum packed conditions, freshly sliced
beef will predictably turn bright red (by oxidation of purple
colored deoxymyoglobin to bright red colored oxymyoglobin) with a
virtually 100% probability, when exposed to ambient air.
Optimum Conditions for Metmyoglobin Formation
[0659] It is known that optimum conditions for formation of
metmyoglobin, at the surface of sliced, fresh beef muscle exposed
to a gas occurs when the free oxygen content of the gas is
approximately 5000 to 30,000 ppm.
Graham's Law of Gas Diffusion
[0660] The rate of gas diffusion is inversely proportional to the
density of the subject gas.
Relationship Between Density of Gas and Temperature
[0661] The density of a gas (and most matter) is inversely
proportional to temperature (i.e.: the gas density increases as its
temperature is decreased).
Henry's Law
[0662] At a given temperature, the solubility of a gas in a liquid
is directly proportional to the pressure of the gas above the
liquid.
The "Mud Puddle Ring" Effect
[0663] According to the present inventors observations and
independently performed empirical trials, the "Effect" can
typically occur, immediately following packaging, when the
following prevailing conditions are generally approximated:
[0664] 1). The subject sliced beef has been allowed to "bloom" as a
result of exposure to ambient atmospheric oxygen immediately prior
to packaging.
[0665] 2). The temperature of the sliced beef is lower than the gas
and packaging materials surrounding it, immediately after
packaging.
[0666] 3). The sliced beef is placed in an "enclosed space" defined
by the "retail package" including an EPS foam tray (or other) and a
high OTR over wrapping web (the "web"). The "enclosed space" is not
completely filled with the subject sliced beef and a remaining
space ("the space") is also contained. "The space" is subsequently
filled with a "suitable gas" during evacuation of master
container.
[0667] 4). The ratio of beef to gas is low, i.e. the volume of
"suitable gas" is relatively low and the volume beef is relatively
high, in the "enclosed space".
[0668] 5). The "retail package" is placed into a substantially gas
barrier "master container" which is evacuated (including the
"retail package") of ambient air and then filled with the "suitable
gas". The composition of the "suitable gas" can be carbon dioxide,
nitrogen and residual oxygen at approximately 100 to <500 ppm.
Thereby, substantially filling "the space" and "other space". The
"other space" is defined by the internal space of the master
container but excluding space occupied by "retail packages".
[0669] 6). The temperature of "suitable gas" is lowest at the
lowest point in "the space".
[0670] FIG. 179 is intended to be representational and not a
depiction of the actual "Effect" which is described as follows.
Immediately after packaging, the highly oxygenated condition of
myoglobin (oxymyoglobin), which is present at the surface of the
beef slices starts to reduce, releasing oxygen gas inside the
enclosed space 1242. At those sliced beef surface locations shown
as 1228, that are in direct and intimate contact with the web 1232
(such that there is no gas between the beef surface and the web),
the released oxygen gas passes through the gas permeable web,
directly and diffuses into the other space 1242 inside master
container but outside retail package 1230. This newly released
oxygen gas is therefore immediately separated and essentially
excluded from within the retail package. Any further gas contact
with this area in direct and intimate web contact is limited to any
gas outside the retail package, where the oxygen concentration
remains relatively low. However, oxygen gas that is released from
the beef surface that is not in contact with the web enters the
space 1242 inside the retailage pack which immediately causes a
significant elevation of oxygen concentration in the small free
space under the web. Even though the web is oxygen permeable the
rate of oxygen gas diffusion therethrough is such that it can take
an extended period of time for the oxygen content in the gas under
the web to equilibrate with the oxygen content of gas outside the
retail package. Furthermore, the temperature of the oxygen
atoms/molecules as they are emitted from the surface of the beef is
the same as the beef which is significantly lower than the
temperature of the gas in the space and therefore the density of
the released oxygen is relatively high. This condition results in
two additional effects. The diffusion rate is lower (Grahams Law)
and because the density is higher, these newly emitted oxygen atoms
tend to sink toward the lowest point in the package and/or remain
in contact with the sliced beef surface for a longer period than
may otherwise be required. Consequently, the partial pressure of
oxygen at the surface of the meat increases and, in accordance with
Henry's Law the level soluble oxygen gas in the meat surface liquid
elevates. The temperature of gas in space 1242 is higher at the
highest point and lowest at the lowest point. It can be concluded
that oxygen gas emitted from the beef surface will remain in
contact with the surface of the beef for a more extended period at
lower locations and therefore higher concentrations will be present
at these lower locations. Conversely, lower concentrations will be
present at higher locations. Correspondingly, concentrations of
metmyoglobin will form in direct proportion to the concentrations
of oxygen. The composition of the gas in direct contact with the
surface of the beef, a layer of gas that is probably less than
about 0.01'' in depth, is the active gas that has effect at the
surface of the beef. Under the conditions described above, the
oxygen concentration in this layer can become significantly
elevated.
[0671] The tendency of the relatively heavier oxygen atoms to move
toward the lower levels in the space 1242 can cause it to tend to
follow the downwardly disposed surface of the sliced beef, carried
with other gasses and liquids that are close to the surface. This
condition can therefore result in an increased level of oxygen
concentration at the surface of the beef which exponentially
increases toward the lowest point in the space 1242 and is
consequently highest at the lowest point in the space 1242. This
results in correspondingly higher (and darker) concentrations of
metmyoglobin at the lowest point in the package and, conversely,
visible but lower concentrations at the highest point.
[0672] A mud pool drying in the sun can appear to be surrounded by
parallel rings that are typically gray/brown in color. These rings
are lightest at the furthermost point from the center of the puddle
and typically darkest at the center of the puddle, with a gradual
color density change between the two points. The color density of
metmyoglobin that is formed under the conditions described above
gradually increases between the highest point in the package where
the color is the lightest to the lowest point in the package where
the color is darkest. Hence the comparison with a mud pool drying
under the sun.
[0673] Eventually, any free oxygen gas released by the reduction of
oxymyoglobin, will become either reabsorbed in the form of
metmyoglobin or will be diffused and equilibrated with the modified
atmosphere contained throughout the master package. However, the
effective, irreversible, deleterious event of formation of
metmyoglobin at the visible surface of the meat will have already
occurred and under the prevailing conditions prior to intended
retail sale of the meat, will permanently remain visible.
[0674] Subjectively, the above occurs in what can appear to be a
confusing manner. The best most highly oxygenated and therefore red
looking beef (as in that having an attractive red "bloom") prior to
packaging in the low oxygen atmosphere will, with an almost certain
predictability, emerge as the worst looking beef after removal from
the master container. Conversely, the worst looking (as in that
beef colored by purple deoxymyoglobin) prior to packaging in the
low oxygen atmosphere will, with an almost certain predictability,
emerge as the best looking beef after removal from the master
container.
[0675] Other issues of multiple species mass transfer with chemical
reaction (i.e. a potential cause for the mud puddle ring problem in
packaged fresh meat) are described as follows.
[0676] 1. Equilibrium between a gas and a liquid is governed by
Henry's law which states that the partial pressure of a gas at
equilibrium is equal to the Henry's Law constant multiplied by the
concentration of the gas in the liquid phase at equilibrium. The
gas is oxygen (O2) and the liquid is water (H20).
[0677] 2. Based on the functional relationship expressed in Henry's
law, several conditions can influence the state of equilibrium
between free O2 in the package and O2 absorbed in water.
[0678] A. Partial pressure of free O2 in the in-package
atmosphere.
[0679] B. Temperature as Henry's constant is temperature
dependent.
[0680] Conversion of absorbed O2 in water due to chemical reaction.
(The work reported by Zhao and Wells indicates that in-package
absolute gas pressure can vary in fresh packaged meat, either
increasing or decreasing due to a combination of factors including
composition, storage time, temperature, pre and postmortem factors,
and others. Since total in-package gas pressure can vary, partial
pressure conditions of O2 can vary causing a migration of O2 in and
out of water solely based on consideration of factor A. With
respect to factor B, it is likely that there are thermal gradients
that develop across products, from the center to the surface, for
even slight temperature variations that are experienced within the
package. This would have two results. The temperature gradients
across a product would help to cause moisture migration within a
product; and the temperature fluctuation would promote a change in
O2 equilibrium concentration within water. In effect, O2 could be
absorbed into water, the water migrate, and subsequently be
deposited somewhere else in the product.
[0681] As a result of factors A and B, and the role of chemical
conversion, it is likely that some aqueous participation is needed.
Given this, the question becomes what relative O2 concentration and
reaction time is needed to produce brown metmyoglobin color. If the
time is sufficiently long, factors A and B would operate to move
O2, seemingly through the product, to a point to produce the mud
puddle ring.
[0682] Because the in-package gas atmosphere in a closely wrapped
product package is minimal, there is very limited opportunity for
bulk convective gas movement by mass transfer within the package.
The enclosed space near the permeable web, product and tray are
particularly prone to development of a boundary layer away from
free mixing of gas molecules within a larger, relatively unconfined
headspace. Boundary layer phenomena may include the establishment
of a proportionate localized gas concentration compared with the
free gas concentration. This situation would aggravate the O2
conditions outlined above in point 2A and 2B compared with a
package with a larger headspace volume.
[0683] Once formed on a slice of fresh red meat, metmyoglobin is
essentially a fixed stain, with unappealing appearance and is
generally unacceptable to consumers. On the other hand,
oxymyoglobin, which imparts an acceptable red bloom color is
attractive to consumers and is therefore desirable.
[0684] The present invention provides methods and apparatus for
grinding meats such as beef by processing boneless beef through a
grinding machine (such as may be supplied by Weiler & Company
of Whitewater, Wis., USA) and substantially preventing exposure of
the ground meat from contacting ambient air until the ground meat
is delivered in any suitable retail package to a point of sale,
such as a supermarket. In this way formation of excessive
quantities of metmyoglobin and/or any cause of excessive
discoloration can be minimized. In a preferred embodiment, the meat
can be vacuum packaged after treatment with CO.sub.2 in any one of
the methods described herein.
Meat Grinding Blending and Methods for Controlling Fat
[0685] Typically meat packing companies slaughter cattle and then
process the dressed carcass by chilling and then dis-assembling the
carcass into portions of meat which can then be, in part, delivered
to the point of sale to consumers, in vacuum packs. However,
approximately 40% of the dis-assembled meat is processed at the
point of animal slaughter by grinding and then blending to provide
ground meat with a selected fat and lean content as required by the
retailer. The fat and muscle content of the ground meat may be, for
example, 20% fat and 80% lean. Current processing methods require
that the boneless meat be firstly coarse ground then blended,
vacuum packaged, delivered to a supermarket or packaging facility
close to the consumer where the coarse ground meat is fine ground
and then retail packaged immediately prior to retail display. This
process inherently results in excessive exposure of the ground meat
to ambient atmosphere during the grinding and blending process at
the point of slaughter. Furthermore, this process requires that
relatively large quantities of ground beef are blended together in
a single batch. Because it is not possible to dis-assemble a
carcass and provide boneless meat therefrom with a precise and
selected ratio of fat to muscle tissue, the typical batch blending
process often requires several attempts to produce the desired
ratio of fat to lean content. The general industry practice is to
deposit selected boneless beef with a fat to lean ratio as close to
a desired tolerance as possible. The selected boneless beef may
have a fat to lean ratio of 15% fat to 85% lean+/-5%. The selected
boneless beef is then coarse ground and blended in a batch blender
such as can be acquired from Weiler and Company. Typically, a
sample of the blended boneless beef is then removed from the
blender and then can be tested to determine fat and lean content
using, for example, a device known as an Analray testing procedure.
After determining the fat and muscle content of the coarse ground
meat addition fat or lean meat is added to the batch blender and
the full batch is again blended for a period of time and then a
second sample is extracted and tested to determine fat and lean
content. If the fat and lean content is as required at this point,
the batch of coarse ground meat can be vacuum packaged and stored
in refrigerated facilities prior to delivery to the point of retail
sale. However if the fat and lean content is not as required then
additional fat or lean meat can be added to the batch and further
mixing is then required. This process is often repeated as many as
5 times or more. Each time the coarse ground meat is blended again
it is damaged by the blending process. This damage may include "fat
smear" or over heating. Heat is generated during this blending
process and "fat smear" occurs when the meat has been exposed to
excessive blending. This procedure is expensive in terms of energy,
labor and equipment time. Furthermore, damage to the ground meat is
undesirable and yet damage typically occurs as a matter of normal
process with the currently predominant industry procedures. During
the process described above the meat is exposed to ambient air and
bacteria such as E. Coli and other dangerous bacteria can be
present in the blended ground meats. Excessive blending can cause
the bacteria to spread throughout the batch of meat in the
blender.
[0686] Ground foods such as ground beef have been produced by
processing in meat grinding and blending equipment and associated
equipment, such as blending and processing equipment manufactured
by Weiler/Beehive. The equipment can be viewed at the following web
site: www.meatingplace.com/com/beehive
[0687] Ground meat such as ground beef is produced by processing
selected portions of boneless meat, including fat and muscle
tissues, through a grinding machine. The relative quantities of fat
and muscle contained in any batch of the portions of boneless meat
is typically arranged to correspond with set industry standards.
The batch of boneless meat may include about 93% muscle tissue and
therefore the balance of about 7% would be fat. The following list
of items 1 to 5, shows the fat and muscle tissue content of some
typical industry specifications for boneless meat: TABLE-US-00002
TABLE 1 Muscle Fat Item Tissue Tissue 1 93% 7% 2 90% 10% 3 75% 25%
4 65% 35% 5 50% 50%
[0688] Although the industry standards are established, it is
difficult to produce large quantity of boneless beef to any
specification or ratio of fat and muscle. This difficulty can arise
as a result of genetic variation in the animals from which the
boneless meat is harvested. Consequently, there is often variations
that could be as much as +/-2% to 3%, which corresponds to a
possible variation of up to 6% and perhaps even more, in the actual
fat or muscle content of the boneless meat.
[0689] Typically, consumers can purchase fine ground beef with a
fat content that is specified and clearly marked on any retail
package. The fat content may be specified to 10%, 25%, or 30% and
it is illegal to sell such retail products to consumers if the fat
content is higher than the amount shown on the retail package.
Therefore, producing retail packages of ground beef with a fat
content of, for example, 25%, may be achieved by grinding a known
quantity of Item 2 (listed above) and blending this with a known,
measured and corresponding quantity of Item 4 (listed above). The
fat content of the resulting ground beef can be measured but it is
common for the fat content variation in the initial quantity of the
boneless beef items to vary to such an extent that a compensating
procedure must be accommodated during production of the product for
retail packaging. This compensating procedure can often result in
production of ground beef that has a muscle content that is higher
than is specified on the retail package. The consumer, however,
only pays for the ground beef according to the fat content shown on
the retail package. Thus a loss of profit for the ground beef
producer can be incurred.
[0690] A quantity of boneless beef, with a specified muscle and fat
content, say Item 5, is loaded into a hopper which is connected
directly to a primary meat grinder. The portions of meat are
progressively carried, by augers and compressed into a tubular
conduit with a perforated grinding plate fitted across. The
grinding plate is typically manufactured from suitably hardened
steal and the perforations may include drilled and reamed holes of
a chosen diameter, which may be about 0.5'' diameter, and which
extend completely through the grinding plate. The primary grinder
typically produces coarse grinds with the diameter of the meat
pieces corresponding with the diameter of the drilled and reamed
holes in the grinding plate.
[0691] After primary grinding a quantity of Item 5 may be blended
with a selected quantity of coarse ground Item 4. After the
blending of Item 5 with Item 4 the resultant mix is processed
through a secondary fine grinding machine prior to portioning and
retail packaging. The secondary fine grinding machine may be
similar to the primary coarse grinding machine except that the
grinding plate can be drilled and reamed with holes of less than
about 0.25'' diameter.
[0692] Typical fine ground meat for retail packaging and sale to
consumers may be produced with fat and muscle content as shown in
the following table: TABLE-US-00003 TABLE 2 Muscle Fat Item Tissue
Tissue 1F 90% 10% 2F 75% 25% 3F 65% 35%
[0693] The existing grinding, blending and processing equipment,
such as Weiler/Beehive equipment, has been demonstrated as
effective for grinding meats of various types. However, little has
been proposed to improve the quality of the ground meats by, for
example, arranging equipment in such a manner so as to
substantially prevent contact of the ground meats with air and/or
atmospheric oxygen during the grinding and blending process. Meats
are ground and blended in such a manner so as to produce ground
meats including a product with a desired ratio of muscle and fat
content. The conventional equipment does not allow for continuously
and automatically grinding and blending the ground meats in such a
manner so as to continuously produce quantities of ground meats to
an exact and predetermined muscle and fat content.
[0694] The present invention provides methods, systems and
apparatus to automatically and continuously grind, condition and
blend the ground meat products with improved accuracy of muscle
tissue to fat tissue ratio, so as to minimize losses to the
processor. The ground meat can then be packaged in suitable
packaging that will enhance the keeping qualities of the products
and provide a safer method of delivering the goods to
consumers.
Meat Grinding and Conditioning Apparatus
[0695] Having described tray construction, web covers, master
container and associated methods for making and packaging, it is
now appropriate to discuss apparatus and methods for treating the
perishable food items that are to be packaged by those methods
herein described. A logical starting point is a method and
apparatus for grinding and conditioning meat.
[0696] Referring to FIG. 180, a cross-sectional view of a preferred
grinding head 1300 constructed according to the present invention
is shown. Preferably, grinding head 1300 is attached to a source
for the carbonation of liquids and water contained in ground meats.
Meat 1310 is processed through grinding head 1300 of a meat grinder
1302 and deposited into vessel 1304. Vessel 1304 is substantially
sealed from the external atmosphere. Preferably, entry point 1306
and exit point 1308 are such that when compacted meat 1310 fills
the grinding head 1300 adjacent to the cutter 1312 and similarly
compacted ground meat 1316 fills the exit point 1308 of vessel 1304
adjacent to the end of screw-auger 1314, the vessel 1304 can be
filled with a gas such as carbon dioxide under pressure.
Preferably, pressure is kept above ambient atmospheric pressure
therefore assisting the dissolving process of carbon dioxide into
water in meat. Preferably, screw-auger 1314 is attached to a driver
(not shown) and rotated so that the ground meat is carried forward
and as it travels down the length of the screw auger 1314, the
space between the tapered flights 1320 of the screw auger 1314
gradually is reduced, thereby compressing the ground meat just
prior to ejection at exit point 1308, thus providing a seal of the
vessel 1304 from ambient atmosphere.
[0697] This embodiment provides a cost effective method of
increasing the pressure of carbon dioxide and elevating the
quantity of dissolved carbon dioxide in water and ground meat to a
desirable level. Gas provided under pressure into the vessel may
include, preferably, a suitable blend of carbon dioxide and other
gasses such as nitrogen, stabilized chlorine dioxide (stabilized
chlorine dioxide brand name Oxine), helium, and other inert gases,
but substantially excluding oxygen, and including an amount of
carbon dioxide of about 5% to about 100% by volume or weight.
[0698] One embodiment of screw-auger 1314 is shown but alternates
may be arranged in other configurations such as when connected
directly to and parallel with screw auger 1318 and housed in a tube
that has an internal diameter slightly larger than the outside
diameter of screw auger 1314, that is also in line and parallel
with screw auger 1318. Such an arrangement passes ground beef
through a pressure box or vessel and exposes the ground beef to
carbon dioxide or other suitable gasses at a gas pressure above
ambient atmospheric pressure.
[0699] Preferably, suitable blends of gasses can be produced and/or
blended at the point of use and injected into vessel 1304 and
grinding head 1300 at ports 1322. Preferably, a stainless steel or
plastic extension tube is fitted to the flanges of the "downstream"
egress/exit point of the pressure box (so as to allow all ground
meat to pass through the tube) and the blend of gases is injected
into the tube so as to substantially expel atmospheric gasses and
oxygen from the tube such that the blend of gasses remains in
contact with the meat within the tube. The tube may house an auger
type screw arrangement to transfer ground meat inside the tube. The
auger has apertures and holes drilled that connect to a pressurized
supply of gas.
[0700] When the gas is injected through the drilled holes and
apertures, exposure of the ground meat to the gasses will be
maximized. The ground meat can be shaped or profiled and cut into
portions of specified size and directly loaded into packaging while
enclosed in a space containing the gas.
[0701] Temperature of the gas or blend of gases can be preferably
controlled, and may include individual gases in varying relative
proportions so as to optimize the cooling of the meat
simultaneously while providing sufficient carbon dioxide to allow
maximized dissolving of carbon dioxide into the water contained in
the freshly ground meat content liquids.
[0702] Gasses will most preferably be injected into the grinding
head at a pressure that will purge or cause to be expelled,
substantially all atmospheric gases from the grinding head and both
upstream and downstream of the grinding head. Preferably, covers
(not shown) will enclose the portions of the grinding process,
package filling and packaging equipment to limit and control escape
of dangerous levels or quantities of carbon dioxide or other gasses
that may cause damage to health of any machine operators and/or
personnel. Preferably gas extraction fans can be located adjacent
to the equipment to ensure that safety to operators of the
equipment is maintained.
[0703] Covers will also preferably restrict egress of atmospheric
gasses, such as oxygen, from contacting the freshly ground beef
and/or meat prior to packaging and hermetic heat sealing of each
package. Such apparatus will substantially inhibit the oxidation of
deoxymyoglobin contained in those freshly ground meat portions that
were previously not exposed to atmospheric oxygen.
[0704] Alternatively, a suitably concentrated solution of carbonic
acid (carbon dioxide dissolved in distilled water) can be injected
into the grinding head 1300 at port 1322, or mixed with the meat
portions immediately prior to grinding such that it becomes mixed
with the meat in the grinding process. Preferably, subsequent to
grinding, the ground meat can be carried through a tube or "tunnel"
that is filled with carbon dioxide.
[0705] Alternatively, prior to grinding the meat, the portions of
meat are passed through a carbon dioxide tunnel to evaporate a
quantity of free water equal to the amount of carbonic acid
injected into the grinding head. Carbonic acid solution may be
sprayed onto the portions of meat while passing through the carbon
dioxide tunnel. Preferably, solid carbon dioxide ("snow") may be
dissolved into water to produce carbon dioxide solution (carbonic
acid and water). A measured quantity of snow may be injected into
the grinding head at a point immediately adjacent but located on
the up stream side of the grinding head such that, during the
grinding process, the solid carbon dioxide is blended with the meat
so as to substantially cover the surface of the meat particles
after grinding. Preferably, a controlled and continuous weighing
and feeder device may be used to accurately dispense the solid
carbon dioxide.
[0706] The process of the present invention advantageously inhibits
the growth of bacteria on the surface of the meat portions and
particles and maximizes shelf life of the meat for a longer period
than the shelf life period that would otherwise be possible without
an increase of dissolved carbon dioxide in surface water and also
minimizes exposure of ground meat to atmospheric oxygen while in
processing from grinder to retail pack. This reduces the normal
event of the oxidation of deoxymyoglobin, contained in the meat
prior to cutting, to oxymyoglobin and then the reduction back to
deoxymyoglobin after packaging in the packages that do not contain
oxygen. Alternatively, freshly ground or cut meat may be passed
through apparatus for removing and collecting some of the free
surface liquid in a continuous or batch process such as with a
centrifuge. The liquid is then processed by way of pasteurization
at a temperature that does not cause any undesired effects on the
ultimate oxidation of the deoxymyoglobin to oxymyoglobin to produce
a desirable fresh red color at the point of sale. The liquid can
also be exposed to carbon dioxide by mixing with solid or gaseous
carbon dioxide. After sufficient carbon dioxide has dissolved into
the liquid, the liquid can be sprayed onto meat or other types of
goods in a continuous production process.
[0707] Alternatively, in another embodiment of the present
invention, the carbonation of the free surface liquid may be
achieved by including a further step in the process/method of
producing modified atmosphere retail packages. Fresh meat can be
packaged in a substantially gas impermeable plastic package
including a thermoformed tray and flexible plastic lid,
hermetically sealed to the tray. The process involves locating the
tray (with fresh meat) into an enclosed chamber and then
substantially removing atmospheric air from within the chamber
before then filling the chamber with a blend of desired gases
followed by hermetically sealing the lid to the tray. The present
invention provides an apparatus and method for, after substantially
evacuating the chamber and filling the chamber with the desired
gas, compressing the gas (blend of N.sub.2 and CO.sub.2 or 100%
CO.sub.2) within the chamber to an optimized pressure of between
slightly above ambient atmospheric pressure and up to 6 bar (6
times the atmospheric pressure). The gas pressure within the
chamber is then lowered to ambient pressure (1 atmosphere) and the
package is then hermetically sealed. This process of carbonation
increases the quantity of carbon dioxide that is dissolved into the
liquid in the meat and goods. After hermetic sealing of the
package, the liquid is substantially saturated with dissolved
CO.sub.2. This inhibits further dissolving of CO.sub.2 into the
liquid, that may otherwise cause the package to collapse, and can
also extend the shelf/storage life of the meat when held under
refrigeration (at preferably between about -2 to about 4 degrees
C.).
Meat Carbonation Equipment
[0708] Referring now to FIG. 181, another preferred pressure vessel
assembly constructed according to the present invention is shown.
The pressure vessel 1600 preferably saturates any given quantity of
ground meat, with absorbed or dissolved gasses and particularly
carbon dioxide gas while also controlling the temperature of the
ground meat and minimizing or eliminating freezing of the ground
meat during the process.
[0709] An adapter tube 1602 is shown connecting a meat grinder 1604
to the pressure vessel assembly 1600 and is most preferably
provided with an airtight connection. Compacted meat 1606 is shown
within the meat grinder 1604. Preferably, the compacted meat 1606
is forced through holes in a plate and cut by a rotating blade in a
manner as is typically incorporated in most meat grinders and is
well known to manufacturers and users of meat grinding equipment.
Preferably, compacted meat provides a seal to substantially prevent
escape of pressurized gasses that may be provided to the pressure
vessel. Preferably, a port 1608 is provided in a section of the
meat grinder 1604 to allow injection of gasses such as carbon
dioxide or blends of carbon dioxide nitrogen or any other suitable
gas. Preferably, injection of the gasses into port 1608
substantially purges air that is in contact with the meat just
prior to grinding and displaces the air with the desired gas.
Preferably, the gasses may include a gas blend of carbon dioxide
and nitrogen where the percentage of carbon dioxide is about 95%
and the balance of about 5% includes nitrogen. Preferably, the
interior of pressure vessel 1600 is substantially isolated from
atmospheric air and is fitted with a removable dome 1610. Removable
dome 1610 can facilitate easy access for general cleaning and
sanitizing purposes. Preferably, the main portion of pressure
vessel 1600 is enclosed by a jacket 1612 providing a space between
the jacket 1612 and walls of pressure vessel 1600. Preferably,
temperature is controlled by circulating fluid through jacket
through port 1614 and extracted through port 1616. A cross-section
of the vessel 1600 taken along line P-P, through the jacket and
pressure vessel walls is shown in FIG. 182 for clarity.
[0710] Preferably, a port 1622 is provided at the apex of removable
dome 1610 providing a port to inject gasses and other substances
such as O.sub.3, F.sub.2, H.sub.2O.sub.2, KMnO.sub.4, HClO,
ClO.sub.2, O.sub.2, Br.sub.2, I.sub.2, or any combination thereof
and flavors into or alternatively extract from within the pressure
vessel through port 1622. Alternatively, a gas blend is injected
into the pressure vessel through port 1622 and maintained at a
pressure of about 25 psi. Most preferably, a gas blend including
nitrogen and/or carbon dioxide and/or ozone (O.sub.3) will be
provided into pressure vessel via port 1622. Water and oils
contained in the ground meat can then absorb carbon dioxide until
it becomes substantially saturated and cannot absorb any additional
carbon dioxide. Preferably, a controller to maintain and/or adjust
and vary pressure of the gasses within the pressure vessel, as
desired, is also provided but not shown. Preferably, a side port
1624 is provided in the wall of the pressure vessel through which
ground beef may be provided into the pressure vessel 1608 for
further processing in the pressure vessel assembly. Preferably, the
size of the pressure vessel can be adjusted to suit requirements.
The dimensions of length and height may be increased or decreased
to accommodate the required processing capacity of the first
pressure vessel assembly. The lower end of the pressure vessel 1600
is attached to a horizontally displaced tube section 1624 within
which an auger 1628 is mounted. Preferably, auger 1628 includes
passageways and holes 1646 provided so as to allow injection of
gasses therethrough by connection to a source of gasses through
port 1648, thus substantially maximizing exposure of the ground
meats to direct contact with the gas blend. Tube section 1634 has a
length dimension L which can be increased or decreased according to
requirements. Preferably, auger 1628 is attached to a driver (not
shown) that can provide a force to rotate auger 1678 in a direction
such that ground meat will be transferred through horizontally
displaced tube section 1626 and toward a tapered tube section 1632.
Preferably, driver has the capacity of rotating auger 1628 at a
desirable speed which can be adjusted as may be required to
optimize throughput of ground meat by first pressure vessel
assembly.
[0711] Fine ground meat passes into the pressure vessel 1600 and
accumulates until the upper level of accumulated ground meat is
adjacent to proximity switch 1650. Switch 1650 sends a signal to
the variable speed drive motor which motor starts to slowly rotate
auger 1628. Ground meat continues to accumulate and when level
reaches a point adjacent to proximity switch 1652 variable drive
motor is accelerated to a higher speed. The level of ground meat
may continue to elevate and when the level reaches proximity switch
1652 drive motor speed is increased to maximum speed causing the
level of ground meat to drop below a level adjacent to 1654 at
which point the drive motor slows down to a lower speed. When the
level of ground meat drops to a level below 1650 the drive motor is
signaled to stop. Therefore, in this fashion, the level of ground
meat within the pressure vessel 1600 can be maintained at a point
between the lowest proximity switch 1650 and the highest proximity
switch 1652.
[0712] Preferably, tapered tube section 1632 has ports 1634 and
1636 to allow injection of gasses into section 1632 or allow gasses
to be extracted from within the tapered section by passage.
Preferably, additional ports may be provided through any part of
apparatus walls as may be required to optimize efficiency and
operation of pressure vessel assembly. A transfer section 1630 is
located at the egress end of tapered tube section 1632. Preferably,
section 1630 is provided with a port through which gasses may be
injected into or extracted from within section 1630. Preferably, a
desired profile can be varied by interchanging an extruded profile
section 1640. Preferably, the continuous length of extruded food
product can be severed by a cutting device such that pieces of
extruded food can be provided with specified and desired lengths.
The pieces of extruded food can then be packaged into packages of
suitable size. Such an extruded profile section 1640 is attached to
the egress end of the transfer section 1630. A cross-section
through section 1640 is shown in FIG. 183 where a rectangular
profile can be seen. Ground meat can be compressed by auger 1628
and thereby forced through section 1640. Preferably, compression of
the ground meat through the profiled section provides a similar
rectangular profile to the ground beef as it passes through the
egress end of section 1640.
[0713] A side view and end view of an alternative extruded profile
section 1640 in the form of a manifold is shown in FIGS. 185 and
184. Preferably, manifold 1642 includes a series of three tube
profiles through which ground meat can be extruded. Such a process
can provide three separate streams of profiled ground meat. The
manifold 1642 may include one or several streams of profiled ground
meat. A tube of similar internal cross-section to the stream of
ground meat may be connected to each stream of ground meat and
thereby contain each stream of ground meat separately within a
corresponding number of tubes so as to allow transfer of the
profiled ground meat to other processing equipment such as
automatic ground meat patty production equipment or a second
pressure vessel. The tube(s) will thereby provide protection to the
ground meat and substantially isolate it from contact with external
contaminants or atmosphere.
[0714] Preferably, a 3 way valve (not shown) can be inserted
between transfer section 1630 and profile section 1640. The 3 way
valve can be attached to section 1630 and section 1640 in a
substantially airtight fashion so as to provide direct connection
to each other or a connection to an alternative tube connected to
other equipment or to port 1624. Preferably, this provides
diverting the ground meat to other equipment for further processing
or, as may be required at the start of a period of production,
diversion of the ground meat into a first pressure vessel through
port 1624 for additional processing to ensure that the ground meat
is substantially saturated with dissolved carbon dioxide or other
gasses. After the ground meat has been re-processed, which may
require return to pressure vessel 1600 via port 1624 repeatedly,
the three way valve can be switched to direct passage of the ground
meat through the extruded profile section 1640 or other equipment
for further processing or retail packaging. Preferably, valves (not
shown), most preferably automated valves to close all ports shown
in FIG. 181 and any others that may be provided, in a substantially
airtight manner, are provided to each port but not shown.
[0715] As can be learned and understood with the foregoing
description an adequately effective gas tight seal can be provided
by compacted meat 1606 within meat grinder 1604. Furthermore, auger
1628 can be arranged so as to fit closely within transfer sections
1632 and 1630 such that when 1628 is rotating, during normal
operation of the apparatus, ground meat will become compacted
within 1632 and 1634 and around auger 1628 and thereby provide an
adequately effective gas tight seal. Therefore, gas pressure within
the pressure vessel 1600 can be increased to above ambient
atmospheric air pressure as required and maintained at a selected
pressure by a controller to maintain and/or adjust and vary
pressure of gasses within the pressure vessel 1600, as desired. The
gasses within the pressure vessel 1600 will therefore be
substantially contained between the compacted meat at 1606 in the
meat grinder and compacted meat 1656, within transfer sections 1632
and 1630 at a desired pressure. Pressure can therefore be
maintained at a pressure most suited for rapid absorption by water
and oils in the ground meat contained within the apparatus during
operation and transfer of the ground meat through the
apparatus.
[0716] Preferably, second and additional pressure vessel assembly
of similar construction to the first pressure vessel assembly, can
be provided and attached to the first pressure vessel assembly via
an adapter tube so as to provide direct passage of the ground meat
from the egress point at the extruded profile section 1640 by way
of a tube connected directly to the adapter tube 1602 into the
second pressure vessel assembly thereby providing direct
communication to the second pressure vessel. After passage of the
ground meat through the first pressure vessel it can therefore be
passed directly into a second pressure vessel. Preferably, the
second pressure vessel is attached to a vacuum pump via a similar
port to that as shown as port 1622 in FIG. 181. Preferably, the
port shown as port 1624 is not provided in the second pressure
vessel. A suitable gas such as nitrogen is injected into ports
provided in the second pressure vessel assembly which are shown as
ports 1608, 1634 and 1636 and the nitrogen gas is also injected
through ports and passageways in auger, also provided in the second
pressure vessel assembly and shown as 1628 in the first pressure
vessel assembly. The gas pressure within the second pressure vessel
assembly is maintained at approximately a pressure equal to or
higher to the prevailing atmospheric pressure. The ground meat is
passed through the second pressure vessel assembly and through
extruded profile section and into other equipment as required for
packaging and or further processing. Passage of the ground beef
through the second pressure vessel assembly removes free carbon
dioxide that may remain within the voids contained within the
ground meat and replaces it with a gas such as nitrogen.
[0717] A preferred embodiment is to provide a method of
substantially restricting the escape of any gasses, such as carbon
dioxide or ozone, from an apparatus, that may be hazardous to the
wellbeing of operators of the apparatus. This can be achieved by
locating the apparatus, such as shown in FIG. 181, within a
confined space such as an enclosed room or other enclosure that is
substantially filled with an inert gas such as nitrogen. The
enclosure may include several parts and be arranged to cover only
certain parts of the apparatus. The apparatus can be arranged such
that certain parts are exposed to allow access or loading.
Preferably, the gas contained in the room or enclosure will be
substantially nitrogen with a residual oxygen content of less than
20,000 parts per million. The enclosures or room can be extended to
enclose or house other equipment such as conveyors and packaging
apparatus that may be used to process and package the ground meat.
Such an arrangement would most preferably isolate the ground beef
from contact with gasses containing oxygen in concentrations
greater that 20,000 parts per million, or greater than 300 parts
per million, and allowing the ground meat, which may be ground
beef, to be packaged in a vacuum pack or a modified atmosphere
package containing a gas that includes a blend of desired gasses
but containing residual oxygen of not more than 500 parts per
million. The gas contained within the enclosures or the room may be
pressurized and vented to a convenient and safe point into the
atmosphere.
Meat Carbonation System
[0718] In another preferred embodiment a series of enclosed vessels
which may be pressure vessels, can be connected together, in
series, via suitable conduit means with a positive displacement
pump located between each pressure vessel and connected to the
conduit means such that a pump can transfer product such as ground
meat, by pumping means, from a first pressure vessel to a second
pressure vessel. Goods such as ground meat can be transferred
directly from a grinder into a first pressure vessel and a first
pump can transfer the ground meat from the first pressure vessel to
a second pressure vessel. A second pump can be provided to transfer
the ground meat from the second pressure vessel to a third vessel
and a third pump can be provided to transfer the ground meat from
the third vessel to a fourth vessel. Any desired number of vessels
and pumps may be assembled in series so as to provide a method of
transferring the ground meat progressively from the first vessel to
subsequent vessels as may be required. Gases and/or other goods and
materials may be transferred by any suitable means into any of the
vessels at any suitable temperature and pressure. Blending and
mixing devices may be installed in the vessels, as may be required,
and any suitable means of controlling and adjusting temperature of
goods transferred into and from the vessels can be provided. In
this way each vessel can be separately and independently controlled
and arranged with a holding capacity to accommodate any desired
quantity of ground meat, with selected gases and other materials
provided therein, and held at any chosen temperature and pressure.
Each pump can be arranged to separate each vessel such that
temperature and pressure can be independently adjusted in each of
the vessels.
[0719] In a preferred embodiment, for example, fat and muscle
tissue contained in a quantity of boneless beef can be separated
into a first quantity and a second quantity where the first
quantity includes only muscle tissue which is then ground or cut
into suitably sized pieces and then transferred directly into a
vessel containing a suitable oxygen free gas and held at a
temperature of 140 degrees F. for a period of time sufficient to
substantially kill any bacteria contained therein. The second
quantity including only fat can be transferred into a second vessel
and subjected to ultra high pressure (UHP), exceeding 80,000 psi,
so as to substantially kill all bacteria contained therein while
maintaining the second quantity of fat at a temperature of not more
than 104 degrees F. The first quantity of muscle tissue can be
chilled to a temperature below 100 degrees F. and processed by
extrusion to provide a first continuous stream of muscle tissue
with a desired cross-sectional profile that can be arranged to be
similar to the profile of the muscle component of a typical New
York strip. The second quantity of fat can be chilled to a
temperature below 100 degrees F. and extruded to provide a second
stream of fat with a profile similar to the fat component of a New
York strip. The first stream of profiled muscle tissue and the
second stream of profiled fat can be then be combined into a single
stream of muscle tissue and fat and the temperature of the single
stream be reduced to about 29.5 degrees F. In this way, a
substantially bacteria free, continuous stream of extruded muscle
and fat having a cross-sectional profile similar to a New York
strip can be produced which can then be sliced into suitable
portions prior to retail packaging.
[0720] In this way, ground meat (and other meats) can be processed
so as to substantially prevent the formation of oxymyoglobin
immediately after grinding. The ground meat can then be retail
packaged in a low oxygen package such as a master package system as
described herein and delivered to the point of sale in a
de-oxymyoglobin condition. The package can be removed from the
de-oxymyoglobin condition immediately prior to retail display so as
to allow generation of the consumer appealing red color or "bloom"
for the first time after grinding.
Meat Grinding and Conditioning Apparatus
[0721] Referring now to FIG. 186, a meat grinding assembly
constructed according to the present invention includes a first and
second meat grinders that are in direct communication via a
pressure vessel 1700. Preferably, first meat grinder 1702 is fitted
with an auger 1704 and meat grinder 1702 is attached to pressure
vessel 1700 via adapter tube 1706 thereby providing direct
communication to transfer ground meat that has been ground by
grinder 1702 directly into the pressure vessel 1700. Preferably,
adapter tube 1706 is provided with a substantially gas tight seal
at the point of connection to pressure vessel 1700 such that
pressurized gas that can be provided into 1700 will not escape.
Preferably, the adapter tube 1706 is fitted with a valve (not
shown), such that when grinder 1702 has completed grinding and no
compacted meat remains in the grinder, the valve can be closed
thereby closing communication between the pressure vessel 1700 and
grinder 1702. Closing the valve can thereby allow continued
processing of any coarse ground meat that may remain in pressure
vessel 1700 with gas provided therein under pressure and above
ambient atmospheric pressure as required and until all coarse
ground meat contained in the pressure vessel 1700 has been
processed through second fine meat grinder 1738 and into downstream
pressure vessel 1730. Furthermore, if so desired an additional
valve, similar to the valve at grinder 1702, can be provided in the
adapter tube 1718 so as to allow further processing of the fine
grinds in the pressure vessel 1730.
[0722] Preferably, pressure vessel 1700 is fitted with a removable
dome 1708 in which is provided a port 1710. Preferably, the lower
portion of pressure vessel 1700 is attached to a housing containing
auger 1712 which is directly attached to a variable speed drive
(not shown) that can rotate auger 1712 in a direction that causes
coarse ground meat to be urged into and through blade 1714 and
plate 1716. Preferably, an adapter tube 1718 is fitted so as to
provide direct communication to pressure vessel 1730 Preferably,
proximity switches 1720, 1722 and 1724 are conveniently located in
walls of the pressure vessel 1724. Preferably, proximity switch
1720 is located at a point higher than the location of switch 1724,
and switch 1722 is located between switches 1720 and 1724.
[0723] Pieces of meat are placed into a hopper (not shown) attached
to first meat grinder 1702 and auger 1712 is rotated to cause
pieces of meat to be urged through a rotating blade and a
perforated plate 1716. Compacted meat 1726 accumulates in a
compressed condition just prior to passing through blade 1736 and
plate 1716, providing a gas tight seal between the grinder 1702 and
the pressure vessel 1700. Coarse ground meat passes into pressure
vessel 1700 and accumulates until the upper level of accumulated
ground meat is adjacent to proximity switch 1724. Preferably,
switch 1724 sends a signal to a variable speed drive motor (not
shown) connected to shaft 1728 which starts motor to slowly rotate
auger 1712. Coarse ground meat continues to accumulate and when
level reaches a point adjacent to proximity switch 1722, the
variable drive motor is preferably accelerated to a higher speed.
The level of ground meat may continue to elevate and when the level
reaches proximity switch 1720, preferably the drive motor speed is
increased to maximum speed causing the level of ground meat to drop
below a level adjacent to switch 1722 at which point, preferably,
the drive motor slows down to a lower speed. When the level of
ground meat drops to a level adjacent to switch 1724, preferably,
the drive motor is signaled to stop. Therefore, in this fashion,
the level of ground meat within the pressure vessel 1700 can be
maintained at a point between the lowest proximity switch 1724 and
the highest proximity switch 1720. Preferably, meat is compacted at
just prior to passing through rotating blade 1714 and perforated
plate 1716, thereby providing a gas tight seal between pressure
vessel 1700 and pressure vessel 1730.
[0724] In this fashion compacted meat remains in a compacted
condition at location 1732 and 1726 providing gas tight seals.
Preferably, a desired gas or blend of gasses can be injected into
pressure vessel 1700 at a desired pressure. Preferably, gas
pressure is slightly above ambient atmospheric pressure or up to
150 psi and is maintained at desired pressure by metering and gas
pressure regulating equipment (not shown). In this fashion gas can
be continuously injected into the pressure vessel 1700 and
maintained at a desired pressure at a rate equal to the rate of
absorption of gasses by the ground meat. The meat and ground meat
may be compacted to provide substantially gas tight seals other
than as described herein while providing for a continuous
production process of meat treatment during the meat grinding
procedure. Production speed can be adjusted to optimize the gas
absorption (and contact with surface of the ground meat) at a
desired rate while maximizing output of the apparatus and
equipment.
[0725] In yet another preferred embodiment, pressure vessel 1700
and/or other pressure vessels attached thereto, preferably are
provided with valves, that can be opened and closed, and that are
provided at all ports, adapter tubes, entry and egress apertures in
the pressure vessel(s), so as to enable isolation of the pressure
vessel(s) from external ambient atmosphere. Preferably, when
isolated, gas pressure within the pressure vessel(s) may be
adjusted to a suitable and adjustable pressure below and/or above
ambient atmospheric pressure. Preferably, the gas pressure, in the
pressure vessel, may be increased and decreased in a pulsating
and/or oscillating frequency and pattern that can provide for the
efficient removal of undesirable gasses and the replacement with
desirable gasses at a desired pressure.
Meat Processing System
[0726] A processing system is disclosed including a meat grinder
and a processing and blending tube with three augers to transfer
the meat through the system. The tube includes a heat exchanger to
maintain temperature and ports for the introduction of conditioning
gases.
[0727] FIGS. 187-189 discloses a preferred apparatus constructed
according to the present invention arranged to process perishable
foods such as ground beef. Preferably, the apparatus can be
assembled in a gas tight manner with components manufactured from
any suitable materials such as approved stainless steel or
plastics. Preferably, the assembled apparatus may be arranged in a
horizontal disposition or with devices to adjust the horizontal
disposition to any desirable angle of repose.
[0728] Apparatus 5600 includes an enclosed vessel 5624 of circular
cross-section profile, with end enclosures 5602 and 5604.
Preferably, vessel 5624 can be arranged to contain any suitable gas
at any suitable internal gas pressure and at any suitable
temperature. Preferably, the temperature of the gas is controlled.
Preferably, vessel 5624 can be fitted with drivers 5614, 5616, 5618
and 5620 attached thereto at suitable convenient locations and as
required to provide driving forces to a round blending tube, shown
as 5622, located inside vessel 5624. Preferably, the drivers can be
controlled to drive the tube 5622 at a suitable constant and
variable speed. The tube 5622 engages with four drive wheels, all
shown as 5626 for clarity, and tube 5622 is supported thereon, but
otherwise is free from contact with other components except for
suitable contact with seals as may be required at each end of the
tube 5622. Preferably, drive wheels 5626, are engaged to the
corresponding drivers 5614, 5616, 5618 and 5620. In this way, the
tube 5622 is retained by the drive wheels, 5626, in a horizontally
disposed position or as may be otherwise required. Preferably,
pressure vessel 5624 is fitted with vent 5628 which can be provided
with a valve (not shown) to allow any excess liquids or gases to be
drained therefrom. A vent with valve and venturi, 5632, can be
fitted to vessel 5624. Preferably, any desired number of vents with
valves and venturis can be fitted to the vessel 5624. Preferably,
venturis can be arranged to provide gas injection into space 5636
in such a manner that will cause the injected gas to flow along
space 5636 and then through tube 5622, in a desired direction at a
suitable velocity.
[0729] The tube 5622 is arranged inside the vessel 5624 and
passageway 5636 is thereby provided between the outer surface of
the tube 5622 and the inner surface of vessel 5624. Gas can
therefore be provided inside the pressure vessel and in the
passageway 5624. Preferably, any suitable gas temperature
controller may be arranged such as by arranging a heat exchanger
5638 connected to the vessel 5624 as shown. Preferably, a first and
second suitably sized tubes, 5640 and 5642 are attached in direct
communication with vessel 5624 such that gas can pass between the
tubes and the vessel 5624. Preferably, tube 5640 is connected to
the heat exchanger 5638 and another connecting tube 5644 is
attached to a gas blower 5646 which in turn is connected to the
connecting tube 5642. In this way gas can pass through tube 5640,
into and through the heat exchanger 5638, through tube 5644, into
and through the gas blower 5646, and through connecting tube 5642.
Preferably, a barrier 5648 is located in space 5636 which can
follow the outer circumference of tube 5622 so as to substantially
inhibit gas passing therethrough. In this way, when gas blower 5646
is activated, gas can be drawn in from space 5636 on one side of
barrier 5648, through tube 5640 and passed through tube 5642 and
back into space 5636 on the opposite side of the barrier 5648.
Preferably, this provides recirculation of any suitable gas along
the space 5636, through tube 5622, back into space 5636 and again
through the heat exchanger 5638. The gas can be re-circulated and
repeatedly passed through heat exchanger, 5638, to maintain the gas
at a desired temperature. A tube shown as 5650 is provided to allow
suitable gas to be injected into the heat exchanger 5638.
Preferably, the suitable gas can be provided in a liquid or high
pressure condition and allowed to expand in the heat exchanger
5638, and thereby cause a lowering of temperature. Suitable gas can
then pass from heat exchanger 5638 and into tube shown as 5652
which is connected to tube 5644. Alternatively, suitable gas can be
allowed to escape through tube 5654 and valve 5656. In this way, by
controlling the flow of gas, the internal temperature of vessel
5624 and all other items therein can be controlled. During the
re-circulation of gas through tube 5622 and heat exchanger 5638, a
quantity of water, contained in the grinds, may evaporate and
condense in heat exchanger 5638. The quantity of condensed water in
the heat exchanger may be processed, sterilized and carbonized, by
dissolving carbon dioxide therein and then injected into the grinds
through vent tube 5658. Preferably, tubes 5652 may be provided with
pressure regulators and valves to allow excess gas to escape
therethrough, from vessel 5624 at a suitable rate and in such a
manner as to maintain the temperature of the gas within a
temperature range of plus or minus about 0.5 degrees F., or at any
other suitable temperature range. Preferably, the suitable gas
and/or any other suitable substances can be provided in vessel 5624
at any suitable gas pressure to facilitate dissolving of the gas
and/or substances into the ground meats contained in the tube 5622.
In this way, the suitable gas can be controlled to either chill or
heat the ground meats being processed in tube 5622, and by the
apparatus.
[0730] Referring now to end enclosure 5602 with a plurality of
apertures. Cover 5660 is located over an inspection access hole so
as to provide a convenient access into the apparatus for any
purpose such as for cleaning. Preferably, a vent 5662 is provided
to allow excess gas to escape. Preferably, vent 5662 can be
attached to suitable valves with gas pressure regulators as may be
required to control gas pressure. A tube 5664 is located through a
tube in the wall of end enclosure 5602. Preferably, tube 5664
connects to a nozzle 5666, that can be arranged to provide
temperature controlled water or other liquids, at any suitable
pressure into the inner space contained within tube 5622.
Preferably, the water or other liquids can be used to clean the
internal surfaces of the apparatus after use of the apparatus.
Bearings such as bearing shown as 5668 are also located in the end
enclosure 5602.
[0731] Referring now to end enclosure 5604, several openings are
shown therein with other apparatus attached thereto. Preferably,
three variable speed drive motors, 5614, 5616 and 5618 are fixed to
the end enclosure 5604 and each motor is attached to corresponding
shafts shown as 5670, 5672 and 5674. A subassembly 5601 is mounted
to end enclosure 5604 in a desired position and can pass ground
beef into the tube 5622 directly from a grinding apparatus without
contacting atmospheric air. Preferably, all shafts, tubes,
components and assemblies attached to end enclosures are sealed in
a suitable and desired gas tight manner, thereby retaining any gas
that may be contained within vessel 5624, at any suitable
pressure.
[0732] Referring again to FIG. 187, three separate augers (two
shown), depicted as 5678, 5680 and 5682 are preferably mounted in
close proximity to each other and with a member 5682 arranged above
auger shown as 5676 separating it from augers 5678 and 5680.
Preferably, augers 5676, 5678 and 5680 can be arranged in a
horizontally disposed and parallel position. Auger 5676 is attached
to drive motor 5614, auger 5678 is attached to drive motor 5616 and
auger 5680 is attached to drive motor 5618. The end sections of
each auger 5676, 5678 and 5674 are arranged with shafts and each
shaft end mates with bearings located in end enclosures 5602 and
5604. Drive motors 5614, 5616 and 5618 are arranged to drive the
corresponding augers at variable rotating speeds in any chosen
direction, either clockwise or counterclockwise, as may be selected
according to any desired direction and at any suitable speed that
will enable optimized mixing of the ground meats processed in tube
5622. Alternatively one or any number of augers may be located in
tube 5622 to provide the most optimized mixing therein.
[0733] Referring again to FIG. 187, sub-assembly 5601 is attached
to end enclosure 5604 and can be operated to grind beef and inject
the ground beef directly into tube 5622. In this way, ground meat
can be continuously provided into tube 5622, at any suitable rate
within the capacity of the apparatus. Referring now to FIG. 190,
the ground beef that flows into tube 5622 can be arranged to fall
directly onto but centrally and between the center lines of augers
5678 and 5680. Preferably, augers 5678 and 5680 can be arranged to
rotate in opposite directions. Direction of rotation of auger 5678
can be in a clock-wise direction and auger 5680 can be rotated in a
counter clockwise direction. In this way, the ground beef can be
carried by augers 5678 and 5680 toward end enclosure 5604 and away
from end enclosure 5604. Member 5682 is arranged to allow
containment of the ground beef between its upper faces and augers
5678 and 5680 for a brief period such that as augers rotate the
ground beef is carried toward the end enclosure 5604. As augers
5678 and 5680 rotate the ground beef will then drop and contact
tube 5622. Preferably, tube 5622 can be arranged to rotate at a
suitable speed, of between about 100 rpm or less and about 500 rpm
or more, such that centrifugal force will hold the ground beef
against the internal surface of tube 5622. When tube 5622 has
rotated by approximately one half of one revolution and the ground
beef is carried to an upper location and above augers 5678 and
5680, a scraper 5625 can be provided to remove the ground beef from
contact with tube 5622. The scraper 5625 can be arranged to cause
the ground beef to be directed back onto augers 5678 and 5680.
Auger 5676 can be driven in a direction that will carry any ground
beef, that it contacts, toward the end enclosure 5602. Preferably,
the rotating speed of each auger can be adjusted as required.
Preferably, auger 5676 can be arranged to have an extended length,
that is longer than 5678 and 5680 such that 5676 extension extends
beyond 5678 and 5680 and into a tubular section, shown as 5722,
with an internal diameter slightly larger than the external
diameter of auger 5676. As shown in FIG. 187, auger 5676 can then
be arranged to carry ground beef from within tube 5622 and through
tubular section 7522 at a desired rate. In this way the ground beef
will be carried toward end 5602 by augers 5678 and 5680 and toward
end 5604 by 5676. The rotation of tube 5622 and its interaction
with the scraper 5625 will then provide further mixing fat and
muscle content of the ground beef. By independently adjusting the
rotating speed of augers 5676, 5678 and 5680 and also tube 5622,
the period of time that the ground beef is retained within the tube
5622 can be controlled to an optimized period of time and thereby
allow an efficient method of blending. Preferably, after a suitable
period of retention, the ground beef will be transferred through
tube 5642 and will then fall downwardly into tube 5724. Tube 5724
can be located directly above and connected to a suitable vane pump
shown as 5726, which may include any suitable vane pump
manufactured by Weiler & Company, Inc. Preferably, the ground
beef can be pumped at a known and controlled velocity by vane pump
5726 into tube 5728 which is connected directly thereto. Tube 5728
can be connected to another measuring device 5730. In this way,
ground beef can be ground and injected into tube 5622, by
sub-assembly 5601, and after passing through a first measuring
device 5730, blended by augers before pumping through a second
measuring device 5730 located between tubes shown as 5728 and 5732.
Ground beef can be conditioned and blended at a production rate
limited only by the chosen size and capacity of the ground beef
conditioning and blending apparatus, which may be varied in size
and capacity as required.
[0734] The conditioned and blended ground beef can thus be pumped
through tube 5732 at a desired and controlled temperature with a
quantity of suitable gas such as carbon dioxide, dissolved in the
ground beef to any desired level of saturation. Vane pump 5726 can
be provided with a variable speed drive motor and arranged to pump
ground beef at a controlled velocity into other apparatus for
subsequent blending with other ground beef or chosen material
and/or further processing.
[0735] In a preferred embodiment the conditioned ground beef may be
exposed to a suitable beam of electrons by locating an electron
beam generator and accelerator such as may be manufactured by
Titan-Scan Systems of 3033 Science Park Road, San Diego, Calif.
92121. Preferably, the electron beam generator may be located in
such a manner that the suitable beam of electrons produced there
with, is directed directly at and through a stream of grinds while
the grinds are passing through a tube such as tube 5754 shown in
FIG. 191. The cross-sectional profile of the tube may be arranged
to provide maximum exposure to the electron beam. In this way the
conditioned ground beef can be sterilized at any temperature while
maintaining a fresh and uncooked condition. Preferably, electron
beam sterilization is used on fresh ground beef which is in a low
oxygen environment to prevent over-oxidation. In an alternative
embodiment the stream of conditioned ground beef can be exposed to
irradiation from a source of gamma rays.
[0736] Referring again to FIG. 191, a section of assembled tubes is
detailed. The section of tubes includes a first tube 5744, a second
tube 5746 and a third tube 5748 which are all joined at a
confluence, 5750, to a fourth tube 5754. The tubes and particularly
the confluence may be manufactured from any suitable plastics or
stainless steel materials and machined so as to ensure that any
processed materials passing therethrough, will not be subject to
significant turbulence until after passing through the confluence
5750. Preferably, any number of two or more tubes joined, at a
confluence, to a single tube 5754, may be arranged to produce
processed materials as may be desired. In a preferred
configuration, a first processing machine (not shown), is arranged
to deliver the processed material via tube 5744, a second
processing machine (not shown), is arranged to deliver the
processed material via tube 5746 and a third processing machine
(not shown) is arranged to deliver the processed material via tube
5748. Preferably, the fat content of each stream of ground beef can
be measured, by any suitable measuring device such as that shown as
5730 in FIG. 195, and the fat content will therefore be known.
Preferably, the velocity of each stream of material can be adjusted
by adjusting the speed of separate vane pumps arranged in such a
manner so as to provide for velocity adjustment. By adjusting the
velocity of each stream of processed material corresponding to the
measured fat content contained therein, delivered quantities of the
processed material, can be adjusted such that when any two or more
streams are combined together, the resultant fat content of the
combined stream will be substantially constant and as required. In
this way, the known fat content of the combined stream of processed
material can be maintained to within a narrow range of variation.
The variation may be within a range of not more than +/-1% of the
fat content of any item such as Item 1F.
[0737] Referring now to FIG. 192, a preferred embodiment including
a group of three blending tubes 5756, 5758 and 5760 is shown, each
tube being similar in operation to tube 5622 shown in FIG. 187.
Preferably, the group of three blending tubes are each assembled
with an auger similar to as described above in association with the
tube 5622 and auger 5676, 5678 and 5680. Rollers 5762, 5764 and
5766 are arranged to engage and retain the blending tubes as shown.
A pressure vessel 5768, is arranged to accommodate the group of
three blending tube assemblies such that drive wheels 5770 are
engaged there with and as shown and can be activated as required so
as to rotate the blending tubes. Ground beef can be provided into
each blending tube by similar apparatus to that disclosed above
with subassemblies 5601 of FIG. 188. In this way, three grades of
ground beef can be processed simultaneously in three continuous
streams. Each of the continuous streams of conditioned ground beef
can be further processed if desired.
[0738] In a preferred embodiment, a plurality of processing
machines are arranged to process material such as fine ground (or
coarse ground) meat, such as beef grinds. Each of the processing
machines may be similar to the apparatus shown in FIG. 187. A total
of three processing machines can include a first machine, a second
machine, and a third machine, and can be arranged so that each
processing machine can process a separate quantity of boneless
beef. The first machine, may process a quantity of Item 1, the
second machine, may process a quantity of Item 2 and the third
machine, may process a quantity of Item 3. The first, second and
third machines will therefore produce first, second and third
streams of ground beef (processed material) that, after processing,
will be pumped, by separate vane pumps (for delivery as required),
along tubes shown as 5732 in FIG. 187.
[0739] Preferably, any number of one or more processing machines
may be arranged so to provide any number of streams of processed
material. Preferably, the streams of processed material may be
combined and joined together in any chosen configuration, to
produce one or more subsequent streams of processed material.
Preferably, the velocity of each stream of material may be
adjusted, so as to deliver a known and corresponding quantity of
processed materials with any desired fat content as required.
Preferably, the fat content and muscle content, of each stream of
processed material can be continuously measured, as described
herein, or in any other suitable manner. One or more streams of
processed materials may be combined to produce a single stream of
processed material. By adjusting the velocity and consequent
delivered quantity of each stream of material (before combining
together into a resultant single stream) any quantity of any
processed material, such as Item 1F can be produced to a
substantially constant and precise specification. The combined
stream of processed materials may be further processed through a
grinder and/or through processing machines such as that shown in
FIG. 187. Additionally, the streams of processed materials may be
directed through a tube that is exposed to sterilization such as by
exposure to gamma irradiation, or any other suitable sterilizer
while contained within the tube.
[0740] Subsequent to processing, the beef grinds or processed
material can be retail or bulk packaged in any suitable manner,
such as a substantially oxygen free modified atmosphere master
package.
[0741] The packaging may be arranged to accommodate a variation in
total volume of the package such as an expansion or contraction in
volume. The package volume variation may occur as the temperature
variation of the packaged processed material. The volume variation
may correspond to the temperature variation as a result of any
gases dissolved in the processed materials "boiling off" or again
dissolving in direct relationship to the temperature variation.
Accommodation of the variation in package volume may be achieved by
provision of a suitably sized, flexible, substantially gas barrier
package.
[0742] Referring again to end enclosures 5602 and 5604 shown in
FIG. 187, suitably located apertures shown as 5736, are provided
therein so as to allow free movement of gas therethrough. The
velocity of the gas can then be controlled by blower 5648 and along
a path through tube 5622, into the spaces shown as 5738 and back
through space 5636. Preferably, the velocity and temperature and
pressure of the gas can then arranged at the most effective
settings to control the temperature of the ground beef and the rate
of gas dissolving therein.
[0743] Referring now to FIG. 194 and particularly, end enclosure
5604, a member shown as 5738 is arranged to mate with member 5604
at a close contacting face shown as 5740. Members 5604 and 5738 are
in contact at interface 5740, and fixed relative to each other but
not locked together. Member 5738 can move relative to 5604 but is
retained by interface 5740 and shafts shown as 5670 and 5674 (and
5672, which is not shown). Suitable bearing surfaces are provided
between 5738 and 5604 and also between 5738 and 5676, 5678 and
5680. Sub assembly 5601 is arranged so as to be removable for
cleaning purposes and plugs may be inserted into the connecting
apertures created by removing sub-assembly 5601. When 5601 is
removed and replaced with the plugs, member 5738 can be moved away
from tube 5622 by sliding along shafts 5676, 5678 and 5680 so as to
provide a space between member 5738 and the end rim of tube 5622.
Preferably, such an arrangement may be installed at either or both
end enclosures of the apparatus in such a manner so as to
facilitate effective cleaning of apparatus after use. Other
cleaning features may be incorporated into the apparatus.
Preferably, pressurized and heated water may be provided inside the
apparatus with suitable sanitizing detergents in such a manner so
as to facilitate an automatic cleaning when augers 5676, 5678 and
5680 and tube 5622 are all rotated in common or opposing directions
and at suitable speeds. Alternatively or additionally high pressure
steam may be provided inside the apparatus to facilitate
sterilization and thorough cleaning of the internal surfaces of the
apparatus. Draining/venting tubes such as 5742 can be provided with
valves, at any suitable and convenient location on the
apparatus.
Lean Muscle and Fat Measuring Apparatus
[0744] A lean tissue and fat analyzer is an optional feature of the
meat processing system. Referring now to FIG. 189, a cross
sectional view of the conduit of FIG. 188 is shown as a square or
rectangular tube 5730. Preferably, tube 5730 and tube 5702 are
similar. Tube 5730 can be manufactured from any suitable material
which includes plastics as well. Preferably, two electrodes, shown
as 5710 and 5712 are located on opposing internal sides of tube
5730 and attached to terminals. Electrode 5710 is attached to
terminal 5714 and electrode 5712 is attached to terminal 5716. An
electrical current can be arranged to flow through terminals 5714
and 5716 and into electrodes 5710 and 5712. Ground beef (ground
meat) is shown as 5715 and in this way, will directly contact the
electrodes as it passes through tube 5730. The electrical current
can therefore pass through ground beef from electrode 5712 and to
electrode 5710. Electrical current will be affected by the
resistance of the ground beef and this resistance will vary
according to the ratio of fat and muscle content of the ground beef
and therefore the electrical resistance can be measured. The
variation in electrical resistance can be measured and such
measurements can be converted and used to determine the ratio of
fat and muscle contained in the ground beef in a continuous
process. Tube 5730 with terminals and electrodes together include a
measuring device shown as 5718. Preferably, the measuring device
may be installed, and used to measure the ground beef fat and
muscle content ratio, at any convenient location as may be
required.
Meat Grinder Sub-Assembly
[0745] A meat grinder sub-assembly is an optional feature of the
meat processing system. Several embodiment of a meat grinder have
been previously described. However, a meat grinder preferably for
use with the processing machine follows.
[0746] Referring now to FIG. 193, a meat grinder sub-assembly
according to the present invention is shown. The sub-assembly
includes a pressure vessel 5684, with an entry port 5686 at an
upper location and an exit port 5688 at a lower location. A
horizontally disposed and tapered auger 5690 is located in a lower
portion of vessel 5684 and arranged with a shaft 5692 that can be
attached directly to a suitable variable speed driver. Preferably,
the tapered auger is suitably profiled and is fitted with
passageways therein to allow any suitable gas to be injected
therethrough. A meat grinding apparatus is attached directly to the
entry port 5686 and can be disconnected therefrom to provide access
for cleaning as required. Boneless meat portions can be processed
by grinder 5694 to produce grinds which are then transferred
directly into vessel 5684 in a continuous stream. Preferably, the
cross-sectional profile of vessel 5684 is circular and a valve
member 5696 is arranged to mate with a valve seat 5698, which is
located between the entry port 5686 and the auger 5690, to provide
a gas tight seal when required. Valve member 5696 can be opened and
closed by valve stem 5697 as required and arranged to automatically
close as required for any reason. Ground beef that is transferred
into vessel 5684 can contact auger 5690. Preferably, any suitable
gas at any suitable pressure can be injected into vessel 5684
through ports 5700 and/or 5702. Each port such as 5702 and 5700 is
fitted with suitable valve and pressure regulator. As desired, gas
can be injected into a port such as port 5702 and allowed to exit
through a port such as 5700. Pressure regulators maintain a desired
gas at any suitable pressure in the vessel 5684. In this way, the
continuous stream of ground beef can be transferred through the
vessel 5684 by auger 5690 at a desired rate and pressure. As the
ground beef is transferred through vessel 5684 by tapered auger
5690, the ground beef is compressed and extruded through a
restriction as shown, so as to exclude gas and produce a
substantially continuous flow of ground beef without gas bubbles
contained therein. In this way the compressed ground beef can
provide an effective gas tight sealing between vessel 5684 and
vessel 5624 of FIG. 187. The continuous flow of ground beef is
passed through a tube section 5702 at a desired and controlled
rate. After passing through tube 5702 the ground beef passes
through the exit port 5688 and can be directed into any suitable
container such as tube 5622 shown in FIG. 187. If desired, a
secondary grinder may be interposed between the vessel 5684 and a
valve 5706. Valve 5706 is provided at the exit port 5688 and can be
arranged with an automatic actuator to open and close at a remote
distance as may be required for any reason. When in a closed
position valve 5706 can seal the exit port 5688 in a gas tight
manner. As the ground beef passes through tube section 5702, the
fat and muscle content of the ground beef can be measured. The
measuring device may include the passing of an electric current
through the ground meat as it passes through the section 5702.
Preferably, the electrical resistance is measured and a muscle and
fat concentration can be obtained.
Meat Pre-Conditioning System
[0747] Referring now to FIGS. 196-197, a plan view and a side
elevation view of an apparatus designed to slice meat while
conditioning in an oxygen free environment is shown. The apparatus
is shown in diagrammatic form and includes a continuous conveyor
5100, with a driver mounted to a rigid frame (not shown) and
horizontally disposed to allow horizontal motion in a machine
direction in intermittent or continuous movement. The conveyor is
fitted with two corresponding and vertically opposed pairs of
pressure chambers includes an upper chamber 5102 with a
corresponding lower chamber 5104 and another upper chamber 5106
with a corresponding lower chamber 5108. An enclosed gassing tunnel
5118 is arranged to enclose the upper section of the conveyor 5100
with a gassing port 5112 affixed thereto to provide any suitable
gas, such as nitrogen gas or carbon dioxide, into the tunnel
5118.
[0748] Referring now to upper chamber 5102 and corresponding lower
chamber 5104 the opposing chambers are arranged so as to open and
close. Upper chamber 5102 is mounted to a driver (not shown) to
provide elevating, lowering and clamping apparatus. Lower chamber
5104 is also mounted to a separate driver (not shown) to provide
elevating, lowering and clamping. Chambers 5102 and 5104 can be
closed together by moving in opposing directions so as to contact
each other along a path around the perimeter of openings. In this
way a single chamber is so arranged in a manner that is airtight
and sealed from external atmosphere. An evacuation port 5114 and a
gas port 5116 are provided so as to allow evacuation and gas
flushing of the closed chamber. As shown in FIG. 196 two separate
pressure chamber assemblies are arranged such that conveyor 5100
passes through both chamber assemblies. Trays with sliced beef or
other meat primal, placed therein, are located into carrier plates
in conveyor 5100. The primals are sliced in a suitable manner and
can then be opened so as to expose the multiple surfaces of the
slices immediately prior to entry into enclosed tunnel 5118.
Enclosed tunnel 5118 is arranged so as to substantially exclude
atmospheric oxygen gas by flushing other suitable gases therein.
The trays with sliced primal 5122 are located in carrier plates and
progressively move through enclosed tunnel 5118 until each tray
with primal is located directly between an upper chamber 5102 and
lower chamber 5104. The upper and lower chambers close together and
around the sliced primal 5122 in an airtight and sealed manner.
Substantially all air is evacuated from the chambers and a suitable
gas, including carbon dioxide, is injected through port 5116. The
suitable gas pressure can be increased to any suitable pressure as
desired. The primal 5122 can be retained in the pressure chambers
for a desirable period of time so as to cause sufficient carbon
dioxide gas to dissolve in the oils and water contained in the
primal 5122. After the primal 5122 has been exposed to the high
pressure carbon dioxide gas for a suitable period of time, the
pressure chambers open and allow conveyor 5100 to carry sliced
primal 5122 in tray, forward in machine direction and through the
enclosed tunnel 5118. A second pressure chamber assembly may also
be closed around the sliced primal 5122 in tray. Any suitable gas
at any suitable pressure can be provided in the second enclosed
chamber. Second chamber includes an evacuation port 5115 and a
gassing port 5117. The sliced primal 5122 in tray is intermittently
carried through the tunnel 5118 until it emerges at the exit end of
the tunnel.
[0749] In this way, rapid formation of oxymyoglobin is inhibited
when the primal 5122 is exposed to ambient atmosphere.
Plant Layout
[0750] Having described meat grinding systems and ancillary
equipment, it is appropriate to describe the integration of
equipment to form a whole production facility for processing and
packaging meats.
[0751] Referring now to FIG. 198, a plan view of a preferred
production plant layout is shown, including ground meat processing,
blending equipment and retail packaging plant. The equipment shown
in FIG. 198 is represented by diagrammatic sketches and is
integrated such that ground beef processed by the equipment shown
can be transferred directly from grinders 6400, 6402 and 6404 into
oxygen free vessels shown as 6408, 6410 and 6412, respectively.
[0752] The chart set out below provides a list of equipment shown
in FIG. 198. TABLE-US-00004 ID Item 6400 Grinder 6402 Grinder 6404
Grinder 6406 Grinder (Fine) 6408 Vessel + Mix 6410 Vessel + Mix
6412 Vessel + Mix 6414 Vessel/Hopper 6416 Vessel/Hopper 6418
Vessel/Hopper 6420 Positive displ. pump 6422 Positive displ. pump
6424 Positive displ. pump 6426 Positive displ. pump 6428 Measure
fat/lean 6430 Measure fat/lean 6432 Measure fat/lean 6434
Continuous blending 6436 Control Panel 6438 Valve (diversion) 6440
Elevator 6442 Elevator 6444 Discharge Ports 6446 Discharge Ports
6448 Discharge Port 6450 Magazine 6452 Gas Exchange 6454 Tray
Welding 6456 Grinds Portioning machine 6458 RT 1800 Packaging
Machine 6460 Horizontal Vacuum
[0753] Boneless beef with a suitable fat/lean composition is loaded
into grinders 6400, 6402, 6404. Ground beef is produced by grinders
6400, 6402 and 6404 and transferred directly into enclosed vessels
6408, 6410 and 6412 that are otherwise filled with a suitable gas
at a suitable pressure.
[0754] Vessels 6408, 6410 and 6412 can be fitted with blending
apparatus so as to blend grinds therein. Positive displacement
pumps 6420, 6422 and 6424 pump quantities of grinds, in three
respectively separate streams from vessels 6408, 6410 and 6412
directly into continuous blender CB. The quantity of grinds pumped
by the positive displacement pumps in the separate streams is
controlled and dictated by the measured fat and lean content of
each stream of grinds. Fat and lean content of each stream of
grinds is measured by measuring devices shown as 6428, 6430 and
6432. Continuous blender 6434 terminates at positive displacement
pump 6424 and blended grinds are transferred directly from 6434
into 6424. Pump 6424 can transfer the blended grinds in a single
continuous stream into either vessel 6418 or vessel 6416.
[0755] Grinds can be stored in vessels 6416 and 6418 as may be
required. The grinding, pumping, measuring and blending apparatus
can be arranged so as to produce a single stream of grinds by
combining three separate streams into a single stream in continuous
blender 6434. The single continuous stream of blended grinds can be
produced according to a specification such as 85% lean and 15% fat.
Alternatively, single stream of blended grinds can be produced
according to any other desired specification such as 90% lean and
10% fat. In this way two separate quantities of specified grinds
can be stored with one in each of vessels 6416 and 6418. For
example, a quantity of 85% lean and 15% fat grinds can be stored in
vessel 6416 and a quantity of 90% lean and 10% fat grinds can be
stored in vessel 6416. Suitable positive displacement pumps can be
arranged to transfer specified quantities of grinds from either or
both vessels 6416 and 6418 for separate or combined grinding in a
grinder such as is shown as 6406 is FIG. 198. Any suitable number
of pumps can be arranged to transfer grinds from either of the
vessels 6416 and 6418 for further blending and/or grinding and
subsequent retail packaging in packaging machine shown as 6458. If
required suitable blending equipment can be provided for blending
of any suitable number of additional pairs of streams of grinds, in
selected quantities, after pumping from vessels 6416 and 6418 to
produce specified quantities of blended grinds that can then be
fine ground prior to retail packaging.
[0756] In this way, ground meat can be processed and packaged while
being contained within a series of vessels and tubes that are
filled with ground meat and suitable gas that substantially
excludes oxygen and any other undesirable gas and/or material.
Therefore, formation of oxymyoglobin on substantially all freshly
cut meat surfaces can be inhibited until after packaging and
immediately prior to retail display or other desired use.
[0757] Referring now to FIG. 199, a plan view of another preferred
production plant layout is detailed including production and
packaging equipment.
[0758] A preferred layout includes items of equipment in the table
below and identified by a reference numeral. TABLE-US-00005 TABLE 3
Item # Production Equipment Packaging equipment 5900 Grinding
machine 5960 Chub/vacuum packaging machine 5902 Grinding machine
5930, Ground beef 5932, portioning machines 5934 5904 Grinding
machine 5940, Over wrapping 5938, packaging 5936 machines 5906
Ground beef processing machine 5954, Foam tray 5956, erecting
machines 5958 5908 Ground beef processing machine 5924, Conveyor
belts 5926, 5928 5910 Ground beef processing machine 5922 Ground
beef processing machine 5942 Gas blower with heat exchanger. 5912
Ground beef Injector 5914 Ground beef Injector 5916 Ground beef
Injector 5944 Ground beef Injector 5946 Vane pump 5948 Vane pump
5950 Vane pump 5952 Vane pump 5918 Multi-tube combining die 5920
Electron beam sterilizer and/or grinder
[0759] Preferably, the equipment shown in FIG. 199, and listed
above, is arranged to continuously produce and retail package, case
ready ground meats. Quantities of specified boneless beef raw
materials are processed by grinding machines 5900, 5902 and 5904 to
produce grinds that are transferred directly into ground beef
processing machines 5906, 5908 and 5910 via corresponding injector
machines 5912, 5914 and 5916. Each grinder processes a quantity of
specified boneless beef raw materials each of which may be selected
from the following table of raw materials Item 1 through Item 5.
TABLE-US-00006 TABLE 4 Muscle Fat Item Tissue Tissue 1 93% 7% 2 90%
10% 3 75% 25% 4 65% 35% 5 50% 50%
[0760] Equipment shown as vessels 5906, 5908 and 5910 is arranged
to process grinds as above described apparatus shown in FIG. 187.
Grinds are injected into vessels from the grinders 5900, 5902 and
5904 by injectors 5912, 5914 and 5916 which are arranged to operate
as the above described apparatus shown in FIG. 193. Conditioned
grinds are transferred in a single continuous stream from each
vessel, by a pump from vessels into transfer tubes which are then
combined at confluence 5918 into a single tube. Confluence 5918
includes a manifold generally as the above described apparatus
shown in FIG. 191.
[0761] Preferably, the fat content of the continuous streams of
grinds is continuously measured by measuring devices as the above
described apparatus shown in FIG. 194. Preferably, the fat content
of the grinds can be continuously measured before injection into
the vessels and immediately after transfer from the vessels and
into the transfer tubes. Preferably by measuring the fat content
and automatically adjusting the flow rate of each stream of grinds,
directly and according to the measured fat content, prior to
combining the streams of grinds, a combined stream of grinds with
consistent fat content can be produced. The combined stream is then
transferred via a tube into a single grinder shown as 5920. An
electron beam generator of suitable capacity may be integrated such
that the combined stream of grinds passes therethrough prior to
injection directly into vessel 5922. Vessel 5922 may be arranged to
process grinds as the above described apparatus shown in FIG. 187.
A single stream of conditioned grinds is then transferred into a
single tube that is divided into four separate streams of
grinds.
[0762] Still referring to FIG. 199, the preferred plant layout
includes four packaging systems and a single supply stream of
grinds is transferred to each of the packaging systems. Preferably,
one stream to "chub/vacuum" packaging machine. Preferably,
apparatus constructed according to the present invention includes
three packaging machines 5924, 5926, and 5928, and a single stream
of grinds to each of three portioning machines, shown as 5930,
5932, and 5934, respectively. Portions of grinds are then retail
packaged by automatic loading into trays which are then over
wrapped by packaging machines shown as 5936, 5938, and 5940. While,
an embodiment has been described and shown to include three
processing trains, any suitable number of processing trains may be
used in accordance with the present invention, which may include
more or less than the three trains herein described.
[0763] The equipment as described herein may be arranged to
automatically produce any quantities of coarse or fine grinds
according to any specifications. The following table shows the
specified muscle and fat tissue content of three types of fine beef
grinds. TABLE-US-00007 TABLE 5 Muscle Fat Item Tissue Tissue 1F 90%
10% 2F 75% 25% 3F 65% 35%
[0764] Equipment as described herein may be arranged to grind,
measure, condition, blend, process and package specified portions
of grinds according to any suitable size by automatically computer
controller. The computer controller may continuously provide
production information including such data as the total fat and
muscle tissue content of each and all streams of grinds during the
processing. In this way, a method to improve efficiency and reduce
total losses is provided by producing grinds to meet precise
specifications according to, for example, the list of fine beef
grinds shown above.
Plant Layout
[0765] Referring now to FIGS. 200 and 201, another preferred
production plant layout including ground meat processing and
blending equipment and a preferred CAP retail packaging plant
layout including packaging equipment is shown. The equipment shown
in FIG. 200-201 is integrated such that ground beef processed by
equipment shown in FIG. 200 is packaged in packaging that is
processed by equipment shown in FIG. 201. The present invention
provides for a method of grinding meats directly into an oxygen
free vessel or hopper and then blend and process the ground meat as
described herein. The present invention also provides a method of
saturating the liquids, water and oils in the ground meats with a
suitable gas or substance such as carbon dioxide, provided at a
suitable pressure, to such a level that when removed from the
processing equipment the ground meat will emit a suitable gas such
as carbon dioxide.
[0766] Items of equipment shown in FIG. 200-201 that are identified
by letters and/or numbers are listed in the following table set out
below: TABLE-US-00008 Item # Production Equipment Packaging
equipment 6006 Conveyor (with variable speed 6122 Magazine control)
6008 Conveyor (with variable speed 6124 Magazine control) 6010
Conveyor (with variable speed 6126 Magazine control) 6018 Conveyor
(with variable speed 6128 Tray material control) evacuation &
gassing 6020 Conveyor (with variable speed 6130 Tray material
control) evacuation & gassing 6022 Conveyor (with variable
speed 6132 Tray material control) evacuation & gassing 6034
Conveyor (with variable speed 6134 Tray flap erection &
control) welding 6036 Conveyor (with variable speed 6136 Tray flap
erection & control) welding 6030 Ultra violet sterilization
6138 Tray flap erection & equipment welding 6032 Ultra violet
sterilization 6140 Conveyor equipment 6038 Grinding machine 6142
Conveyor 6040 Grinding machine 6144 Conveyor 6100 Grinding machine
6116 Ground beef portioning machine 6104 Grinding machine 6118
Ground beef portioning machine 6108 Grinding machine 6120 Ground
beef portioning machine 6046 Tube connection 6146 Conveyor 6050
Tube connection 6148 Conveyor 6048 Ground beef hopper 6150 Conveyor
6052 Ground beef hopper 6000 Over wrapping packaging machines 6058
Ground beef hopper 6002 Over wrapping packaging machines 6064
Ground beef hopper 6004 Over wrapping packaging machines 6056
Statiflo blender 6062 Statiflo blender 6090 Statiflo blender 6092
Statiflo blender 6094 Statiflo blender 6096 Gas injection ports.
6054 Positive displacement pump 6060 Positive displacement pump
6066 Positive displacement pump 6068 Positive displacement pump
6070 Positive displacement pump 6072 Positive displacement pump
6074 Positive displacement pump 6076 Positive displacement pump
6078 Epsilon GMS-40 6084 Epsilon GMS-40 6080 Epsilon GMS-40 6086
Epsilon GMS-40 6082 Epsilon GMS-40 6088 Epsilon GMS-40 Electron
beam sterilizer and/or grinder
[0767] The equipment shown in FIG. 200-201 is listed above and is
arranged to automatically and continuously produce selected grades
of retail packaged, case ready ground meats. The ground meats may
include quantities of muscle and fat tissues such as shown in the
following chart, where item 1F includes ground meat with about 90%
muscle tissue and about 10% fat tissue, with a muscle to fat tissue
variation within about +/-0.2%. The packaging equipment shown in
FIG. 201 can be arranged so that the packaging machine 6000 will
produce CAP case ready packages containing ground meats according
to a specification equivalent to item 1F. Similarly, packaging
machine 6002 can produce CAP case ready packages containing ground
meats according to a specification equivalent to item 2F and
packaging machine 6004 can produce CAP case ready packages
containing ground meats according to a specification equivalent to
item 3F in TABLE 7. TABLE-US-00009 TABLE 7 Muscle Fat Muscle/Fat
Item Tissue Tissue Tissue Variation 1F 90% 10% +/-0.2% muscle
content 2F 85% 15% +/-0.2% muscle content 3F 80% 20% +/-0.2% muscle
content
[0768] Referring again to FIG. 200, variable speed conveyors 6006,
6008 and 6010 are preferably arranged in close and parallel
proximity such that each conveyor can carry specified quantities of
selected boneless beef. In this way conveyor 6006 can be arranged
to carry specified quantities of raw material, which may be
boneless beef selected from the chart shown below, in a direction
indicated by arrow 6012, conveyor 6008 can be arranged to carry
specified quantities of selected boneless beef in a direction
indicated by arrow 6014 and conveyor 6010 can be arranged to carry
specified quantities of selected boneless beef in a direction
indicated by arrow 6016. The specified quantities of selected
boneless beef can be varied between the conveyors marked 6006, 6008
and 6010 such that 6006 carries selected boneless beef shown as 2X,
in TABLE 8, conveyor 6008 carries selected boneless beef shown as
3X and conveyor 6010 also carries the selected boneless beef shown
as 3X.
[0769] Preferably, variable speed conveyors 6018, 6020 and 6022 are
arranged in close and parallel proximity such that each conveyor
can carry specified quantities of selected boneless beef. In this
way conveyor 6018 can be arranged to carry specified quantities of
raw material, which may be boneless beef selected from TABLE 8, in
a direction indicated by arrow 6024, conveyor 6020 can be arranged
to carry specified quantities of selected boneless beef in a
direction indicated by arrow 6026 and conveyor 6022 can be arranged
to carry specified quantities of selected boneless beef in a
direction indicated by arrow 6028. The specified quantities of
selected boneless beef can be varied between the conveyors marked
6018, 6020 and 6022 such that conveyor 6018 carries boneless beef
shown as 1X in TABLE 8, conveyor 6020 carries boneless beef also
shown as 1X and conveyor 6022 carries boneless beef shown as 2X.
TABLE-US-00010 TABLE 8 Muscle Fat Item Tissue Tissue Muscle/Fat
Tissue Variation 1X 99% 1% +1%/-3% muscle content 2X 93% 7% +/-3%
muscle content 3X 75% 25% +/-3% muscle content
[0770] Preferably, the variable speed conveyors 6006, 6008 and 6010
can be arranged in close and parallel proximity and located inside
an ultra violet light (UV) tunnel shown as 6030 in FIG. 200. Tunnel
6030 can be arranged so as to expose any of the selected boneless
beef to sufficient UV light so as to substantially sterilize the
surfaces of the boneless beef. A suitable device of turning and/or
rotating the boneless beef can be provided in the tunnel, so as to
ensure that substantially all external surfaces of the boneless
beef are exposed to the UV light to ensure the sterilization of the
surfaces. Similarly, the variable speed conveyors 6018, 6020 and
6022 can be arranged in close and parallel proximity and located
inside an ultra violet light (UV) tunnel shown as 6032 in FIG. 200.
Tunnel 6032 can be arranged so as to expose any of the selected
boneless beef to sufficient UV light so as to substantially
sterilize the surfaces of the boneless beef. A suitable method of
turning and/or rotating the boneless beef can be provided in the
tunnel, so as to ensure that substantially all external surfaces of
the boneless beef are exposed to UV light to ensure sterilization
of surfaces.
[0771] Preferably, the variable speed conveyors 6006, 6008, 6010,
6018, 6020, and 6022 can be provided with independent drivers and
arranged to pass through a tunnel with a device to independently
measure the fat and muscle content of the boneless beef carried on
each individual and separate conveyor. Any suitable method of
measuring the fat and muscle content of the boneless beef may be
integrated with the conveyors 6006, 6008, 6010, 6018, 6020, and
6022 so as to provide a method of separate and continuous
measurement of the fat and muscle content of the boneless beef
separately carried on each conveyor. Preferably, the variable speed
conveyors 6006, 6008, and 6010 can be arranged to converge and
deposit the boneless beef, carried by each independent conveyor
onto a conveniently located secondary conveyor shown as 6034 in
FIG. 200. Similarly, the variable speed conveyors 6018, 6020, and
6022 can be arranged to converge and deposit the boneless beef,
carried by each independent conveyor onto a conveniently located
secondary conveyor shown as 6036 in FIG. 200. Preferably, the speed
of each conveyor can be varied in direct relationship to the
variation of measured fat and muscle content of the boneless beef
carried by each conveyor.
[0772] Preferably, the length of the variable speed conveyors 6006,
6008, 6010, 6018, 6020, and 6022 can be extended so as to allow
operators, such as carcass disassembly workers, to deposit the
boneless beef raw material thereon immediately after disassembly
and separation from an animal carcass source of the boneless beef.
Furthermore, the carcass disassembly workers can, for example
adjust the fat content of boneless beef that is deposited onto each
of the conveyors 6006, 6008, 6010, 6018, 6020, and 6022 according
to requirements. More specifically, if it is determined by the fat
measuring device that a reduced quantity of fat and an increased
relative quantity of muscle (lean) tissue is required on any
particular conveyor, this can be accommodated. Conversely, if it is
required to deposit an increased relative quantity of muscle tissue
onto any particular conveyor, this also, can be accommodated. In
this way, the fat and lean content of the boneless beef that is
deposited onto each of the individual conveyors can be adjusted to
suit requirements which can be determined by the fat content
measuring method through which each of the conveyors can be
arranged to pass. Preferably, boneless beef can be deposited onto
variable speed conveyors 6006, 6008, and 6010 according to
requirements and by varying the speed of each conveyor and
therefore the quantity of boneless beef carried and deposited onto
conveyor 6034, a combined stream of boneless beef including fat and
muscle tissue with a desired and constant relative ratio can be
produced and carried on the conveyor 6034. Similarly, with variable
speed conveyors 6018, 6020, 6022, boneless beef can be deposited
onto each conveyor according to requirements and by varying the
speed of each conveyor and therefore the quantity of boneless beef
carried and deposited onto conveyor 6036, a combined stream of
boneless beef, carried on conveyor 6036 and including fat and
muscle tissue with a desired and constant relative ratio, can be
produced and carried on the conveyor 6036.
[0773] Referring again to FIG. 200 and in particular to conveyor
6034, it can be seen that boneless beef carried on 6034 will be
carried and deposited into meat grinder 6038. Similarly, it can be
seen that boneless beef carried on conveyor 6036 will be carried
and deposited into meat grinder 6040. By adjusting the ratio of fat
and muscle content of boneless beef carried on each conveyor 6006,
6008, and 6010 and adjusting the speed and therefore the volume of
boneless beef carried on each conveyor, a single stream, indicated
as stream 6042 in FIG. 201, of boneless beef including fat and
muscle tissue of a desired ratio can be provided and carried
forward on conveyor 6034. Similarly, by adjusting the ratio of fat
and muscle content of boneless beef carried on each conveyor 6018,
6020, 6022 and adjusting the speed and therefore the volume of
boneless beef carried on each conveyor 6018, 6020, and 6022, a
single stream, indicated as stream 6044 in FIG. 201, of boneless
beef including fat and muscle tissue of a desired ratio can be
provided and carried forward on conveyor 6036.
[0774] Preferably, in this way, boneless beef stream 6042 may
include boneless beef with a fat and muscle content of about 95%
lean muscle and about 5% fat with a fat content variation of about
+/-0.3%. Preferably, boneless beef stream 6044 may include boneless
beef with a fat and muscle content of about 80% lean muscle and
about 20% fat with a fat content variation of about +/-0.3%.
[0775] Boneless beef stream 6042 is carried forward by conveyor
6034 and deposited into grinder 6038. Conveyor 6034 and grinder
6038 may be enclosed inside a substantially sealed outer covering
with a suitable gas such as nitrogen contained therein in such a
manner so as to substantially exclude ambient air from presence
therein. The boneless beef carried in stream 6042 is ground in the
grinder 6038 and transferred through tube 6046 and into hopper
6048. It can also be seen that the boneless beef stream 6044 is
carried forward by conveyor 6036 and deposited into grinder 6040.
The conveyor 6036 and grinder 6040 may also be enclosed inside a
substantially sealed outer covering with a suitable gas such as
nitrogen contained therein in such a manner so as to substantially
exclude ambient air from presence therein. The boneless beef
carried in 6044 is ground in grinder 6040 and transferred through
tube 6050 and into hopper 6052.
[0776] Stream 6042 of ground beef is then transferred by a pump,
such as a positive displacement pump 6054, from hopper 6048 into
and through static blending tube 6056 and into hopper 6058. Stream
6044 of ground beef is then transferred by a pump, such as a
positive displacement pump 6060, from hopper 6052 into and through
static blending tube 6062 and into hopper 6064. Preferably,
positive displacement pumps 6054 and 6060 can be fitted with
variable speed drivers Hoppers 6058 and 6064 can be substantially
filled with a suitable gas such as carbon dioxide or any other
suitable substance, and both hoppers 6054 and 6060 are arranged to
have an adequate capacity to accommodate any quantity variations in
normal production of boneless beef that may result from any
variable requirement.
[0777] Hopper 6058 is connected with three positive displacement
pumps shown as 6066, 6068 and 6070. Preferably, any number of pumps
may be provided and connected to hopper 6058. Similarly, hopper
6064 is connected with three positive displacement pumps shown as
6072, 6074 and 6076. Preferably, any number of pumps may be
provided and connected to hopper 6064. Preferably, each of the
positive displacement pumps shown as 6066, 6068 and 6070 can be
fitted with suitable, independently controlled, variable speed
drivers such that any required quantity of ground boneless beef
contained in hopper 6058 can be pumped therefrom at a desired
velocity, and through a measuring device, such as the Epsilon
GMS-40 shown as 6078, 6080 and 6082. Similarly, each of the
positive displacement pumps shown as 6072, 6074 and 6076 can
preferably be fitted with suitable independently controlled,
variable speed drivers such that any required quantity of ground
boneless beef contained in hopper 6064 can be pumped therefrom and
through a measuring device, such as the Epsilon GMS-40 shown as
6084, 6086 and 6088.
[0778] The Epsilon GMS-40-40 Meat Analyzer is a fat measuring
device and is commercially available from Epsilon Industrial, 2215
Grand Avenue Parkway, Austin, Tex. 78728. Specifications for the
GMS-40 are available from this supplier and information is also
available from their web site at www.epsilon-gms.com. While this
component is specified herein, other suitable fat measuring devices
can be used as an alternate for fat and/or muscle content
measurement.
[0779] As can be seen in FIG. 200, Epsilon GMS-40 measuring devices
shown as 6078 and 6084 are preferably attached directly to junction
box X, Epsilon GMS-40 measuring devices shown as 6080 and 6086 are
preferably attached directly to junction box Y and Epsilon GMS-40
measuring devices shown as 6082 and 6088 are attached directly to
junction box Z. Suitably sized tubes connect pumps directly to
corresponding Epsilon measuring devices as shown. The fat content
of ground beef that is pumped by pump 6066 through the connecting
tube and directly through Epsilon GMS-40 measuring device 6078, is
measured by device 6078. The fat content of ground beef that is
pumped by pump 6072 through the connecting tube and directly
through Epsilon GMS-40 measuring device 6084, is measured by device
6084. The ratio and percentage quantity of fat in each separate
stream of ground beef pumped by pumps 6066 and 6072 can therefore
be measured and compared and the pumping rate of pumps 6066 and
6072 can be automatically adjusted according to the respective fat
content of each stream of ground beef so as to provide a single
stream of ground beef, after combining in junction box X, with a
desired fat content. In this way selected quantities of boneless
ground beef can be pumped directly from hopper 6058, containing
ground beef from stream 6042 and hopper 6064, containing ground
beef from stream 6044, by pumps 6066 and 6072 respectively and
through Epsilon GMS-40 measuring devices shown as 6078 and 6084
into junction box X. Similarly, selected quantities of boneless
ground beef can be pumped directly from hopper 6058, containing
ground beef from stream 6042 and hopper 6064, containing ground
beef from stream 6044, by pumps 6068 and 6074 respectively and
through Epsilon GMS-40 measuring devices shown as 6080 and 6086
into junction box Y. Preferably, selected quantities of boneless
ground beef can be pumped directly from hopper 6058, containing
ground beef from stream 6042 and hopper 6064, containing ground
beef from stream 6044, by pumps 6070 and 6076 respectively and
through Epsilon GMS-40 measuring devices shown as 6082 and 6088
into junction box Z.
[0780] Preferably, selected quantities of ground meat from stream
6042 and stream 6044 can be combined in junction boxes X, Y and Z.
By varying the pumping rate of variable speed positive displacement
pumps 6066 and 6068, a selected blend of ground beef, with a
pre-determined and known ratio of fat to lean muscle tissue, can be
pumped into junction box X. The fat content of the selected blend
of ground beef pumped into junction box X may be, for example,
about 10%+/-about 0.3%. Alternatively, the fat content of the
selected blend pumped into junction box Y may be, for example,
about 15%+/-0.3% and the fat content of the selected blend pumped
into junction box Z may be, for example, about 17%+/-about 0.3%. By
processing ground meats in this way, the fat content of any given
production quantity of selected ground beef can be controlled
within a narrow margin of variation, such as about +/-about 0.3%
and the muscle and fat content selected as desired by adjusting the
fat content of raw materials that are deposited onto conveyors
6006, 6008, 6010, 6018, and 6020 accordingly. Furthermore, the
energy required to blend the ground beef in the methods described
herein is much less than is typically required to produce ground
meats using currently common industry practice.
[0781] The selected ground beef blend that is pumped into junction
box X by way of two streams from pumps 6066 and 6072 is then
transferred through blender 6090. The selected ground beef blend
that is pumped into junction box Y by way of two streams from pumps
6068 and 6074 is then transferred through blender 6092. The
selected ground beef blend that is pumped into junction box Z by
way of two streams from pumps 6070 and 6076 is then transferred
through blender shown as 6094.
[0782] Blender 6056, 6062, 6092, and 6094 are all conveniently
arranged with gas injection ports shown as 6096. Preferably, gas
injection ports 6096 are arranged to provide suitable gas, such as
carbon dioxide, into blenders in such a way as to ensure that all
ground meat that is pumped through the blenders is exposed to gas
as desired and to an extent that will, for example, ensure that
ground meat is saturated with dissolved suitable gas as required.
Blenders 6056, 6062, 6090, 6092, and 6094 may include suitably
sized continuous static mixing equipment such as may be supplied by
Statiflo International, Macclesfield, Cheshire, UK. Preferably, any
continuous blender may be integrated and located where indicated in
FIG. 200 by blender reference numerals 6056, 6062, 6090, 6092 and
6094 or in any desired configuration that will ensure blending of
ground meats as required.
[0783] The process described in association with FIG. 200-201 shows
a combination of equipment that is configured to preferably produce
a first 6042 and a second 6044 stream of ground meat. Stream 6042
and stream 6044 are provided by measuring the fat content of two
pair of three streams of boneless meat where streams 6012, 6014 and
6016 converge into a first stream 6042 and where streams 6024,
6026, and 6028 converge into a second stream 6044.
[0784] Preferably, the fat and muscle (lean) meat content of stream
6042 is determined by the following factors: The total quantity of
boneless meat deposited onto the conveyors that include the streams
6012, 6014, and 6016 and the fat and muscle content of the boneless
meat. The velocity of the streams 6012, 6014, and 6016.
[0785] Correspondingly, the fat and muscle (lean) meat content of
stream 6044 is determined by the following factors: The total
quantity of boneless meat deposited onto the conveyors that include
the streams 6024, 6026 and 6028 and the fat and muscle content of
the boneless meat. The velocity of the streams 6024, 6026 and
6028.
[0786] The fat and lean content of streams 6042 and 6044 can be
determined by adjusting the velocity of streams 6012, 6014, 6016,
6024 and 6028 and the fat content of the boneless meat provided
into streams 6012, 6014, 6016, 6026 and 6028.
[0787] Referring now to FIG. 200, streams 6098, 6102 and 6106 are
shown to be connected directly to meat grinders 6100, 6104 and
6108. Grinders 6100, 6104 and 6108 are arranged to fine grind the
corresponding stream of ground meat and transfer directly into a
corresponding portioning apparatus. Grinder 6100 is arranged to
fine grind ground meat in stream 6098 and transfer the stream of
fine ground meat directly into portioning apparatus. Grinder 6104
is arranged to fine grind ground meat in stream 6102 and transfer
the stream of fine ground meat directly into portioning apparatus
6118. Grinder 6108 is arranged to fine grind ground meat in stream
6106 and transfer the stream of fine ground meat directly into
portioning apparatus 6120. Preferably, any suitable variable speed
driver may be integrated into equipment shown in FIG. 200 and may
be controlled by a central processing computer.
[0788] The fat and muscle (lean) content of the stream of ground
meat that is shown as stream 6098 and which is delivered to grinder
6100, is determined by the fat and lean content of a quantity of
ground meat from both stream 6042 via pump 6070 and an additional
quantity of ground meat from stream 6044 via pump 6076. The fat and
muscle (lean) content of the stream of ground meat that is shown as
stream 6098 is also determined by the velocity (and quantity of
ground meat pumped therethrough) of the ground meat stream pumped
into junction box Z by pump 6070 and the ground meat stream pumped
into junction box Z by pump 6076. By adjusting the speed of pumps
6070 and 6076 the fat content of the ground meat in stream 6098 can
be selected. The fat content of the ground beef in the stream
pumped by pump 6070 is measured by the Epsilon (or other suitable
fat measuring devices) fat measuring devices 6082. The fat content
of the ground beef in the stream pumped by pump 6076 is measured by
the Epsilon (or other suitable devices) fat measuring device 6086.
The velocity of pumps 6070 and 6076 can therefore be controlled and
set by the fat measurements provided by 6082 and 6086. In this way,
a selected fat content can be produced by an automatic controller
such as a computer that is preferably connected to all associated
pumps and fat measuring devices.
[0789] The fat and muscle (lean) content of the stream of ground
meat that is shown as stream 6102 and which is delivered to grinder
6104, is determined by the fat and lean content of a quantity of
ground meat from both stream 6042 via pump 6068 and an additional
quantity of ground meat from stream 6044 via pump 6074. The fat and
muscle (lean) content of the stream of ground meat that is shown as
stream 6104 is also determined by the velocity (and quantity of
ground meat pumped there along) of the ground meat stream pumped
into junction box Y by pump 6068 and the ground meat stream pumped
into junction box Y by pump 6074. Preferably, adjusting the speed
of pumps 6068 and 6074 the fat content of the ground meat in stream
6102 can be selected. The fat content of the ground beef in the
stream pumped by pump 6068 is measured by the Epsilon (or other
suitable fat measuring devices) fat measuring device 6080. The fat
content of the ground beef in the stream pumped by pump 6074 is
measured by the Epsilon (or other suitable devices) fat measuring
device 6080. The velocity of pumps 6068 and 6074 can therefore be
controlled and set by the fat measurements provide by 6080 and
6074. In this way, a selected fat content can be produced by an
automatic controller such as a computer that is connected to
preferably all associated pumps and fat measuring devices.
[0790] The fat and muscle (lean) content of the stream of ground
meat that is shown as stream 6106 and which is delivered to grinder
6108, is determined by the fat and lean content of a quantity of
ground meat from both stream 6042 via pump 6066 and an additional
quantity of ground meat from stream 6044 via pump 6072. The fat and
muscle (lean) content of the stream of ground meat that is shown as
stream 6106 is also determined by the velocity (and quantity pumped
there along) of the ground meat stream pumped into junction box X
by pump 6066 and the ground meat stream pumped into junction box X
by pump 6072. Preferably, by adjusting the speed of pumps 6066 and
6072 the fat content of the ground meat in stream 6106 can be
selected. The fat content of the ground beef in the stream pumped
by pump 6066 is measured by the Epsilon (or other suitable fat
measuring devices) fat measuring device 6078. The fat content of
the ground beef in the stream pumped by pump 6072 is measured by
the Epsilon (or other suitable devices) fat measuring device 6084
The velocity of pumps 6066 and 6072 can therefore be controlled and
set by the fat measurements provided by devices 6078 and 6084.
Preferably, any quantity of ground meat with any selected fat
content can be produced by an automatic controller such as a
computer that is connected to preferably all associated pumps and
fat measuring devices.
[0791] The configuration shown in FIG. 200 preferably provides for
automatic production of three streams of ground meat 6110, 6112 and
6114, each with a selected fat and lean content. A configuration of
the required equipment, with any chosen capacity and size to suit
any rates of production, can be arranged to produce any suitable
number of one or more streams of ground meat, each with a selected
fat and lean content, as may be desired.
Overwrapping and Web Stretching Apparatus and Method
[0792] Controlled Atmosphere Packages (CAP) are packages prepared
or treated in an oxygen deficient atmosphere to remove or prevent
the accumulation of oxygen within the package materials. Packages
are overwrapped with apparatus having web stretching capabilities
in one aspect of the invention.
[0793] Referring to FIGS. 202-204, details of a controlled
atmosphere packaging system according to the present invention is
shown. FIG. 202 shows a section of PVC web material 6200 is about
0.0008'' in thickness. Preferably, any suitable thickness or gauge
can be used. Preferably, web 6200 can be coated, fully or in part
and with any desired pattern such that parts of the web remain
clear and other coated parts may be opaque. Web 6200 is shown with
a suitable heat sealing coating that has been applied in two
continuous strips along the edges of the web such that a
continuous, central strip remains clear. The width of the clear
section 6202 central strip may be about 50% of the total width of
the web 6200 and the outer two printed sections 6204 of about equal
width being about 25% of the full width each, of web 6200 such that
when formed into a tube 6214, a fin seal, 6308, can be provided by
heat sealing there together. Preferably, a sealed tube including an
upper clear section through which the tray 6210 can be seen and a
lower, opaque section 6212 through which tray 6210 cannot be
seen.
[0794] Web 6200 can be processed by a modified Hayssen RT1800, for
example, in such a manner so as to form a continuous tube 6214, and
shown as PVC web material "fin" sealed tube. Suitable packaging
trays such as Mono-Pak.TM. trays 6210 that have been filled with
perishable goods such as ground beef can be inserted into the tube
6214, by automatic devices (not shown) or any other suitable
devices, and lateral stretching can be induced into the tube 6214.
The lateral stretching can cause the tube 6214 material to firmly
contact the tray 6210 and hold the perishable goods contained
therein firmly. After the trays 6210 are located inside the fin
sealed tube 6214 the tube can also be stretched longitudinally.
After the longitudinal stretching of the tube 6214, lateral fin
seals, followed by severing of the tube 6214 adjacent to the
lateral fin seals, can be provided so as to provide a fully and
hermetically sealed package as shown in FIG. 204. The lateral and
longitudinal stretching can be provided prior to sealing and
severing of the lateral fin seals. Longitudinal stretching can be
effected by the modified Hayssen RT1800 after modification and as
generally described below.
[0795] Referring now to FIG. 201, items 6000, 6002 and 6004 shown
thereon include three modified versions of the Hayssen RT 1800
(modified RT1800), flow wrapping packaging machine. The
modifications to each item 6000, 6002 and 6004 refers to the
inclusion of a sub-assembly to each machine which is detailed in a
cross-sectional sketch shown as FIGS. 205-206 so as to enable
processing and use of pPVC web material on the RT1800 packaging
machines. The following disclosure details the modification that
can be incorporated in the RT1800 so as to facilitate the use of
pPVC web material as the over wrapping packaging material used
thereon to over wrap such packages as the Mono-Pak EPS foam
tray.
[0796] The Hayssen RT 1800 is manufactured by Hayssen, a division
of the Barry-Wehmiller Company, which is located at 225
Spartangreen Boulevard, Duncan, S.C. 29334. Other information
describing the RT1800 can be obtained from the following web site:
www.hayssen.com. The RT 1800 incorporates a "rotary die wheel" in
such a manner so as to provide a continuous movement of the web
during machine operation and package sealing. This arrangement
provides a method to process and seal packages more rapidly than
other types of over wrapping machines but hitherto the RT 1800 has
not been used to over wrap packages with pPVC (plasticized
polyvinylchloride) web material.
[0797] It is desirable to use pPVC web material, in this particular
application, because of its most suitable physical characteristics
for the packaging of fresh meats such as ground meats and poultry
pieces. However, the standard RT1800 is not ideally suited to
process pPVC web material and in order to ensure efficient
stretching and sealing of the pPVC web the modifications to the
RT1800 are necessary.
[0798] The HAYSSEN RT1800 rotary die wheel concept operates on the
principal of maximizing dwell time. Individual MAGNUM sealing dies
are released on demand as packaging material and product move
through the machine. The RT1800 packaging equipment is well known
to those skilled in the arts and all details of the RT1800 machine
construction are readily available from the manufacturer to
potential end users of this popular packaging equipment.
[0799] Packaging materials may include the Mono-Pak.TM. EPS tray,
over wrapped with plasticized PVC web material, (supplied by
AEP/Borden or Huntsman).
[0800] It should be noted that the readily available, low cost,
pPVC web material as intended for use in this application, has the
following properties:
[0801] 1. Glass clarity
[0802] 2. Stretch and high extensibility (50-100% before exceeding
elastic limit)
[0803] 3. Memory, providing a "return to its original condition"
after stretching (within elastic limit).
[0804] 4. Standard, enhanced oxygen permeability.
[0805] 5. Rapid heat sealing to itself.
[0806] 6. Rapid hot "knife" cutting, providing clean cut edges.
[0807] 7. Generally, the basic RT1800 machine, as manufactured by
Hayssen, would remain similar to existing standard equipment,
except for the modification described herein. The existing
longitudinal fin or lap sealing (as shown as 6208, in FIG. 203) may
require adjustment to facilitate an enhanced lateral web
"stretching" capability for a pPVC web. The longitudinal web
stretching apparatus, as disclosed herein, should be capable of
installation without major structural and basic frame modifications
to the existing equipment.
[0808] FIGS. 205-206 include an assembly intended for optional and
interchangeable use on standard Hayssen RT1800 or similar packaging
machines, shows detail of the following items.
[0809] Referring now to FIGS. 205-206, the apparatus constructed
according to the present invention includes a die wheel 6216 shown
in part with the axis of the wheel marked as axis 6218. A number of
die carriers 6220 are also shown. The complete die wheel 6216 and
drive is not shown, however, since a person skilled in the art will
readily recognize the proposed modification when viewing the
representation of the die wheel with die carriers as shown. The
wheel die assembly fixture may include a standard Hayssen component
modified to suit convenient attachment of the "Stretch Web Clamp
Assembly".
[0810] The packaged product may include any of the number of trays
disclosed herein, for example, the tray shown in FIG. 55, over
wrapped with standard (with enhanced O.sub.2 permeability)
plasticized PVC web material, (supplied by AEP/Borden or Huntsman).
The EPS material can be produced with a surface finish that will
not "cling" to the pPVC web material.
[0811] Plasticized web of stretch over wrap material is preferably
printed or plain material can be used. Preferably, partial coating
of the inside web surface, with a low melt heat activated coating
(HAC), can provide for improved performance.
[0812] A full width, lateral, impulse, heat sealing, element (e.g.
cut from Inconnell SS sheet or other "marine" grade, SS sheet
material) is installed by attachment to a horizontally disposed
rigid and suitably heat tolerant, non metallic base. Preferably,
compensation for normal expansion and contraction of the element,
during heating and cooling, can be provided. The element is covered
with suitable material (PTFE) so as to provide a "non-stick"
surface that will not "cling" to pPVC web. The heat sealing
assembly is arranged with the heating sealing element in close,
adjacent and parallel disposition to a full length strip of a
portion of the outer surface of roller 6224, as shown in the
sketch. When held together under suitable pressure with two webs of
pPVC material located between member 6228 and roller 6224, a full
length and hermetic seal between the two webs can be produced.
[0813] An alternative heat sealing device includes a heat bank. Use
of either impulse or heat bank devices may be determined by
manufacturer preference. In the case of a heat bank device, the
clamping bars 6230 and 6232 would be separated and insulated from
the adjacent heat bank members 6230, 6232 and 6234, 6228 would
require independent, return spring mounting. A suitable distance or
gap (for insulation and sealing/cutting control devices), between
the elevation of the clamping surface of the clamping bar and the
elevation of the contact surface of the heat bank, would be
required. This would allow clamping of the web(s) by the clamping
bar with subsequent web clamping, sealing and cutting by the heat
bank.
[0814] Web clamping bar 6232 includes a strip like component that
is arranged in parallel and close proximity to assembly 6228 so as
to provide a clamp to web 6236 at the same time and with similar
clamping effect as member 6232 when roller 6224, 6232 and member
6228 are arranged so to do.
[0815] Rubber coated roller with cam/clutch bearing 6224 includes a
heat resistant rubber coated and suitably ground, solid steel,
hardened, rigid roller. Roller 6224 is located between two end
plates 6240 and 6242 (not shown) and mounted thereto by bearing
(one located at each end of the roller 6224. The bearings are of
identical dimensions with "cam/clutch" feature provided in one only
bearing. Such arrangement allows the roller 6224 to rotate in a
clockwise direction only.
[0816] Impulse heat sealing element assembly is arranged to mirror
image assembly 6228.
[0817] Web clamping bar 6230 is arranged to mirror image web
clamping bar 6232.
[0818] Rubber coated roller with cam/clutch bearing 6244 includes a
heat resistant rubber coated, solid steel, hardened, rigid roller
identical to roller 6224 but with a "cam/clutch" feature provided
in one only bearing so as to allow roller 6244 to rotate in a
counter clockwise direction only, as shown by an arrow in the
sketch. The surface finish on both rollers 6244 and 6224 can be
arranged so as to cling to web 6236 when contact occurs between
suitably tensioned web 6236.
[0819] Two end plates 6240 and 6242 are arranged to rigidly retain
rollers 6244 and 6224 in relative, respective, parallel and
separated proximity, allowing the rollers to rotate as described
above. Both end plates may be fitted with suitable coil or flat
return springs to hold the rollers 6244 and 6224 in a normal
position at a desired distance from bars 6230 and 6232 and heating
elements 6234 and 6228.
[0820] A cam follower is mounted to each end plate 6240 and 6242 so
as to engage with cam tracks (not shown but mounted to main frame
of FFS machine) arranged to provide a web sealing pressure to web
6236 by causing depression of end plate return springs.
[0821] The web stretching bar 6226 includes a strip of suitable
material profiled as shown and provided with an outer surface
treatment that can cling to pPVC web material. Web stretching bar
6226 is attached to two pneumatic cylinders [6246 (shown) and 6248
(not shown)] with slotted fixture apertures so as to eliminate
locking that may otherwise occur during operation. The
web-stretching bar is shown in a normally withdrawn (closed)
position and also in a fully extended position, by dotted lines.
When in the normally closed position, the upper and highest edge of
the bar extends along its full length and is in permanent contact
with web(s) 6236. This contact is arranged so as to ensure a
suitable tension is induced in the web(s). This can provide a
condition allowing the free movement (by stretching) of the web
material over roller's 6244 and 6224 only inwardly and toward the
web-stretching bar. The cam/clutches installed in the rollers will
not allow the web to be pulled away from the web-stretching bar.
Preferably, web 6236 can be freely stretched but is essentially
clamped by its tensioned and intimate contact with the surface of
the rollers and the upper edge of the web-stretching bar.
[0822] The Rollers Assembly, includes two off each rollers, 6244
and 6224, endplates 6240 and 6242, cam followers 6250 and 6252,
fasteners and return springs as required. When assembled with the
complete web stretching assembly and in a normally closed position,
a suitable gap is maintained between the rollers and the adjacent
contact surfaces of items 6230, 6234, 6232 and 6228, thereby
allowing free stretching of the web 6236, by activation of
web-stretching bar 6226.
[0823] A pneumatic cylinder is shown, attached to the
web-stretching bar 6226 to extend bar 6226 to the position shown by
dotted lines and thereby stretch the web 6236. Preferably, two
cylinders would be provided. Compressed air flow and pressure
controls can be arranged to activate cylinders 6246 and 6248 so as
to optimize induced tension in web 6236. Any suitable alternative
method of web-stretching bar activation and control may be
used.
[0824] A vacuum tube may be conveniently located so as to provide a
method of removing scrap web material (excess material for
accumulation in a canister.
[0825] In this configuration independent pivoted mounting of each
roller and clamping assembly 6256 and 6258 is provided. Each
assembly 6256 and 6258 is held in the normal central position
(close together), by controlled return springs. Activation of the
web-stretching bar 6226 will cause the two assemblies to move away
from the central position until contact with the packages 6254.
Such an arrangement will provide consistent web stretching with a
final web heat sealing at a constant distance from the package. In
this configuration end plates 6240 and 6242 would require slotting
to accommodate outward rotation of each assembly.
[0826] Products, pre-filled with ground beef portions/blocks, are
automatically loaded onto the entry end of the Hayssen FFS
equipment. Orientation of the products may be in normal or inverted
disposition. A normal disposition (with package "open top" side
facing upward) would require a side fin or lap web seal, whereas an
inverted disposition would require a bottom web seal. Normal
operation would include longitudinal sealing after induction of
maximum stretch in web 6236. Lateral sealing would occur after
longitudinal stretching by web stretching bar 6226. Activation of
the web-stretching bar would not commence until closure of the
subsequent closing of the closest clamp to its rear, on the wheel.
In this way gradual stretching of the pPVC over wrap, during the
wheel rotation, can occur until the desired level of stretch and/or
tension is achieved when web heat sealing and simultaneous cutting
could be provided immediately prior to ejection of the finished
package(s). The finished packages could be ejected in a normal and
upright disposition, assuming that the packages were loaded in an
inverted disposition, alternatively, the packages could be inverted
after ejection if the packaging had been loaded onto the RT1800
packaging machine in a normally upright position.
[0827] By incorporating the above described modification in the
Hayssen RT 1800 packaging machine a web stretching arrangement is
provided to stretch the over wrap material 6236 during the normal
rotation of the die wheel. It is anticipated that, in view of the
rapid heat sealing and cooling characteristics of thin gauge
(0.0008'') pPVC, the operational speed of the Hayssen RT 1800 could
be increased to more than 1800 feet per minute.
Blending Apparatus
[0828] Referring now to FIGS. 207-208, details of an apparatus that
can be used to blend one or more individually controlled streams of
ground meats that can also be combined with selected conditioning
gases or suitable materials and blended together to produced a
single stream of blended and conditioned ground meat, is shown.
FIG. 208 shows a diagrammatic representation of three streams of
ground meats, 6300, 6302 and 6304 that are each pumped through
conduits shown as 6306, 6308 and 6310 at independently controlled
velocities. Preferably, the apparatus can be arranged to provide
one or more streams of ground meat but most preferably three
streams will be provided where, for purposes of example, one stream
may have an approximate fat content of about 20%, a second stream
has an approximate fat content of about 30% and a third stream has
a fat content of about 7%. Preferably, the content of each stream
can be varied as may be required. Conduits 6306, 6308 and 6310 can
be arranged to house independent measuring devices such as the
Epsilon GMS-40 in-line measuring equipment. The streams of ground
meat can be pumped, by positive displacement pumps that are
independently driven by variable speed drivers, at velocities that
are continuously adjusted directly corresponding with the
respective fat and muscle content of each stream such that when the
three streams are subsequently combined together into a single
stream of ground meat, the fat and muscle content of the combined
stream is substantially consistent and constant at a chosen
composition with percentage quantities of fat and muscle held
within a range of less than about +/-1% fat content. Furthermore,
even though the velocity of each separate stream of ground meat is
independently varied according to the fat and muscle content of the
respective stream, the resultant single, combined stream can be
arranged, by adjusting the velocity of each of the streams 6300,
6302 and 6304, to be at a constant velocity, volume and production
rate and as desired within the capacity of the apparatus.
[0829] Referring now to FIG. 207, a housing 1318 is arranged with
six suitably profiled blades 6312 that are attached together at a
central axis 6314 which in turn are attached to a driver 6316.
Blades 6312 are attached at axis 6314 and to a driver 6316 in such
a manner that blades 6312 can be rotated within the confinement of
housing 6318, which is sealed and separate from external
atmosphere. Blades 6312 are arranged so as to not contact but be in
close proximity to the internal surfaces of the housing 6318. A
total of six spaces or segments shown as 6320, are therefore
arranged between the blades 6312 that include equal volumes and a
recess 6322 is provided at the axis of the blades 6312 so as to
allow direct communication between the spaces. The direct
communication between the spaces 6320 may be provided or otherwise,
if so desired, not provided. A conduit 6324 is attached to the
housing 6318 with a spiral auger 6326 contained therein. Auger 6326
may be directly connected to suitable driving devices (not shown)
that can provide a variable speed rotating of the auger as required
to further blend the single stream of combined ground meats.
Preferably, the streams of ground meat can be transferred directly
through housing 6318 and into conduit 6324. Blades 6312 can be
rotated about the axis by driver 6328 at a suitable speed.
Preferably, a series of conduits 6330 can be arranged to have
direct communication with the spaces between the blades 6312, as
they rotate adjacent thereto, so as to allow injection of any
suitable substances such as carbon dioxide into the spaces at any
suitable pressure and from a suitable source and in controlled
quantities. Preferably, a known quantity of ground meats can be
transferred from conduits 6310, 6308 and 6306 into spaces 6320 with
a known and controlled quantity of gas or other suitable substance
provided therein via conduits 6330, as spaces 6320 rotate about its
axis 6322, and pass through conduits. Blades 6312 are arranged with
edges that are parallel and in close proximity to the internal
surfaces of housing 6318. As ground meat is transferred from the
conduits into the spaces 6320 at controlled rates and quantities,
controlled quantities of carbon dioxide can also be transferred
into the spaces. Preferably, selected quantities of ground meat and
carbon dioxide can be transferred, consecutively, into spaces 6320
and transferred as a single volume of materials into conduit 6324
and blended therein, in a continuous process of measured amounts of
ground meat and carbon dioxide. Preferably relatively small
quantities of measured amounts of ground meat with a selected
quantity of carbon dioxide can be blended most efficiently in a
continuous process. Such a method of blending can provide a method
of thorough and accurate blending with a minimum energy
requirement. It can now be seen that the apparatus herein described
can be used to efficiently produce a blend of ground meats that has
been pre-conditioned with such substances as carbon dioxide and at
a chosen rate of production within the capacity of the apparatus.
The apparatus shown in FIGS. 207-208 can be enclosed in any
suitable jacket or containment so as to allow any suitable heat
exchanging medium to contact the housing and thereby, by a heat
exchanger means provide precise temperature control of the
apparatus and any goods processed therethrough. The temperature
control can be precise and set at any suitable temperature within
any suitable temperature range. In a preferred embodiment the
conduit 6324 may include a suitable portion of static mixing
conduit as may be supplied by Statiflo, alternatively auger 6326
may be driven by a suitable driver at any suitable speed. Conduit
6324 may be connected to a suitable positive displacement pump or
other suitable pump so that any goods that may have been processed
by the apparatus shown in FIGS. 207-208, can be directly
transferred thereto and then pumped at a desired rate into suitable
holding containers or directly into further processing and/or
packaging equipment.
Pre-Conditioning Apparatus
[0830] Referring now to FIG. 209 a side elevation of a ground meat
pre-conditioning apparatus intended for use in pre-conditioning
ground meats and any other suitable goods, is shown.
[0831] Preferably, the pre-conditioning apparatus is intended for
use to pre-condition such perishable goods as ground meats in a
continuous process (as opposed to a batch process where the
perishable goods may be transferred into a pressure vessel which is
then sealed prior to removal of any undesirable gases and provision
of desirable and suitable gases therein). The continuous process
may be arranged so that the ground meats are continuously
transferred through an entry orifice that restricts the transfer
into a vessel in such a manner so as to provide a seal. The vessel
can be filled with any suitable gas at any suitable pressure and
maintained at any suitable temperature. The vessel can be arranged
to accommodate any suitable quantity of the ground meats for any
suitable period of time or residence time. The ground meats can be
arranged to exit the vessel after a suitable period of time by
transfer through a restricting exit orifice. The exit orifice and
the entry orifice can be arranged to restrict transfer of ground
meats therethrough in such a manner so as to prevent suitable gases
provided in the vessel from escaping therefrom.
[0832] A meat hopper 5400, meat grinder 5402 and drive motor 5404
is arranged to grind meat which passes from the meat grinder 5402
directly into a first conical shaped connection to a tube 5410.
Tube 5410 includes a length of high pressure stainless steel tube
or other suitable material, and connects with a second conical
shaped connection 5412 to grinder 5408. First conical connection
5406 is provided so as to elevate the pressure of the ground meat
as it is transferred from said grinder 5402 to tube 5410. Tube 5410
may follow any convenient path and is arranged to have any suitable
length and, save two end portions of convenient length, is located
in an insulated tank enclosure 5414 that contains a suitable liquid
cooling medium 5416, such as brine or glycol. Tube 5410 can be
completely immersed in the cooling medium 5416 which can be
maintained at a desired and suitable temperature that may be set
between about 32 and about 33 degrees F. Another tube 5418 connects
the tank enclosure 5414 to a heat exchanger 5420 via a suitably
sized pump 5422. Tube 5424 connects the tank enclosure 5414 to the
heat exchanger 5420. The pump 5422 is arranged in such a manner
that cooling medium 5416 can be pumped at a controlled rate through
the heat exchanger 5420 so as to maintain 5416 at a desired
temperature. Tube 5426 connects the heat exchanger with a source of
suitable gas 5428, such as carbon dioxide, provided at a suitable
volume, temperature and pressure. Tube 5430 is arranged to carry
any excess quantities of gas 5428 away from heat exchanger 5420 as
may be required. Tube 5426 is arranged to connect gas 5428 supply
to tube 5410 via the heat exchanger 5420 and connects to the tube
5410 at connection 5432. Connection 5432 is arranged to allow a
constant flow of gas 5428 directly into or through suitable valves
attached to tube 5410 at a position approximately equal distance
from each end of tube 5410.
[0833] Meat, which may have been dipped in or sprayed with any
suitable bactericide such as natural citric acids, is loaded into
the meat hopper 5400 at a convenient rate and is processed by
grinding in the meat grinder 5402. Meat grinder 5402 is driven by
drive motor 5404 at a suitable speed and ground meat which may be
coarse ground, is forced into the first conical connector at a
suitable pressure. Ground meat is therefore forced under suitable
pressure into and along tube 5410. Due to the immersion in the
medium 5416, the temperature of the tube 5410 is approximately
equal to the temperature of the medium 5416 and therefore
temperature of the coarse ground meat is affected and will be
either heated or cooled accordingly. The coarse ground meat can be
held in the tube 5410 for such a period of time that will allow the
temperature of the coarse ground meat to become substantially equal
to the temperature of the medium 5416 by transfer of heat through
the walls of the tube 5410. The coarse ground meat can pass through
the entire length of the tube 5410 and into the second conical
shaped connection 5412 to grinder 5408. Grinder 5408 is driven by
motor 5434 and is arranged to grind the coarse ground meats and can
be further arranged to produce fine ground meat from coarse ground
meat. A speed controller can be arranged to control the speed of
motor 5434 and the corresponding production rate or output of the
grinder 5408 can thereby be controlled as may be required to
correspond with the speed and output of the grinder 5402. Suitable
gas 5428 can be injected at a suitable rate, into tube 5410 via
tube 5426, at a suitable temperature which may be equal to the
temperature of medium 5416, and at a suitable pressure which may be
about 200 psi. Gas 5428 may be carbon dioxide and can therefore
dissolve into coarse ground meat as it passes through tube 5410.
The diameter of tube 5410 can be arranged to be smaller than the
internal diameter of grinders 5402 and 5408. The source of gas 5428
can be arranged to provide gas at a suitable pressure and in
quantities sufficient to meet the desired rate of absorption by the
ground meat passing through the tube 5410 and also the quantity
required to maintain medium 5416 at the desired temperature. If the
volume of gas 5428, required to maintain the suitable temperature
of medium 5416 exceeds the volume of gas required to be provided
into tube 5410 then excess gas can be vented to atmosphere through
tube 5430. Conversely, if the quantity of gas 5428 required to be
provided into tube 5410 is greater than the quantity required to
maintain the temperature of medium 5416 at a suitable level, such
that the temperature of medium 5416 is otherwise thereby depressed,
then a heater can be provided. The heater can be arranged to heat
gas 5428 as required to ensure and maintain the temperature of
medium 5416 as required.
[0834] A suitable device to vary the quantity of medium 5416, that
is pumped by pump 5422 through tube 5418 can be provided. Gas 5428
may be injected into the tube at any suitable gas pressure that may
be 200 psi, however, under such conditions gas 5428 will be soluble
and therefore dissolve in liquids contained in tube 5410, resulting
in a pressure drop as the gas and liquids are transferred along
tube 5410 toward grinder 5408.
[0835] The quantities of gas 5428 and ground meat present in tube
5410 and the length of tube 5410 can be arranged so as to allow
partial or complete dissolving of gas 5428 into ground meat while
still present within tube 5410.
[0836] It may be important that ground meats are not exposed to
conditions that will either partially or fully freeze the ground
meats during processing in the pre-conditioning apparatus.
Accordingly, heat exchanger 5420 can be arranged so as to provide a
method of transferring heat between the ground meat within the tube
5410 and gas 5428, and medium 5416 as required and in such a manner
that will inhibit and/or prevent freezing of the ground meat during
the pre-conditioning process. Heat exchanger 5420 can be arranged
so as to provide a method to ensure that, irrespective of the
temperature of the meat provided in the hopper 5400, the
temperature of the ground meat 5436 will be maintained at a
suitable temperature that may vary within a limited range of plus
or minus about 0.5 degrees F. Ground meat 5436 can be processed in
the pre-conditioning apparatus so as to saturate or partially
saturate, to any suitable level, the ground meat with any suitable
dissolved gases.
[0837] Preferably, any suitable gas such as nitrogen may be
provided directly into grinder 5402 through tube 5438 shown, so as
to substantially purge and remove any air that may be present with
the meat in hopper 5400. The quantity of meat transferred along
tube 5410 and the quantity of gas 5428 injected into the tube 5410
at connection 5432 can be measured and controlled with motors 5404
and 5434 and pump 5422, by a programmable logic controller (PLC).
Ground meat pre-conditioning apparatus may be controlled by any
suitable controller so as to provide an automatic process. The
apparatus can be manufactured to suit any required rate of
production.
[0838] An auger or other pump to assist in transfer of the ground
meat through tube 5410 may be located between the meat grinder 5402
and the first conical connection 5406 or any other suitable
location.
[0839] A suitable tube (not shown) and valves to open and close the
tube, may be provided to connect the second conical connection 5406
to the meat grinder 5402 thereby allowing any re-cycling of ground
meats that has passed through tube 5410. Such a re-cycling would
allow for further pre-conditioning of any goods that had not been
correctly processed during a first passage through tube 5410.
[0840] Vents to allow excess gas may be provided at suitable
locations in tube 5410 or at any other suitable location.
[0841] Ground meat 5436 may be further processed by direct transfer
from grinder 5408 to any other suitable processor such as a pattie
forming machine or directly into a vacuum packaging machine. The
transfer of the ground meat 5436 may be via an enclosed mode of
transfer so as to eliminate or minimize exposure to ambient
atmosphere prior to further processing or packaging.
[0842] The pre-treatment of any perishable goods, such as ground
beef, as described herein can enhance the keeping qualities of the
perishable goods. Preferably, the goods can be placed into a sealed
pressure vessel with a known quantity of suitable gases at any
suitable pressure for a suitable period of time and maintained at a
suitable temperature. Preferably, the suitable gas pressure may be
selected at a pressure above ambient air pressure. The quantity of
the suitable gas can be increased by providing additional
controlled quantities into the pressure vessel as desired.
Preferably, the suitable pressure, time and pre-treatment
temperature can be precisely controlled and arranged so as to allow
the suitable gas to dissolve into any water and oils and/or other
substances contained in the goods. The quantity of suitable gas
that dissolves into the goods, can therefore be controlled and may
be equal to the maximum amount that can dissolve therein at any
suitable gas pressure and thereby saturating the goods with the
suitable gas in solution. Preferably, a known amount of gas can be
dissolved into the goods at a given gas pressure and pre-treatment
temperature. The perishable goods can then be removed from the
pressure vessel and packaged in any suitable packaging such as a
hermetically sealed vacuum package that may include a gas barrier
plastic pouch of suitable size. Preferably, after vacuum packaging
the perishable goods into the suitable gas barrier pouch at ambient
air pressure, the goods can be stored in ambient atmosphere and
maintained within a suitable storage temperature range. The
suitable storage temperature range can be maintained at a suitable
level above the pre-treatment temperature. Preferably a quantity of
dissolved gas can emerge from the perishable goods and partially
inflate the gas barrier pouch. The size of the gas barrier pouch
can be arranged to accommodate the partial inflation without damage
to the hermetic sealing of the pouch. The emerged gas then
contained within the gas barrier pouch can enhance the keeping
qualities of the perishable goods. The emerged gas can subsequently
dissolve into the goods again and re-emerge corresponding to any
temperature fluctuations that may occur within the suitable storage
temperature range. Preferably, a quantity of free suitable gas can
be maintained in gaseous condition with the goods within the
packaging and the quantity of free gas can be arranged and
controlled at a minimum suitable quantity. However, if the
temperature of the goods in the gas barrier pouch is increased as a
result of failure of refrigeration or any other type of temperature
"abuse" to an unacceptable high level (for example 50 degrees F.)
for an unacceptably prolonged period so that the quality of the
goods is compromised, additional gas will be released from solution
therein and cause further expansion of the gas barrier pouch. The
gas barrier pouch can be sized such that it will accommodate a
known amount of released gas. The known amount of the released gas
can be limited to such an amount that will be released by goods at
an acceptable temperature and if the acceptable temperature is
exceeded any additional release of gas can cause rupturing of the
gas barrier pouch (or any other suitable packaging material).
Rupturing of the packaging, therefore, can be used as an indication
that goods have endured an unacceptable level of abuse.
[0843] In yet another preferred embodiment, goods may be treated by
exposure to an adequate quantity of suitable gases at a suitable
temperature and pressure in such a manner so as to allow a specific
quantity of suitable gas to dissolve in the goods. The specific
quantity of suitable gas can be arranged so as to equal an amount
that will saturate the goods with the suitable gas dissolved
therein to a suitable level. The goods can then be packaged in any
suitable packaging of suitable size which may include an additional
quantity of suitable gas contained and hermetically sealed in the
suitable packaging with the goods therein. Preferably the total
volume of the goods with specific quantity of suitable gas
dissolved therein plus additional quantity of suitable gas can be
arranged so as to completely fill the suitable packaging of
suitable size to provide a finished package with goods and the gas
sealed therein. Therefore, any change in temperature of the
finished package and the goods therein will result in a change in
the total volume of the goods plus the additional quantity of
suitable gas. The packaging, the goods with the suitable gas
dissolved therein plus the additional quantity of suitable gas can
be arranged so as to accommodate a known variation (increase or
decrease) in the total volume, as desired. The known variation can
be used as an indicator of the temperature history of the finished
package. For example, the packaging may be provided with a valve
indicator that will permanently open or break if the temperature of
the finished package with the goods, increases to an unacceptable
level and extent so that the volume of gas therein and
corresponding pressure thereof increases to an unacceptable
level.
Primal Meat Portion Shaping Apparatus
[0844] Referring now to FIG. 210, an apparatus for shaping primal
meat portions includes a container 2800 and plug 2802. Container
2800 and plug 2802 may be manufactured by injection molding a
plastics material such as nylon or alternatively a gas permeable
and porous material such as a chemically foamed polypropylene or
polyester plastic material. Alternatively the container and plug
may be manufactured from a stainless steel mesh. The apparatus
includes a container 2800, with lugs 2842 and 2844 that are engaged
with rails 2814 and 2846. The rails may include, for example,
parallel, round, stainless steel bars, suitably mounted to
framework, conveniently spaced apart and horizontally disposed,
extending for any convenient and desired length that may have bends
and curves allowing for the powered or manual movement of the
containers 2800 there along while maintaining engagement between
the lugs and horizontal rails. The cross-section shown in FIG. 210
provides detail of the container, plug and apparatus through one
cross-section only. Other views are not considered necessary since
the profile of the container and plugs, across a different section
may be similar, differences may only include variations in for
example, length. The mechanism, container and plug may be arranged
in any suitable and desired shape and size to suit the requirements
for each portion of pre-rigor fresh red meat. Generally, the
internal volume of an assembled container with a corresponding and
matching plug in position, is approximately equal to the volume or
displacement of the corresponding fresh red meat primal shown as
2822. The plug 2802 can slide inside the opening of the
corresponding container 2800 such that rim 2810 remains in contact
with the inside surfaces of the container wall. The displacement of
similar fresh red meat primal that have been harvested from
different animals will vary. Therefore, in order to accommodate the
variation of similar fresh red meat primals, the internal volume,
shown as space 2812, of the assembled container and plug can be
adjusted to suit the actual displacement of the corresponding fresh
red meat primal. The fresh red meat primal 2822 is located in the
container and a plug 2802 is located inside the upper portion of
the container such that substantially all air has been excluded
from the enclosed cavity containing the primal, under the plug. The
container 2800 is shown located in close proximity with a press
base 2848, with perimeter wall 2850. The press base is mounted onto
an elevating shaft 2852 thereby providing a means to elevate the
press base so as to contact and retain the lower portion of the
container 2800, and also lower the press base parallel with shown
center line, such that the 2800 will be suspended on the rails 2814
and 2846 and the press base will not contact or interfere with 2800
and allow the container to slide freely along the length of the
rails when the press base is in a lowered position. An assembly,
including an outer wall 2816 with a series of driven,
concentrically mounted clamps, about a central clamp and located
therein, is positioned directly above and aligned with the press
base 2848. The wall 2816, and clamps marked 2818, 2828, 2826, 2824
are independently driven in a reciprocating and vertical direction,
parallel with the center line shown. A concentric slot 2860 is
provided around the perimeter of the clamp 2816, such that a vacuum
can be applied to the upper side of the container. A side view of
an alternative profiled plug 2856 is shown in FIG. 211.
[0845] The container includes a rectangular, round or oval plan
profile with a flat bottom and substantially vertical walls
extending upwardly from the base. The base and walls are
continuously attached via a suitably radiused confluence. Two lugs
are conveniently located, one on each opposing side of the
container. The consistency of container 2800 is such that it will
deform slightly when subjected to pressure but will return to its
original shape when the pressure is released. A bevel 2806 is
molded as shown to provide an easy penetration by the plug
2802.
[0846] Plug 2802 includes a "rigidly" flexible, relatively shallow
cup with a flat or profiled face 2808, and flexible walls with
tapering thickness and flaring outwardly at an angle of about 5
degrees from vertical. The upwardly extending walls are connected
to the plug face with a radius therebetween as shown. The upper
rim, 2810, of plug wall is tapered and flexible.
[0847] The profile and dimensions of the plug are arranged so as to
provide an easy penetration into the matching opening of the
corresponding container. However as the plug penetrates the
container opening, the tapered disposition of the walls provides
for intimate contact and sealing between rim 2810 and inner surface
of container vertical walls. The container and plug, when assembled
together, provide an enclosed space 2812 that is substantially
sealed and isolated from external atmosphere. Space 2812 has a
volume that can be varied within the limitations of the container,
by moving the plug position, relative to the container, within the
container. In all positions, however, the intimate contact between
rim 2810 and the inside surface of the container walls is
maintained in a substantially "airtight" fashion.
[0848] Preferably, containers and matching plugs of different sizes
and suitable profiles may be manufactured to suit various sizes of
primal portions of fresh red meat, however, in each case the
container and corresponding plug are sized to provide a limited but
variable internal volume of space shown as 2812. Preferably, primal
meat portions, of limited varying size and profile can be
accommodated within the same containers provided for similar primal
portions.
[0849] It should be noted that animals used as a source of primal
meat portions vary in profile and size but are typically graded
prior to slaughter such that the corresponding primal portions are
approximately similar.
[0850] This present invention provides for de-boning of carcasses
that are still in pre-rigor mortis condition, immediately after
animal slaughter and preparation while the temperature of the
carcass remains close to normal body temperature. The de-boning of
the carcasses at such temperatures is very much easier and provides
for much more rapid completion of the de-boning process, thereby
substantially reducing costs. Furthermore, pre-rigor mortis
disassembly provides the opportunity to control and "mold" the
primal meat portion profile such that when the primal portions are
chilled, the firm, rigor mortis condition occurs after shaping
within the container and plug.
[0851] More specifically, according to this present invention, the
pre-rigor mortis primal meat portion, having been de-boned, is
sprayed with or dipped into a solution of one or more of the
following: carbonic acid, acetic acid, ascorbic acid, citric acid
and any other suitable substance that can be used to inhibit or
eliminate bacterial growth on the primal meat portion. Primal meat
portion is then placed into a container of correspondingly suitable
dimensions and a plug is inserted into the open end of the
container. The assembled container, primal meat portion and plug is
located with plugs engaged onto rails 2814 and positioned directly
and in alignment above the press base. The press base is elevated
so as to closely retain the container. The wall 2816 is lowered so
as to engage with the outer surface of the upper portion of the
container walls as shown in FIG. 210. Clamp 2818 is then lowered
and penetrates opening of the container with radius 2820 end with
bevel 2806 and stretching the container opening outwardly thereby
clamping it against the inner surface of wall 2816 and providing an
airtight seal therebetween. Wall 2816 is attached to an upper plate
(not shown) forming a chamber that is isolated from external air. A
vacuum source is attached and air is evacuated from between
clamping assembly and plug. Progressively, Clamp 2818 is lowered so
as to compress the plug against primal, followed by clamp 2826 and
finally clamp 2828 is lowered. Clamps 2828, 2826, 2824 are then in
contact with the upper surface of the plug and all applying
suitable pressure. The vacuum source is then disconnected, allowing
atmospheric air to apply pressure to the outer surface of the plug.
In this manner, substantially all air can be removed from within
the container assembly.
[0852] The container assembly can then be immersed into brine or
other suitably treated, bacteria free, temperature controlled
medium that may be elevated to as much as about 140 degrees F. and
held for a suitable period so as to cause death of bacteria that
may be present. Following the desired reduction or elevation of the
primal temperature, the container assembly can be relocated within
a pressure chamber and exposed to an ultra high pressure on the
order of about 30,000 psi or more. This procedure can tenderize the
primal and also kill bacteria that may be present.
[0853] Alternatively, sequentially or simultaneously, the container
assembly can be attached to an electrical source so as to provide
passing a high voltage current through the primal and thereby treat
by way of "Ohmic" heating. In this manner, any bacteria that may be
present with the primal can be substantially eliminated or
killed.
[0854] The assembled container can then be removed from the
pressure chamber and again immersed in a cooling medium when the
temperature of the primal can be reduced to a desired and optimum
temperature prior to removal from the container and followed by
automatic slicing. In this manner rigor mortis occurs such that the
shape of the primal meat portion after cooling within the container
is similar to the inner profile of the container, providing a more
efficient shape for slicing with automatic slicing equipment.
[0855] Referring now to FIG. 212, an adjustable container arranged
to provide a desired internal profile that can be used to contain,
and thereby mold, a suitable cut of meat that has been separated by
cutting from an animal carcass immediately after slaughter of the
animal and prior to rigor mortis of the animal carcass. FIG. 212
shows details of a molding assembly apparatus constructed according
to the present invention including an adjustable container 2830,
constructed from any suitable metallic or plastics material, that
provides a desired internal space with a suitable profile, is
shown. Apparatus can be used to contain in the internal space, and
thereby shape by molding to the profile therein, any suitably cut
meat primal, that has been separated by cutting devices from an
animal carcass immediately after slaughter of the animal and prior
to rigor mortis of the animal carcass and primal cuts. The
apparatus may be arranged in any suitable manner including the
arrangement shown in FIG. 212 which is constructed from four
components, including a "trough" shaped member 2832, a mating
closure 2834 and two identical plugs 2836. Plugs 2830 are profiled
to act as "pistons" in a conduit that is arranged by assembly of
the components 2832 and 2834. The conduit includes member 2832 with
mating member 2834 which, when in a closed and operating position,
has an irregular cross-section profile and the "piston" like plugs,
2836 are arranged to sealingly fit, closely within the conduit. The
conduit has parallel horizontally disposed walls that provide the
conduit along which the "piston" like plugs can be positioned at
any desired location within the conduit and thereby providing a
space, between plugs 2836, into which item 2838 can be located. The
apparatus is arranged to be stackable and the lower, outer surface
of member 2832 is profiled to mate with the upper external surface
of member 2834 by "nesting" therewith when stacked in a vertically
arranged column.
[0856] A suitable (pre-rigor mortis) primal cut of meat, 2838 such
as a New York Strip primal, can be placed in trough 2832, with
plugs 2836 positioned, one at each end of primal, to provide a
defined space with primal located therein. Member 2832 can be mated
with member 2832 and closed so as to contact plugs 2836. Members
2832 and 2834 can be fixed in position relative to each other and
plugs 2836 can be moved, by mechanical powered devices and under
pressure toward each other so as to compress item 2838 to the
extent required that will cause item 2838 to adopt a profile
identical to the internal profile of the space defined by members
2832 and 2834 and plugs 2836. Assembly including members 2832, 2834
and plugs 2836 with item 2838 contained therein can be fixed by any
suitable method to a finished configuration and stacked with other
similar assemblies such as on any suitable pallet. Pallet with
assemblies stacked thereon, can then be re-located into a
temperature controlled chamber. Temperature controlled chamber can
be set at any suitable temperature that may be elevated up to not
more than about 140 degrees F. for a selected period of time after
which the temperature may be gradually reduced to about 29.5
degrees F. Item 2838 will therefore cool and rigor mortis will
cause "setting" of the profile of item 2838. Item 2838 can then be
removed from molding assembly and sliced. Slicing can be conducted
automatically while located inside an oxygen free chamber and with
carbon dioxide or any other suitable gas or blend of gases provided
at any suitable pressure, present therein.
[0857] In another preferred embodiment smaller portions of
pre-rigor boneless meat such as beef can be placed into the
container assembly and processed therein in such a manner that will
result in smaller pieces of pre-rigor boneless meat adhering
together to form a single piece that can then be sliced into
consumer desirable slices. Pre-rigor boneless beef may include
portions of fat and muscle tissue that can be placed into the
container, prior to processing, in any desired arrangement such
that after processing, the single piece of meat will have a similar
appearance to a primal such as a New York strip. In this way, less
valuable smaller pieces of boneless beef can be used to produced
larger and more valuable primal cuts of beef.
Containers and Plugs for Shaping Meat Primals
[0858] FIG. 215 shows a container and plug 3802, which may be
manufactured by injection molding and from a plastics material such
as nylon or alternatively a gas permeable and porous material such
as a chemically foamed polypropylene or polyester plastics
materials may be manufactured from a stainless steel mesh.
Preferably, a plurality of profiles of the containers and plugs
that facilitate an adjustable volume feature will be required in
order to provide for all primal shapes and sizes. For example about
80 different containers and plugs would be required to accommodate
all of the various shapes of primal meat portions that are
typically produced in the dis-assembly of a single beef cow.
[0859] The container may typically include a rectangular, round or
oval plan profile with a flat bottom and substantially vertical
walls extending upwardly from the base. The base and walls are
continuously attached at a suitably radiused confluence. One, two
or more lugs 3804 can be conveniently located, one or more on each
opposing side of the container to locate the container onto rails
3800 so as to retain and hold the container in a desired position
at a desired height from the floor. The rails may be arranged with
an electrically or pneumatically powered driver to move or slide
the container along the rails, to another position for further
processing such as placing the plug 3802 in position by automatic
or mechanical apparatus, after loading the primal into space 3808.
The consistency of the material from which the container is
manufactured can be such that it will deform slightly when
subjected to pressure but will return to its original shape when
the pressure is released. A bevel 3810 is provided as shown so as
to facilitate an easy penetration by the plug 3802 or 3812, into
the opening in the container.
[0860] The plug may be provided in various profiles. An alternative
plug 3812 is shown in FIG. 216 with additional details shown in
enlarged cross-sectional view of FIGS. 218-219. The plug includes a
"rigidly" flexible, relatively shallow (shallower than the
container 3800), "cup" shaped plug, with a flat or suitably
profiled face 3814, and upwardly extending, flexible walls 3816
with tapering thickness, flaring outwardly and terminating at a rim
3818. The flexible walls can be provided at an angle of about 5
degrees from vertical relative to horizontal face 3814. The
upwardly extending walls are joined to the plug face 3814 with a
suitable radius therebetween as shown. The upper rim 3818 of the
plug wall is tapered to provide a thin cross-section at the outer
edge of the lip and is flexible. An additional rim 3820 located on
the opposite side of recess 3822 as shown, that follows a path
around the perimeter of face 3814 thereby providing a recess. Slots
3824 are provided through rim to a depth equal to the height of the
rim such that the base of each slot is on the same plane and level
with face. Slots allow liquids such as liquid purge and blood to
escape therethrough and then between the flexible walls of the plug
and the inner surface of the container 3800. A controlled and
pre-determined pressure P can be applied to the plug 4101 as shown
in FIG. 221 so as to cause the liquid purge to be expelled from
space 4107 through sides 4105. The pressure P is equal to the
weight W of red meat primal contained therein multiplied by a
constant x. Constant x is determined by the type of meat being
processed and could be equal to W, or several times W and is
determined by customer quality requirements.
[0861] The profile and dimensions of the plug are arranged so as to
provide an easy penetration into the matching opening of the
corresponding container, however, as the plug penetrates the
container opening, the tapered disposition of the walls provides
for intimate contact and sealing between the rim 3818 and the inner
surface of the container vertical walls. The container and plug,
when assembled together as shown in FIG. 216 provide an enclosed
space 3808 that is substantially sealed and isolated from external
atmosphere. The space 3808 has a volume that can be varied within
the limitations of the container, by moving the plug position,
relative to the container. Preferably, however, the intimate
contact between the rim 3818 and the inside surface of the
container walls is maintained in a substantially "airtight"
fashion.
[0862] More specifically, according to this present invention, the
pre-rigor mortis primal meat portion, having been de-boned, is
sprayed, washed or dipped in a solution including one or more of
the following: carbonic acid, acetic acid, ascorbic acid, citric
acid and any other suitable substance that can be used to inhibit
or eliminate bacterial growth on the primal meat portion. The
primal meat portion is then placed into the container of
correspondingly suitable dimensions and the plug is inserted into
the open end of the container. The assembled container, primal meat
portion and plug can be located with the lugs engaged onto the
rails and positioned directly and in alignment above the press
base. The press base is elevated so as to closely retain the
container as shown. The wall 3830 is lowered so as to engage with
the outer surface of the upper portion of the container walls as
shown in FIG. 216. Clamp 3832 is then lowered and penetrates
opening of the container with radius 3834 engaging with bevel 3810
and stretching the container opening outwardly thereby clamping it
against the inner surface of wall 3830 and providing an airtight
seal therebetween. Wall 3830 can be attached to an upper plate (not
shown) forming a chamber that is isolated from external air. A
vacuum source is attached and air is evacuated from between
clamping assembly and plug. Progressively, 3836 is lowered so as to
compress the plug against primal 3838, followed by clamp 3840 and
finally clamp 3842 is lowered. Clamps 3842, 3840, 3836 are then in
contact with the upper surface of the plug and all applying
suitable pressure. The vacuum source is then disconnected, allowing
atmospheric air to apply pressure to the outer surface of the plug.
In this manner, substantially all air can be removed from within
the container assembly.
[0863] The container assembly is opened as follows: A port 3844 is
shown in the container base. The port is provided to allow
connection to a source of compressed clean gas or clean air. The
compressed gas can then be injected through the port and assist in
the removal of the primal when desired or after the primal has been
stored in the container for a desired period of time.
[0864] The assembled container and plug with the primal contained
therein may be immersed into clean water, brine or other suitably
treated, bacteria free, temperature controlled medium that is
temperature controlled by refrigeration. Following the desired
reduction or elevation of the primal temperature the container
assembly can be relocated within an ultra high pressure (UHP)
chamber and exposed to an ultra high pressure on the order of about
30,000 psi to about 100,000 psi or more. This procedure can
tenderize the primal and also kill bacteria that may be present.
UHP equipment used may be similar to such equipment manufactured by
Flow International, Incorporated of Kent, Wash., USA.
[0865] Alternatively, sequentially or simultaneously, the container
assembly can be attached to an electrical source so as to pass a
high voltage current through the primal and thereby treat by way of
"Ohmic" heating. Preferably, any bacteria that may be present with
the primal can be substantially eliminated or killed.
[0866] The container and plug assembly can then be removed from the
pressure chamber and again immersed in a cooling medium when the
temperature of the primal can be reduced to a desired and optimum
temperature prior to removal from the container and followed by
automatic slicing. In this manner rigor mortis occurs so that the
shape of the primal meat portion after cooling within the container
is similar to the inner profile of the container, providing a more
efficient shape for slicing with automatic slicing equipment.
[0867] In another preferred embodiment the container may be
arranged and used to process several, smaller, (thinner) fresh
primals simultaneously. This can be achieved with the use of
partitions or separating plates. The separating plates can be
interposed between the smaller fresh primal portions in an
arrangement that can include placing a first primal into the
container followed by a separating plate, followed by a second
primal, followed by a second separating plate, followed by a third
primal, followed by a plug. Any quantity of fresh primal portions,
that can fit within the container, can be processed in this
manner.
Containers and Plugs for Shaping Multiple Meat Primals
[0868] In another preferred embodiment, the container may be
arranged and used to process several primals simultaneously. FIG.
217 shows an assembly constructed according to the present
invention that includes container 3900, a first 3902, second 3904
and third 3906 primal with first 3908 and second 3910 separating
plates therebetween. The plug is shown in position after insertion
and all air has been removed from the space between the container
base and the plug 3812. The assembly can then be immersed in
cooling medium for further processing and chilling.
[0869] In yet another preferred container embodiment, the container
may be arranged and used to process several primals simultaneously
without the use of separating plates. FIG. 220 shows detail of a
cross-section through an assembly constructed according to the
present invention that includes a container 4000 with a first 4002
and second 4004 tenderloin contained therein. The plug 4006 is
shown in position after insertion and substantially all air has
been removed from the space between the container base and the
plug. The assembly can then be immersed in a cooling medium for
further processing and chilling. This process can provide an
apparatus of attaching two tenderloins together to produce a single
tenderloin of uniform profile and cross-sectional shape. The
tenderloin can then be removed and sliced into slices of equal
profile size and weight.
[0870] In yet a further preferred embodiment, the primal meat
portions can be removed from the container 4100, after chilling and
rigor mortis, and sliced automatically and without separation of
slices. Preferably, after slicing and while still generally held
together in a single item, the sliced primal meat portion can be
placed into a preformed gas barrier bag and sealed therein or
alternatively placed into a gas barrier packaging tray that has
been automatically thermoformed, in-line on a machine such as a
Multivac R530 (Manufactured by Multivac Sepp Haggenmuller GmbH
& Co. The gas barrier packaging tray can be profiled and shaped
so as to be similar and/or identical in internal profile to the
container 4100. The gas barrier packaging tray can then be located
into a vacuum chamber and a substantially gas barrier lid, that may
be a skin vacuum package (otherwise known by those skilled in the
arts, as SVP), and conveniently heat sealed therein at flanges
around the cavity of the gas barrier packaging tray. Preferably, a
hermetically sealed primal meat portion package can be produced
that contains the primal meat portion that has been conveniently
sliced according to a customer specification and requirement. The
vacuum or SVP packaging process, that can be automatically
performed with the use of R530 can rapidly and automatically
produce a plurality of the hermetically sealed primal meat portion
packages can be stored in temperature controlled storage
conditions. Preferably, a hermetically sealed primal meat portion
package can be further processed by UHP apparatus prior to sale and
delivery to customers.
Plant Layout
[0871] Referring now to FIG. 222, a preferred equipment layout
according to the present invention includes three rectangular
components being identified by the reference numeral 3350.
Preferably, the equipment includes three similar components. Each
component is arranged to form a horizontally displaced, rectangular
or square tube with doors at each end. The tube is conveniently
position so that access to the doors at each end of the tube can be
accessed for loading of packaging materials into the tube. When the
doors are shut, the tube is sealed to provide a fully enclosed
container or enclosure in which the EPS or FP trays can be stored.
Conveniently located ports are provided into the walls of the tube
such that suitable gasses can be introduced as required within the
tube thereby displacing substantially all atmospheric air and most
particularly atmospheric oxygen there from.
[0872] The tube is loaded with quantities of EPS and/or FP trays
and the doors are closed to provide a sealed container. Most
preferably nitrogen, other inert and/or any other suitable gasses
are provided into the tube so as to displace substantially all air
from the interior of the tube and thereby providing a condition
where the gas is in contact with the surface of the EPS and/or FP
trays. Preferably, an ozone generator may be installed and chlorine
gas may be provided within the enclosure. Any gasses and most
particularly oxygen, that may be present within the cells of the
trays can therefore freely diffuse and exchange with the gas in
contact with the tray surfaces. With the passage of time, gas
contained within the cell structure of the tray walls will
therefore be displaced with gas in contact with the outer surface
of the trays. Preferably, oxygen gas will be substantially removed
from the cell structure. Oxygen will gradually accumulate and the
level of "free" residual oxygen remaining in the tube can be
monitored by automatic gas analysis and maintained at a minimum and
desired level. This is achieved by extracting gasses from within
the tube at a point near an end of the tube while providing an
equal quantity of additional oxygen free gas into the tube at a
point near to the opposite end of the tube from the extraction
point at the other end of the tube.
[0873] Equipment 3302 is a tray sealing apparatus which is arranged
to produce packages, including tray, web and perishable goods
contents shown as ground meat. The perishable goods may be portions
of beef, pork or any other suitable perishable goods.
[0874] Referring now to equipment 3318, a representation of an
apparatus is shown for producing substantially gas barrier "master
containers" from a roll of suitable material 3316. Equipment 3318
may be a Multivac R 530 that has been adapted to suit the
production system of the present invention. Equipment 3320 shown at
can be provided for (optionally) locating an oxygen absorber into
each master container with the retail packages before sealing a
barrier lid to the master container. The barrier lid material 3322
includes a roll of the barrier plastics lid material.
[0875] Apparatus 3334 shown in FIG. 222 represents a typical
carousel style vacuum packing machine, such as an "Old Rivers"
equipment that has 8 vacuum chambers fitted thereto. The carousel
style vacuum packing machine, 3332, is shown fitted with 8 vacuum
chamber assemblies similar to that as shown in FIG. 223 and
described herein. Referring now to FIG. 223, a closed vacuum
chamber 2700 including upper vacuum chamber 2702 and lower vacuum
plate 2704 is shown. A rack 2700 with 2708 trays containing
perishable goods, red meat, are shown inside closed vacuum chamber
2700. An evacuation port 2710 in direct communication with a source
of vacuum is provided. A switch is attached to the vacuum source so
as to provide on/off control. Two continuous and concentric `O`
rings 2712 are located between the edges of 2702 and 2704 and
spaced apart providing a space 2714 therebetween. The distance
between `O` rings is arranged such that when multiplied by the
length of space 2714 the total projected area between the
concentric `O` rings can be calculated. Total projected area shall
therefore be equal to PI.times.`L1`. When a vacuum is applied to
port 2710, the closing force created between 2702 and 2704 can be
determined. Assuming that vacuum can be represented in terms of 80%
of atmospheric air pressure, at approximately 14 psi, then the
chamber total closing force, in pounds, would be equal to
DI.times.LI.times.0.8.times.14. A gas or blend of desired gasses
can be provided within the closed vacuum chamber at a pressure
above atmospheric pressure which will provide a chamber opening
force. However, in this arrangement, the closing force can be
arranged to exceed the opening force thereby providing a method of
maintaining a pressure with the closed chamber at a level above
that of the prevailing atmospheric air pressure while the closed
vacuum chamber remains closed due to the closing force provided. A
further evacuation port 2716 is provided in 2702 and a gassing port
2718 is provided also. The upper vacuum chamber 2702 is arranged so
that it can be lifted vertically upward and away from 2704 allowing
removal of the rack with trays and another rack with trays can be
placed therein such that a continuous production process can be
undertaken. The upper vacuum chamber 2702 and the lower vacuum
plate 2702 may be arranged with clamping and structural supports so
as to allow an increase of gas pressure to gas provided therein to
any desired pressure such as 500 psi or more.
[0876] Perishable goods are located in an EPS (foamed polystyrene)
tray with inherent or enhanced gas permeability. A gas permeable
web is positioned above the EPS tray. The web has adhesive applied
to the region of the web that will come into contact with flanges
of the tray so as to provide a seal between web and tray. The web
is then sealed to the flanges of the tray. The flange of the tray
may be compressed as shown to provide improved structural integrity
and strength.
[0877] The EPS tray with inherent or enhanced gas permeability can
quickly transfer, remove and exchange substantially all oxygen gas
from foam cells during "carousel evacuation and gassing
process".
[0878] The web may be printed on one or both sides with panels that
can be seen from the upper side after sealing to the tray. A bar
code can be applied to label on the underside of the package. The
bar code can include code information such as the specific weight
of tray contents, date packaged and type of content goods.
Information can be read by a scanner at any time after packaging
and converted to consumer readable information that can be printed
by, for example, ink jet printers onto the panel prior to retail
display.
[0879] A device to cause oscillation of gas pressure within the
chamber at a frequency that will cause improved and more rapid
exchange of air and oxygen contained within cells of EPS tray with
desired gas provided in chamber, can be provided. Furthermore, the
oscillation of gas pressure within the chamber, can cause the
permeable web to raise and lower and provide a space between the
web and upper surface of the goods thereby allowing the gas
provided in the chamber to directly contact the tray contents
beneath the web. Oscillation can also provide improved contact with
the goods and enhanced absorption of the gasses by the goods. The
oscillation may be set at a range of gas pressures that are above
or below prevailing atmospheric pressure. The gas may include other
substances in vapor, atomized or powder form and the composition
may be selected and include the most suitable blend of one or more
of the following: nitrogen, oxygen, argon, carbon dioxide,
hydrogen, krypton, neon, helium, xenon, O.sub.3, F.sub.2, H.sub.2,
O.sub.2, KMnO.sub.4, HClO, ClO.sub.2, Br.sub.2 and I.sub.2.
[0880] A desirable blend of gasses such as carbon dioxide and ozone
can be provided within the closed chambers 2702 and 2704 with the
rack with trays contained therein.
[0881] Referring now to FIG. 223, racks with trays can be
automatically loaded into open vacuum chambers 3332 which are then
closed. A vacuum source is then applied to port 2710 and a desired
gas provided into closed vacuum chambers after removal of
atmospheric air there from. The carousel is rotated,
intermittently, in the counterclockwise direction shown in FIG. 222
and stopped such that after each vacuum chamber assembly 3332 has
fully traveled around the perimeter of the carousel the rack with
trays can be automatically removed from each vacuum chamber and
replaced with another. Therefore a continuous and automatic process
of treating trays containing perishable goods with desired gasses
can be provided.
[0882] Referring now to equipment 3326, a diagrammatic
representation of an automatic carton erecting, filling and sealing
equipment is shown. A supply of cartons is also shown as 3324.
[0883] Referring now to equipment 3328, a representation of an
automatic carton palletizer, such as model FL 100 manufactured by
Columbia Machine, Inc., Vancouver Wash., is shown. The palletizer
is arranged to automatically palletize finished cartons of packaged
perishable goods with a supply of empty pallets 3330. Finished
cartons can be automatically transferred from equipment 3326 to the
palletizer 6.
[0884] Equipment 3334 is a representation of equipment configured
to locate tray flange covers prior to loading of the perishable
goods into the tray. The flange covers are described in Australian
patent application PM8415. Equipment 3308 is a representation of a
section of the packaging equipment that is exposed as require to
facilitate efficient loading of the perishable goods into the
trays. Equipment 3310 is a representation of equipment configured
to remove tray flange covers and as generally described in
Australian patent application PM8415. Equipment 3306 is a
representation of the direction of flow of an alternative
perishable goods to be optionally loaded into the trays.
[0885] Equipment 3336 is a representation of equipment configured
to receive, grind, condition and process meat and other similar
perishable goods like the one shown in FIG. 186. Equipment 3340 is
a meat grinder. Equipment 3342 is a pressure vessel. Equipment 3344
is a secondary meat grinder. Equipment 3346 is a pressure vessel.
Equipment 3338 represents the perishable food item, such as
portions of meat, that is to be processed and packaged. Equipment
3304 is a diagrammatic representation of equipment configured to
locate tray flange covering members prior to loading of the
perishable goods into the tray. Equipment 3308 is a diagrammatic
representation of a section of the packaging equipment that is
exposed as require to facilitate efficient loading of the
perishable goods into the trays. Equipment 3312 is a representation
of a roll of plastics lid material intended for sealing to flanges
of the trays after perishable goods have been placed therein.
Equipment 3314 is a representation of an optional feature and
equipment for locating labels onto the underside or, after
adjustment, upper side of the retail packages after sealing of lid
material to flanges of the trays. Equipment 3318 is a
representation of an apparatus for producing substantially gas
barrier "master containers" from a roll of suitable material 3316,
locating an optional oxygen absorbing material into each master
container with the retail packages and sealing a lid to the master
container that is unwound from a roll of plastics lid material
shown as 3322. Equipment 3334 is a representation of a typical
carousel type vacuum packaging machine that has been modified
according to the description provided herein, and located adjacent
to both packaging equipment items 2 and 3, so as to facilitate easy
transfer of finished packages therebetween. Equipment 3332 is one
of 8 vacuum chambers mounted to the carousel and as shown in FIG.
223. Equipment 3326 is a representation of an automatic carton
erecting, filling and sealing equipment with a supply of cartons
3324. Equipment 3328 is a representation of an automatic
palletizer.
[0886] Equipment 3300 is a representation of equipment configured
to exchange air and more particularly, atmospheric oxygen,
contained within the cell structure of foamed polystyrene trays
(EPS trays) and foamed polyester trays (FP trays). FIG. 240 shows a
cross-sectional side view of half of the arrangement and FIG. 241
shows a cross-section across the full width of the arrangement,
through parts of a preferred apparatus and packaging.
[0887] Equipment 3350 is a diagrammatic representation of an
alternative equipment configured to exchange air and atmospheric
oxygen, contained within the cell structure of foamed polystyrene
trays (EPS trays) and foamed polyester trays (FP trays).
Thermoforming Apparatus
[0888] Referring now to FIG. 224, a plan view of equipment layout
according to the present invention is shown that can be used to
produce trays constructed according to this invention.
[0889] The equipment layout is shown in a convenient arrangement
for the efficient production of the trays. Primary extruder 4600 is
arranged adjacent to secondary extruder 4602 in a normal condition
for production of expanded polystyrene foam sheet. Direction of
flow is shown traveling toward wind-up mechanism 4604 with spool
4606 attached thereto. A roll of EPS sheet material 4608, is shown
adjacent to tube 4610. Tube 4610 follows a path that is
conveniently arranged parallel with tube 4612. A cross-section
through tube 4610 is shown in FIG. 225. Tube 4610 extends to a
point of termination adjacent to thermoforming machine shown as
4614. A second EPS foam extrusion system with primary extruder 4616
and secondary extruder 4618 is located adjacent to the first EPS
foam sheet extrusion system 4600 and 4602. Second extrusion system
extrudes sheet in direction of flow as shown and toward winder
4620, spool 4622 and roll 4624 adjacent to the entry end of tube
4612. The construction of tube 4612 can be identical to tube 4610.
Tube 4610 and tube 4612 are parallel to each other and follow a
concentric path such that 4612 terminates at an end in close
proximity to thermoforming machine 4626. Tubes 4610 and 4612 follow
parallel and concentric paths that spiral upwardly thereby
providing an extended length of tubes 4610 and 4612 and contained
within a convenient area.
[0890] Referring now to FIG. 225, a section through tube 4612 is
detailed. Spool 4606 can be seen inside tube 4612 resting on belt
4628 and belt 4630. Belt 4628 and belt 4630 are held taught and
arranged to engage with drive sprockets conveniently located so as
to engage the belts. Belts can, thereby, carry spool 4606. Carrying
members extend throughout the full length of tubes 4610 and 4612
thereby carrying spools 4606 through tube 4612 and 4610. A dish
4632 is mounted to a pneumatic cylinder 4634 such that when
extended the dish can elevate the spool 4606 upwardly so as to lift
the spool away from driving belts 4628 and 4630. Tube 4612 is shown
mounted directly onto a floor, however the tube can be elevated
above the floor by suitable frame members. Gas 4636 is provided in
tube 4612, gas may be nitrogen gas. A three dimensional sketch of
spool 4606 is shown with roll of material 4612 wound thereon.
Spools 4606 can be loaded into the entry end of tubes 4612 and 4610
which are conveniently located adjacent to the winding members
attached to foam extrusion equipment. Spools can be carried through
tubes 4610 and 4612 on belts 4628 and 4630 that may be operating
continuously. Dish 4632 is located conveniently between belt 4628
and belt 4630. Dish 4632 and spool 4606 can thereby be elevated, by
activating pneumatic cylinder, upwardly and away from contacting
belts 4628 and 4630. Pneumatic cylinder 4634 with dish attached
thereto may be provided in sections that extend throughout the full
length of tubes 4610 and 4612. By operating belts 4628 and 4630
with forward driving motion and pneumatic cylinder 4634 and dish,
spools 4606 can be carried through tubes 4610 and 4612 according to
demand.
[0891] Preferably, tubes 4610 and 4612 can be flooded with a
suitable gas such as nitrogen or a blend of gasses including argon,
carbon dioxide, nitrogen and a quantity of oxygen that does not
exceed about 5% and is not less than about 1000 PPM of blend of
gasses, through ports 4640 and 4612. Spools with rolls of EPS foam
material can be stored in tubes 4610 and 4612 for a period of time
as may be required in the normal aging of EPS foam material. This
period of time may be in the order of twelve hours and accordingly
the length of tubes 4610 and 4612 will be arranged so as to
accommodate sufficient spools of material required for production
of trays and also allowing for the twelve hour residence time as
required. After storing the spools 4606 in tubes 4610 and 4612
quantities of spools can be removed from the exit end of the tubes
adjacent to the thermoforming machines. Spools can be loaded onto
the thermoforming machines and thermoformed trays with flaps can be
manufactured, as required.
[0892] Referring now to FIG. 227, a cross-section through a
thermoforming machine oven is shown. The oven includes a
substantially sealed and enclosed rectangular tube with heaters
4633, 4635 arranged above and below EPS sheet 4631 that can be
carried therethrough. The EPS sheet can be fed into the oven
through a slot that is slightly larger than a cross-section through
the EPS sheet. Tube 4646 is attached to the under section of the
oven and tube 4644 is attached to the upper section of the oven.
Gas can be provided at a pressure above the ambient atmospheric
pressure, from a "nitrogen generator" directly into tube 4646. Gas
can be extracted from tube 4644 that follows a path along path 4648
and through cooler 4650. Tube 4644 delivers the gas and an
additional quantity of air along tube 4644 and into the nitrogen
generator. The nitrogen generator generates nitrogen gas by way of
separating oxygen from air and allowing only nitrogen to pass into
and through tube 4646. Gas may be provided into tube 4646 directly
from tube 4644 if required.
[0893] Referring again to FIG. 224, a plan view of tubes 4660,
4662, 4664, 4666 are shown passing through a wall. The tubes may be
filled with a suitable gas. Fully formed trays with flaps can be
loaded into the tubes for direct transfer and use on packing
machines.
[0894] Preferably, the thermoforming apparatus herein described can
be incorporated into the plant layout schematic of FIG. 222.
Referring now to FIG. 228, a slight modification to a previous
equipment plan is shown for producing trays according to the
present invention. Equipment includes four tubes 4700, 4702, 4704,
and 4706. Each item is arranged to form a horizontally displaced,
rectangular or square tube with doors at each end. Each tube is
conveniently positioned so that access to doors at each end of tube
can be accessed for loading of packaging materials into tube. When
the doors are shut, the tube is sealed to provide a fully enclosed
container or enclosure in which the EPS or FP trays can be stored.
Conveniently located ports are provided into the walls of the tube
such that suitable gasses can be introduced as required within the
tube thereby displacing substantially all atmospheric air and most
particularly atmospheric oxygen there from.
[0895] Each tube is loaded with quantities of EPS and/or FP trays
and doors are closed to provide a sealed container. Most preferably
nitrogen, other inert and/or any other suitable gasses are provided
into the tube so as to displace substantially all air from the
interior of the tube and thereby providing a condition where gas is
in contact with the surface of EPS and/or FP trays. Additionally,
an ozone generator may be installed and chlorine gas may be
provided within the enclosure. Any gasses and most particularly
oxygen, that may be present within the cells of the trays can
therefore freely diffuse and exchange with the gas in contact with
the tray surfaces. With the passage of time, gas contained within
the cell structure of the tray walls will therefore be displaced
with gas in contact with the outer surface of the trays. Most
importantly oxygen gas will be substantially removed from the cell
structure. Oxygen will gradually accumulate and the level of "free"
residual oxygen remaining in the tube can be monitored by automatic
gas analysis and maintained at a minimum and desired level. This is
achieved by extracting gasses from within the tube at a point near
an end of the tube while providing an equal quantity of additional
oxygen free gas into the tube at a point near to the opposite end
of the tube from the extraction point at the other end of the
tube.
Open and Closed Cell Structures
[0896] Referring now to FIGS. 229-237, cross-sectional and enlarged
views of expanded polystyrene (EPS) foam sheet are shown, wherein
FIG. 229 shows a cross-section through a portion of co-extruded EPS
foam including three layers 4500, 4502 and 4504. FIG. 230 shows a
cross-section through a portion of extruded EPS foam sheet
including three layers 4506, 4508 and 4510 and wherein layers 4506
and 4510 include skin similar to the section shown in FIG. 233.
[0897] Referring to FIG. 229, outer layers 4500 and 4504 sandwich
an inner layer 4502. Outer layers 4500 and 4504 include closed cell
EPS foam as shown in FIG. 232. "Closed cell" EPS foam describes a
physical condition where the cells or bubbles, that are filled with
gas, generally include enclosed spherical spaces where the cell,
bubble or sphere is not fractured and therefore any gas contained
therein can enter or exit the spheres by diffusion through the
spherical wall only and not through fractures or openings in the
sphere wall. FIG. 232 shows a grouping of cells or bubbles that
contain a gas which may be air. Layer 4502 includes a layer of open
celled EPS foam as shown in FIG. 235. "Open cell" EPS foam is a
physical condition where most cells or bubbles are fractured and
allow gas and other matter to invade the internal space of the open
cells readily. Production of open cell EPS foam can be effected by
introducing contaminants into the polystyrene melt prior to
foaming. The contaminants may include a surfactant to enhance
liquid absorbing properties, can cause fractures in the cell walls
to appear. Closed cell EPS foam is produced by ensuring that there
are no contaminants in the polystyrene melt prior to foaming.
Closed cell foam generally provides a more mechanically stable and
rigid structure than does open cell foam. Therefore in order to
produce a more mechanically stable and rigid packaging tray, closed
cell polystyrene is a preferred construction material. However
closed cell EPS foam resists absorbing liquids such as blood, water
and purge. In order to produce a superior EPS foam packaging
material that has both liquid absorbing and structurally sound
properties use of a combination of both types of open and closed
cell foam is preferable. A preferred material would include three
layers of co-extruded multi-layer foam sheet where layers 4500 and
4504 include closed cell EPS foam and layer 4502 includes open cell
EPS foam.
[0898] Referring now to FIG. 230 a cross-section through a
preferred material is shown where a three layer material includes
two outer layers 4506 and 4510 and a center layer 4508. Layers 4506
and 4510 are similar and include a skin that can be induced by
exposing a mono extruded layer of EPS foam, before the foam has
cooled and solidified, to relatively cool air applied thereto under
regulated pressure. By applying the regulated compressed air in
this way a skin can be formed by deflating the open or closed cell
structure at one or both surfaces of the EPS sheet. The layer 4508
includes a layer of open cell EPS foam.
[0899] Referring now to FIG. 231, the closed cells are shown
schematically, as being exposed to gas pressure that is higher than
gas pressure inside the closed cells. Enlarged view of closed cell
FIG. 237 shows a ratio of a pressure differential where P equals
the external gas pressure and P1 the closed cell internal gas
pressure. FIG. 234 shows a grouping of closed cell EPS foam cells
where the internal pressure P1 is greater than the external gas
pressure P.
[0900] The present invention to provides a method to substantially
remove oxygen gas that may be retained within the cell structure of
the EPS foam packaging materials and to also reduce the amount of
oxygen and/or slow the rate at which oxygen may re-enter the cell
structure after removal from storage and processing in a suitable
gas. The following steps disclose a method that can be used to
achieve this condition. Any or all of the following steps may be
effected in the sequence shown or any other sequence that enhances
the most efficient and rapid removal of undesirable gasses,
including oxygen, from the structure of the packaging
materials:
[0901] Place a quantity of EPS foam packaging materials, such as
trays with flaps, in a gas tight and sealed pressure chamber, with
evacuation and gassing ports therein and valves attached so as to
allow evacuation and gassing, with suitable gas, of the pressure
chamber as desired.
[0902] Provide a vacuum inside the pressure chamber, by lowering
gas pressure therein, and maintain for a period of time so as to
enhance the removal of oxygen from the structure of the packaging
materials in a desired manner.
[0903] Introduce a suitable gas into the pressure chamber at an
initial selected and suitable pressure that may be below ambient
atmospheric pressure.
[0904] Maintain the selected and suitable pressure for a period of
time that enhances the removal of oxygen from the structure of the
packaging materials in a desired or optimized manner.
[0905] Progressively increase the pressure of the suitable gas in
the pressure chamber, in a continuous or intermittent manner, over
time, until the gas pressure is above atmospheric pressure.
[0906] Maintain the gas pressure for a period of time that enhances
the removal of oxygen from the structure of the packaging materials
in a desired or optimized manner.
[0907] By heating and/or cooling apparatus, maintain the
temperature of the packaging materials and the suitable gas in the
pressure chamber, at a temperature that enhances the removal of
oxygen from the structure of the packaging materials in a desired
or optimized manner.
[0908] During the process, described above, exchange the suitable
gas, while maintaining the suitable gas pressure in the pressure
chamber as required, which can continuously occur during the
process, at a suitable rate of exchange to ensure that any
undesirable gas, including oxygen, that may become present in the
suitable gas, is substantially removed from within the pressure
chamber.
[0909] Remove the packaging materials from the pressure chamber and
allow the packaging materials to physically expand as can occur due
to a higher relative gas pressure that may exist in the closed cell
structure of the EPS packaging materials.
[0910] Maintain the packaging materials at a suitable temperature
for a suitable period of time, after removal from the pressure
chamber.
[0911] The steps disclosed above may be repeated, sequentially or
otherwise and in a manner that provides an efficient process to
remove undesirable gasses from the structure of the packaging
materials and to enhance the expansion of the packaging materials
in a desired manner.
[0912] In this way oxygen gas can be removed, from within the open
and closed cell structure of EPS foam material, and replaced with
the suitable gas at a pressure above atmospheric pressure. The
packaging materials can then be used for packaging. The higher
pressure within the closed cell structure can gradually equilibrate
with that of the prevailing ambient atmospheric air pressure,
however during this equilibration period the rate of re-entry of
atmospheric oxygen into the structure of the packaging materials
can thereby be reduced.
[0913] In another preferred embodiment, adhesives such as any
suitable bonding medium may be applied to surfaces of the flaps of
tray and the tray walls and base by any suitable "ink jet"
apparatus. Furthermore, colored graphic printing and any desired
information can be printed and/or applied to any desired surfaces
of the tray and flaps by any suitable "ink jet" apparatus. The "ink
jet" equipment is manufactured by several companies such as Hewlett
Packard, Xerox, SciTex, Marconi/Video Jet and others. The equipment
can be arranged to apply inks, lacquers and adhesive materials as
required by, for example, arranging the ink jet equipment adjacent
to a conveyor that can transport the trays with flaps at a suitable
speed and in such a manner as to allow application of the inks and
other materials to the trays and flaps, as required. The conveyor
may be arranged adjacent to and integrated with thermoforming
machinery such that immediately after producing trays with flaps,
the trays can be automatically transferred onto the conveyor. The
conveyor can be arranged to carry trays with flaps at a controlled
speed and as required to allow application of inks and any suitable
materials thereto by ink jet printer.
Tray Treatment Method and Apparatus for the Removal of Oxygen
[0914] Referring now to FIG. 238, details of an apparatus for
storing foam (EPS or polyester foam) trays, for exchanging gas in
cells with a preferred gas is shown. This apparatus provides a
method to substantially remove any residual oxygen that may be
retained in the cell structure of EPS packaging materials intended
for use in packaging fresh red meats in a "low oxygen" master
container, case ready packaging system. The method disclosed herein
can provide a process to remove and replace the residual oxygen,
with a desired gas, more rapidly than occurs when the EPS packaging
materials are stored in a chamber containing desired gas in a
static condition at ambient atmospheric pressure. The apparatus
includes a rectangular or suitably profiled tube 4200. The tube
4200 is arranged to have two open ends 4202 and 4204, one at each
end of the tube 4200. The tube is provided with evacuation port
4206 and gas entry port 4208. The tube can be filled with precut
foam (EPS) trays with flaps, or sheets of foam 4210. The tube can
be arranged to have a suitable length and be configured in such
manner as to allow automatic loading from the trim press of a
suitably modified thermoforming and tray trimming apparatus. The
tube can further be arranged so as to allow automatic removal of
one tray with flaps at a time for subsequent automatic processing
of the tray with flaps to form a finished tray with bonded and
sealed flaps.
[0915] Open ends 4202 and 4204 can be arranged to mate with
covering caps (not shown) in such a manner as to completely enclose
the tube and provide airtight seals at both open ends. The
completely enclosed tube 4200 can thereby provide a vacuum chamber
containing the trays with flaps such that when a vacuum source is
connected to evacuation port 4206 substantially all air contained
therein can be removed. After evacuation of the air from the tube,
the vacuum within the tube can be maintained for a period of time,
the period of time being sufficient to allow removal of
substantially all retained air and oxygen from the cell structure
of the trays with flaps. After removal of substantially all air and
oxygen from within the cell structure, a suitable gas such as
nitrogen or carbon dioxide can be provided into the tube via gas
entry port 4208. The gas can be retained within the enclosed and
sealed tube 4200 for a period of time sufficient to allow the cell
structure to become filled with the suitable gas. Alternatively,
evacuation of air from within the tube can be adjusted to provide a
remaining gas or air pressure therein at any pressure between zero
and ambient atmospheric air pressure and suitable gases can be
provided in the tube so as to blend with any remaining air
contained therein after evacuation to a desired pressure. Such
process of evacuation and gassing can be repeated in accordance
with an optimized process that will result in the most rapid
exchange of retained oxygen in the cell structure with a desired
gas.
[0916] In another preferred embodiment, the evacuation port 4206
may be provided in the sealing cover over open end 4204 and the gas
entry port 4208 may be provided in the sealing cover over the open
end 4204. The preferred embodiment can thereby provide an
arrangement where a vacuum source can be attached to the evacuation
port and a gas source can be attached to gas entry port and provide
a continuous flow of gas through the tube from one end to the other
so as to contact the surface of the trays with flaps contained
herein. The pressure of the gas flowing through the tube can be
arranged at a level most suitable to achieve the most rapid removal
of air and oxygen that may be contained within the cell structure
of the trays with flaps and thereby exchange the oxygen with the
desired gas.
[0917] Referring now to diagram FIG. 238, details are shown of an
apparatus for storing foam (EPS or polyester foam) trays, for
exchanging gas such as oxygen that may be contained in the cell
structure of the trays, with a preferred gas. The apparatus removes
any residual oxygen that may be retained in the cell structure of
the EPS trays that are intended for use in packaging fresh red
meats in a "low oxygen" master container, case ready packaging
system. The apparatus and method disclosed herein can provide a
process to remove and replace the residual oxygen, with a desired
gas, more rapidly than occurs when the EPS packaging materials are
stored in a chamber containing desired gas in a static condition at
ambient atmospheric pressure.
[0918] The apparatus includes a rectangular or suitably profiled
tube 4200. The tube is arranged to have two open ends 4202 and
4204, one at each end of the tube. The tube is provided with
evacuation port 4206 and gas entry port 4208. The tube can be
filled with precut foam (EPS) trays with flaps, or sheets of foam
4210. The tube can be arranged to have a suitable length and be
configured in such manner as to allow automatic loading from the
trim press of a suitably modified thermoforming and tray trimming
apparatus. The tube can further be arranged so as to allow
automatic removal of one tray with flaps at a time for subsequent
automatic processing of the tray with flaps to form a finished tray
with bonded and sealed flaps as described above.
[0919] The open ends 4202 and 4204 can be arranged to mate with
covering caps (not shown) in such a manner as to completely enclose
the tube and provide airtight seals at both the open ends. The
completely enclosed tube can thereby include a vacuum chamber
containing the trays with flaps such that when a vacuum source is
connected to evacuation port 4206 substantially all air contained
therein can be removed. After evacuation of the air from the tube,
the vacuum within the tube can be maintained for a period of time,
the period of time being sufficient to allow removal of
substantially all retained air and oxygen from the cell structure
of the trays with flaps. After removal of substantially all air and
oxygen from within the cell structure, a suitable gas such as
nitrogen or carbon dioxide can be provided into the tube via gas
entry port 4208. The gas can be retained within the enclosed and
sealed tube for a period of time, which may be 1 to 2 hours,
sufficient to allow the cell structure to become filled with the
suitable gas. In a preferred procedure, the air will be
substantially evacuated through the evacuation port 4206 and then a
gas such as nitrogen will be introduced through port 4208 at a
suitable low pressure. The gas will be held at the suitable low
pressure for a period of time and then, the low pressure of the gas
will be gradually increased, over a period of time, and until the
gas pressure is increased to a maximum gas pressure above ambient
atmospheric pressure. The maximum gas pressure may be 60 psi or
more.
[0920] Alternatively, a partial evacuation of air from within the
tube 4200, to a level that does not completely evacuate the tube
but lowers the air pressure therein to a pressure above zero and
below ambient atmospheric air pressure. A suitable, oxygen free,
gas such as nitrogen can be provided into the tube, through the
port 4208, so as to blend with the remaining air contained therein.
This process of partial evacuation followed by gassing can be
repeated, sequentially until the oxygen gas contained in the EPS
cell structure is removed and in an optimized process that will
result in the rapid exchange of the retained oxygen in the cell
structure with a desired gas.
[0921] In another preferred embodiment the evacuation port 4206 may
be provided in the sealing cover over the open end 4204 and the gas
entry port 4208 may be provided in the sealing cover over the open
end 4202. A vacuum source can be attached to the evacuation port
4206 and a suitable gas source, such as nitrogen or a blend of
gasses including argon, carbon dioxide, nitrogen and a quantity of
oxygen that does not exceed 5% and is not less than 1000 PPM, can
be attached to the gas entry port 4208 and thereby providing a
continuous flow of gas through the tube from port 4208 to
evacuation port 4206 so that the suitable gas contacts the surface
of the trays with flaps contained herein. The pressure of the gas
flowing through the tube can be arranged at a level most suitable
to achieve the most rapid removal of air and oxygen that may be
contained within the cell structure of the trays with flaps.
[0922] In yet another preferred embodiment, a plurality of the
rectangular tube 4200, may be conveniently stacked together and
located inside a suitably sized vacuum chamber. Substantially all
air may be evacuated from within the vacuum chamber and held with
the vacuum source attached thereto for a period of time sufficient
to allow removal of substantially all gas from within the expanded
polystyrene foam cell structure. A suitable gas, such as nitrogen
can then be provided into the vacuum chamber, at a pressure equal
or greater than ambient atmospheric pressure so as to completely
fill the vacuum chamber and contact all surfaces of foam trays in
the tubes. After a period of time the plurality of tubes can be
removed from the vacuum chamber.
[0923] Referring now to FIG. 239, another embodiment of a
rectangular tube having top bottom open ends is shown. Preferably,
the rectangular tube may be manufactured from any suitable material
such as stainless steel or other plastics material and may be
arranged to have any convenient length. Preferably, the rectangular
tube can be manufactured with longitudinally parallel sides and a
cross-section that corresponds with the cut size of the trays that
are shown therein. More specifically the rectangular tube will have
a cross-sectional opening that is sized so as to be slightly larger
that the cut size of the trays contained therein. For example, if
the plan, cut size dimensions of the trays is 5 inches long by 4
inches wide the opening in the rectangular tube will be about 5.125
inches long by about 4.125 inches wide.
[0924] A gas entry port 3302 is shown located in the wall of the
rectangular tube at about equal distance from each end of the
rectangular tube. A plurality of additional gas entry ports may be
provided at any suitable location in the wall of the rectangular
tube. Most preferably, a suitable gas or blend of gasses, such as
nitrogen, may be provided inside the rectangular tube through the
entry port 3302. The gas may be provided by an injector into the
rectangular tube through one or more of gas entry ports at a set
pressure and volume. Gas may be provided at a pressure that is
varied by normal methods or alternatively by way of a set pitch
sound that may also be varied in a manner to enhance gas exchange.
Preferably, length of rectangular tube 3300 can be arranged such
that when trays are passed through the rectangular tube, the
residence time of trays within the rectangular tube will be
sufficient to allow gas exchange to occur between suitable gas
provided through the entry port and into the rectangular tube and
gasses such as oxygen that may be contained within the cell
structure of the trays. Trays may be loaded through an opening at
the open tope of rectangular tube and unloaded through the open
bottom.
[0925] Preferably, rectangular tube is vertically disposed such
that gravity will provide sufficient force to cause the trays to
pass through the opening through the rectangular tube, when trays
are removed from the bottom of rectangular tube. Alternatively, the
rectangular tube may be horizontally disposed and a driver such as
an auger (not shown) may be provided to transfer the trays through
the rectangular tube. Preferably, the rectangular tube may be
arranged so as to connect with an automatic tray dispenser so that
trays can be automatically removed, one or more at a time, and
subsequently be positioned onto a packaging machine in readiness
for loading of perishable goods such as fresh red meat therein. A
plurality of rectangular tubes may be arranged together in a
grouping so as to process a plurality of trays simultaneously.
[0926] The rectangular tube can be manufactured to suit trays of
any size.
Tray Forming Apparatus
[0927] Referring now to FIGS. 240-241 where a cross-section of the
tray forming apparatus 2200 is illustrated. The apparatus is
intended for used in a method for removing oxygen gas from the
structure of expanded polystyrene packaging materials that are
intended for use in packaging perishable goods that could be
deleteriously affected by the presence of oxygen in quantities that
exceed 500 PPM. The method includes but is not limited to the use
of any suitable gas at any suitable pressure arranged to pass
through the packaging materials by providing the suitable gas to
one side of the packaging materials at a pressure above what is the
gas pressure of any gas that is present on the opposing side of the
packaging materials. The suitable gas will thereby be caused to
pass through the packaging materials and furthermore cause a
reduction in oxygen contained in the structure of the packaging
materials.
[0928] The apparatus includes two parts. The first part shown in
FIG. 240 is a side view cross-section with the apparatus in a
closed position and a tray clamped between an upper chamber 2252
and a lower chamber 2254. FIG. 240 shows half of the apparatus with
a center line marked through what would be the center of the
apparatus. The other half of the apparatus is a mirror image of the
part that is shown. FIG. 241 shows a cross-section across the
entire width of the upper and lower chambers 2252 and 2254.
[0929] The apparatus 2200 includes an upper and lower chamber which
are arranged so as to be moveable toward and away relative to each
other, thereby allowing trays to be processed in a continuous
mode.
[0930] A porous mold 2256, that is profiled to follow the contours
of the tray and to neatly fit within the confinement of the
chambers 2252 and 2254, is provided and can be fixed to the upper
chamber. A gassing port 2258 is provided in the lower chamber 2256
and an evacuation port 2260 is provided in the upper chamber 2252.
The porous mold 2256 can be manufactured from a suitable porous
material and may have grooves and slots machined across the surface
of the profiled face 2262 that are all connected to evacuation port
2260, thereby allowing gasses to be evacuated therethrough and
through port 2260. The apparatus can be configured to accommodate
one or more trays, however, for ease of explanation the apparatus
shown in FIGS. 240-241 preferably accommodates one tray. A blade
2264 is provided within chamber 2254 which is attached to a moving
member. The blade 2264 can be arranged in a continuous length to
provide a knife edge that follows the perimeter of what will become
the processed and cut tray. Space is provided between the surface
of the profiled mold 2256, as shown, providing a space into which a
suitable pressurized gas can be provided.
[0931] A tray 2268, having extended flanges, 2270, is located on
the porous mold 2256 and the chambers 2252 and 2254 are closed so
as to clamp the flange `TF` around the full perimeter of the tray.
The tray 2270 may be thermoformed from expanded polystyrene and
therefore has a porosity and can therefore allow pressurized gas to
pass therethrough. Pressurized nitrogen gas can then be provided
into the space through port 2258 at a suitable pressure. A vacuum
source can be attached to port 2260. The gas thereby passes through
the porous tray walls and can displace oxygen gas that may be
present therein. The pressurized gas can be provided into the space
and passed through the tray porous walls for sufficient time to
displace substantially all oxygen gas that may have formerly been
present therein. The blade 2264 with knife edge can be activated
and moved by the moving member 2250 so as to cut through the tray
flange 2270. Chambers 2252 and 2254 are opened allowing the tray
2268 to be removed in readiness for additional trays to be
processed in a similar fashion as described above. Trays 2268 can
be removed and replaced on the porous mold 2256 in a continuous,
intermittent and automatic procedure. The porous mold 2256 can be
interchanged with other molds having different profiles to suit
other trays of different size and profile.
[0932] Flange 2270 and any other part of the tray 2270 and the flap
2272 may be compressed, as desired, to substantially remove gas
from the foam cells thereby forming a substantially solid section
in the tray, flap 2272 and flange 2270 as required. In this way the
solid section can be arranged to provide a continuous solid section
around the perimeter of the tray such that a web of material such
as pPVC can be sealed to the solid section along a strip like path
around what will become a perimeter of a finished package. The
solid section may be located at the connection between the flap
2272 and the tray 2268 such that the flap 2272 and the tray 2268
can be hinged and folded so as to allow contact of tray flange 2270
with the tray 2268.
[0933] The apparatus is similar to a standard expanded polystyrene
thermoforming machine, where two parallel platens are arranged in
close relative proximity and with a powered device for moving the
platens toward and away from each other. Matched tools including
two parts, are typically mounted onto the platens such that a
heated sheet of expanded polystyrene or other suitable sheet, can
be located between the platens and separated matched tool parts.
The platens can be moved toward each other to a position that
clamps the heated sheet between the two parts of the matched tool,
thereby imparting a three dimensional profile that corresponds to
the profile of the matched tool, into the sheet. After the sheet
cools, the platens and the matched tool open and the profiled sheet
can be removed automatically to allow the positioning of another
sheet of EPS sheet therebetween. The EPS sheet is typically
arranged in a continuous web.
[0934] As disclosed in the aforementioned description, trays can be
processed in an automatic and continuous mode, such that any oxygen
gas that may be retained in the EPS cell structure can be
substantially removed and replaced with a desired gas such as
nitrogen. The method and apparatus described herein, can also be
incorporated into standard thermoforming machinery used for
production of thermoformed EPS trays.
[0935] In a preferred embodiment, the trays with flaps can be
produced on an automatic apparatus that heats a web of EPS sheet in
an oven that substantially excludes oxygen so as to ensure that
during any expansion of the EPS sheet during heating, immediately
prior to thermoforming of the EPS sheet, oxygen gas will be
substantially prevented from entering into the cell structure of
the EPS sheet. This can be achieved by providing a suitable gas
such as nitrogen in the oven during the heating of the EPS sheet,
the nitrogen gas being in direct contact with the surfaces of the
EPS sheet. The EPS sheet can then be transferred directly into a
forming station that is arranged to substantially exclude oxygen
gas therefrom and furthermore, apply pressurized nitrogen gas to
one side of the tray with flaps during the forming process and
causing the nitrogen gas to pass into and through the tray and
flaps during the forming process. Adhesive or solvent can then be
applied to selected areas of the flaps and the tray, either before
or after trimming the tray with flaps from the sheet of EPS
material. Then automatically fold the flaps and mechanically apply
sufficient pressure to the flaps to hold against the walls of tray
and cause bonding between the flap and the tray at desired regions
therebetween.
[0936] A preferred embodiment includes, but is not limited to
automatically or manually performing the following steps:
[0937] 1. Providing a tray that may be thermoformed from expanded
polystyrene (EPS) with flaps as shown in diagram. The tray having
dimensions that will provide for the efficient use of the internal
capacity of typical, refrigerated transport vehicles.
[0938] 2. Exposing the tray to a gas that excludes oxygen and
allowing the gas to exchange with any gasses contained within the
cells of the EPS thereby substantially displacing any atmospheric
oxygen from the cells.
[0939] 3. Providing perishable goods onto the base of the tray. The
perishable goods having been treated and processed to substantially
eliminate any bacteria thereon.
[0940] 4. Sealing a gas permeable material such as pPVC to the
flanges of the tray.
[0941] 5. Folding and then sealing the flaps to flanges of the
tray.
[0942] 6. Placing the tray or a plurality of similar trays into a
gas barrier master container.
[0943] 7. Displacing substantially all atmospheric gas, and
particularly atmospheric oxygen, within the master container, with
a desired single or blend of desired gasses.
[0944] 8. Sealing a lid over the opening in the master container to
form a hermetically sealed package containing the trays with
perishable goods and desired gas.
[0945] 9. Placing the master container inside a carton such as can
be manufactured from corrugated cardboard and enclosing the master
container.
[0946] 10. Locating a plurality of the closed cartons onto a
standard (GMA specified) pallet (Dimensions of 40''.times.48'') so
as to maximize the efficient use of the area provided by the
pallet.
Tray Materials of Construction
[0947] A multi-layer, co-extruded plastics sheet product extruded
through an annular die is disclosed, including substantially
amorphous polyester polymers, with additives, similar, but not
exclusively, to the structures shown in FIGS. 242-240 where at
least one of the layers is a foamed polyester and where at least
one or more other layers includes at least about 30% regrind
material derived from the skeletal scrap remaining after production
of thermoformed trays from the sheet, with the balance of the
regrind layer including a chosen virgin amorphous polyester
polymer.
[0948] FIG. 242 shows a multilayer coextruded plastic sheet
constructed according to the present invention including five
layers. Beginning from the uppermost layer 2900, the co-extruded
first layer 2900 includes a mix of blended components about 50%
Eastman 6763 and about 50% Eastman 19411. The first layer 2900 is
about 0.001 inches thick. The second co-extruded layer 2902
includes Eastman 9921 and is about 0.0025'' thick. The third
co-extruded layer 2904 includes a blended mix of foamed Eastman
9663 and Eastmann additive G4ZZZ-3AZZ, and is about 0.012'' thick.
The fourth co-extruded layer 2906 includes Eastman 9921 and is
about 0.0015'' thick. The fifth layer 2908 includes regrind
material recovered from tray thermoforming processes, and is about
0.002'' thick. The overall thickness of the sheet material shown in
FIG. 242 is about 0.018'' thick.
[0949] FIG. 243 shows a multilayer coextruded plastic sheet
constructed according to the present invention. The sheet material
includes four layers. Starting from the uppermost layer, the first
co-extruded layer 2909 includes a blended mix of about 60% Eastman
9921 and about 40% Eastman 6763. The first layer 2909 is about
0.002'' thick. The second co-extruded layer 2910 includes a blended
mix of foamed Eastman 9663 and Eastman additive G4ZZZ-3AZZ, and is
about 0.011'' thick. The third co-extruded layer 2912 includes
regrind material derived from skeletal scrap recovered from the
tray thermoforming process, and is about 0.0015'' thick. The fourth
co-extruded layer 2914 includes a blended mix of about 60% Eastman
9921 and about 40% Eastman 6763 and is about 0.002'' thick. The
overall thickness of the material shown in FIG. 243 is about
0.0165'' thick.
[0950] FIG. 244 shows a multilayer, coextruded plastic sheet
including three layers. Beginning with the uppermost layer, the
first co-extruded layer 2916 includes a blended mix of about 20%
Eastman 6763, 50% Eastman 9921, and about 30% of regrind material.
The first layer 2916 is about 0.0025'' thick. The second
co-extruded layer 2918 includes a mix of blended and foamed Eastman
9663 and Eastman additive G4ZZZ-3AZZ. The second layer 2918 is
about 0.011'' thick. The third co-extruded layer 2920 includes a
mix of about 20% Eastman 6763, about 50% Eastman 9921, and about
30% regrind material. The third layer 2920 is about 0.0025'' thick.
The overall thickness of the sheet material of FIG. 244 is about
0.016'' thick.
[0951] FIG. 245 shows a multilayer, coextruded plastic material
constructed according to the present invention. The sheet material
includes five layers. Beginning with the uppermost layer, the first
co-extruded layer 2922 includes a blended mix of about 50% Eastman
19411 and about 50% Eastman 6763. The first layer 2922 is about
0.0015'' thick. The second co-extruded layer 2924 includes a
blended mix of about 90% Eastman 9921 and about 10% of regrind
material derived from skeletal scrap recovered from the tray
thermoforming process. The second layer 2924 is about 0.006''
thick. The third co-extruded layer 2926 includes a blended mix of
about 90% of regrind material derived from skeletal scrap from the
tray thermoforming process and about 10% of Eastman 9921. The third
layer 2926 is about 0.003 inches thick. The fourth co-extruded
layer 2928 includes a mix of blended and foamed Eastman 9663 and
Eastman additive G4ZZZ-34ZZ. The fourth layer 2928 is about 0.019
inches thick. The fifth co-extruded layer 2930 includes a mix of
about 90% Eastman 9921 and about 10% of regrind material. The fifth
layer 2930 is about 0.0005'' thick. The overall thickness of the
sheet material of FIG. 245 is about 0.03'' thick.
[0952] FIG. 246 shows a multilayer, coextruded plastic sheet
material constructed according to the present invention. The sheet
material includes five layers. Beginning with the uppermost layer
2932, the layer 2932 includes about 50% blended Eastman 6763 and
about 50% Eastman 19411. The first co-extruded layer 2932 is about
0.0015'' thick. The second co-extruded layer 2934 includes about
10% blended Eastman 9921 and about 90% regrind materials derived
from skeletal scrap recovered from tray thermoforming process. The
second layer 2934 is about 0.0015'' thick. The third co-extruded
layer 2936 includes blended and foamed Eastman 9663 and Eastman
additive G4ZZZ-3AZZ. The third layer 2936 is about 0.010'' to about
0.019 thick. The fourth co-extruded layer 2938 includes about 10%
blended Eastman and about 90% regrind materials derived from
skeletal scrap recovered from tray thermoforming process. The
fourth layer 2938 is about 0.0015'' thick. The fifth co-extruded
layer 2940 includes about 50% blended Eastman 6763 and about 50%
Eastman 19411. The fifth layer 2940 is about 0.0015'' thick. The
overall thickness of the sheet material of FIG. 246 is about
0.016'' thick.
Tray Materials of Construction
[0953] Referring now to FIG. 247, a cross-sectional view through a
portion of material constructed according to the present invention
is shown. Polyester sheet material is co-extruded in a three layer
construction having two outer layers 2000 and 2002 of Eastman APET
9921 (about 0.002'' thick, each) and an inner layer 2004 of foamed
Eastman 9663 with an Eastman recommended quantity of Eastman melt
strength enhancer G4ZZZ-3AZZ. Inner layer 2004 is about 0.015''
thick. Inner layer 2004 is foamed with a suitable quantity of
nitrogen gas, substantially excluding air from foam cells. The
total thickness of co-extruded sheet is approximately 0.019''
thick. The gas barrier properties of the outer layers of Eastman
9921 are such that air will be substantially prevented from
permeating into the inner layer of foamed polyester. Sections of
the material have been compressed so as to solidify the inner layer
of foamed Eastman Polyester 9663 with the melt strength enhancer.
Both edges of co-extruded sheet are sealed together, by any
suitable sealer, preferably immediately after co-extrusion and
prior to winding onto a roll. Sealing edges substantially prevents
air from permeating into inner layer 2004 of foamed polyester.
Material is wound onto a roll and is then stored, most preferably
in a temperature controlled storage area and at a temperature below
10.degree. C. Following storage, the roll of co-extruded polyester
material is substantially converted into trays of a desired profile
and size by a thermoforming apparatus such as shown in FIG. 248
where a cross-section through such a tray is shown. Thermoforming
apparatus includes a typical method of pre-heating the sheet,
clamping convenient rectangular sections of the heated sheet and
vacuum (or pressure) forming the sheet onto a suitable tray forming
mould, however, at the moment of thermoforming and prior to cooling
of the sheet, a suitably shaped tool, that may also be heated to a
desired temperature, can be pressed against the flange regions, or
edge of the flange regions, of the trays during the forming process
and thereby compress the flanges. Most desirably the compression of
the flanges will cause substantially all gas to be expelled from
the inner layer of foamed polyester in the flange regions only.
Said trays are severed, by a cutting member, from the sheet of
material such that the edges of the flange are substantially sealed
together. Such a process can provide a tray with gas barrier outer
layers of polyester and an inner foamed layer of polyester such
that the inner layer is substantially prevented from direct contact
with ambient air. In this way ambient air will be substantially
prevented from permeating into the inner layer and also providing a
gas barrier to substantially prevent nitrogen gas within the foam
cells from escaping and exchanging with air.
[0954] FIG. 249 shows a cross-section of the material showing an
upper 2000, an inner 2004, and a lower 2002 layer. The upper layer
2000 is about 0.002'' thick, the inner layer 2004 of foam polyester
is about 0.15 thick and the lower layer 2002 is about 0.002''
thick. FIG. 250 shows the material of FIG. 249 when the material is
compressed according to the present invention. Outer layers 2000
and 2004 remain substantially about 0.002'' thick, but inner layer
2004 has been compressed to about 0.001'' thick.
Tray Rib Forming Apparatus
[0955] Referring now to FIG. 251 a tray with ribs formed in
accordance with this invention is shown. The inventor has
previously invented a system whereby a low oxygen modified wing
system including a "master container" (container) with trays
therein, is evacuated. During evacuation, all contents of the
container are exposed to a very high level of vacuum, furthermore,
the pressure of nitrogen gas, contained within the inner layer foam
cells which is approximately equal to the prevailing ambient
atmospheric pressure, will exert an "exploding" pressure against
the inner surfaces of the outer layers. Pressure can cause
distortion resulting in, at least, partial separation of inner
layer from outer layers. Furthermore, in extreme cases tray walls
could rupture and burst open. Clearly, such an event is undesirable
and this present invention provides a method, equipment and
production of a tray (product), that can minimize this undesirable
event. By including regions of dense material, the inventor has
discovered that trays can withstand the low pressure atmosphere
used in the above application.
[0956] FIG. 251 shows a three dimensional section of a tray that
has been thermoformed from sheets of material similar to those
described in the structures shown in FIGS. 242-246. FIG. 253 is a
view of a section through a wall of the tray with ribs 2100
provided therein. Referring now to FIG. 256, an apparatus that can
be used to provide ribs 2100 is shown. Ribs can be provided by
closing heat bank 2118 onto wall of tray 2114 when tray 2114 is
supported by pad 2116. Heat bank 2118 can thereby weld/heat seal a
portion of the inner surface of the outer layers 2108, 2112 to each
other after compression of inner layer 2110 foam cells such that
the outer layers become welded/heat sealed to each other at the
point of contact. Radius 2106 of ribs 2100 as shown in FIG. 253 can
be adjusted and also the distance of pitch from radius to radius
can also be adjusted by production of equipment providing the
desired adjustments. Adjustments can be made in order to provide
for optimized configuration of radius 2106 and pitch such that the
exploding effect of exposure to high vacuum that could otherwise
result in the rupturing of the tray, as described above can be
minimized.
[0957] In a preferred embodiment, an apparatus for compressing a
web of material 2124 to provide ribs therein is detailed in FIG.
255. Heat banks 2120 and 2124 are arranged, as required, in a
mechanism so as to enable compressing of material therebetween and
thereby bond outer layer 2126 and inner layer 2130 together with
compressed foamed polyester layer 2128 therebetween. A
cross-sectional view through a portion of compressed material 2124
with an aperture punched therethrough is shown in FIG. 256.
Additionally a mechanism for providing perforations in an outer
layer of a tray wall thermoformed from the material shown in FIG.
247, is also detailed in FIG. 257. Perforations 2136 can be
provided to allow communication and transfer of gasses from the
foamed polyester layer 2128 and through perforations 2136.
Rib Forming Apparatus
[0958] Referring now to FIG. 258, a cross-section through a tooling
assembly of tool parts 2200 and 2202, with a section of material
2124 (after processing/forming), is shown. Tooling part 2200 is
temperature controlled by passing liquid 2206 through conveniently
located passageways shown as ports 2204. Liquid is preconditioned
to a specified and desired temperature and is passed through ports
2204 at a rate sufficient to control the temperature of tooling
part 2200. Similarly part 2002 can be temperature controlled in a
similar manner (not shown). Evacuation holes 2208 are located in
part 2200 and evacuation ports 2210 are also located in tooling
part 2202. A plan view of cavity 2212 is shown in FIG. 259 with
length and width dimensions respectively also shown. FIG. 260 shows
a cross-section through a section of material, which has been
sealed around its periphery 2124 by compressing and sealing the
outer layers together, before processing with matching tool parts
2200 and 2202. Tooling assembly includes two parts 2200 and 2202
and the face 2214 of part 2200 is arranged to have width and length
dimensions such that it can enter and partially penetrate cavity
2212 with a clearance around the perimeter of the cavity of
0.010'', such that the parts 2200 and 2202 are in close proximity
but substantially do not contact each other. The tooling parts 2200
and 2202 can be mounted onto independently moving members that can
simultaneously provide a predetermined closing movement toward each
other and with a desired force. Face 2214 is parallel to face 2216
and when parts 2200 and 2202 are closed together in a closed
position, parts 2200 and 2202 are arranged so as not to contact and
the distance between face 2214 on part 2200 and 2216 on part 2202
is at a set predetermined distance. A vertical wall 2218 is located
around cavity 2212 and when part 2200 and 2202 are in a closed
position an enclosed space is so defined by face 2214, face 2216
and walls 2218. Therefore, the volume of space can be predetermined
and the displacement of section of material 2124 can also be
predetermined. Volume and displacement can be arranged to be
substantially equal. A section of material 2124, shown in FIG. 260
is heated to a desired temperature and located into the cavity 2212
immediately prior to closing parts 2200 and 2202, such that when
parts 2200 and 2202 are closed and a vacuum source is applied to
evacuation ports 2210 and passageways 2208 in parts 2200 and 2202,
the profile of the section of material 2124 will be altered, so as
to substantially conform to the profile of the space wherein ribs
2220 will be formed by rib mold 2222 in face 2214. This method of
forming a part with a desired profile from a substantially flat
(two dimensional) sheet of material 2124 can be applied to form
parts such as trays. The profile of the trays will be determined by
the profile of the tooling parts which can be manufactured to
specific requirements and particularly to provide a method of
producing trays of optimized profile and rigidity for use, for
example, in master container modified atmosphere packaging system
as described herein.
Removal of Oxygen from Cell Structures
[0959] Referring now to FIG. 261, a cross-sectional view of a
pressure chamber apparatus, vacuum tube 4900, is shown. The
apparatus is intended to be used in the process of removing any
oxygen gas that may be retained within the cell structure of
expanded polystyrene foam packaging materials such as trays with
flaps, that are intended for use in packaging perishable products
such as red meats in a low residual oxygen modified atmosphere
package. The vacuum tube 4900 includes a tube of suitable length,
open at both ends with end caps 4904 and 4906 fitted to each end
which together, provide a sealed and air tight pressure chamber.
The end caps can be clamped in position and are removable as
desired. The vacuum tube 4900 may be manufactured from any suitable
material such as aluminum, stainless steel or a plastic material or
a combination thereof. The size and profile of the vacuum tube can
be arranged to suit and accommodate a magazine, such as is detailed
in FIG. 263. The magazine has an outer profile and dimensions such
that it can be readily located inside the vacuum tube 4900. The
inner profile of the magazine 4908 is arranged to suit a particular
size of tray with flaps. A plurality of a particular size of tray
with flaps can be located within the magazine and held in this
position as required for further processing as a complete unit. A
plurality of magazines can be provided to suit any desired sizes of
trays with flaps. A piston 4910 fitted with seals between the
piston and the internal surface of bore of the vacuum tube 4900 can
be located in the bore of the vacuum tube adjacent to end cap 4906.
The piston can be manufactured from materials that include a
suitable quantity of a magnetic material such as iron. The piston
is arranged so as to move easily within the confines of the vacuum
tube along the bore. The end cap 4906 can be manufactured with an
electromagnetic devices attached thereto that are capable of
activation as required in a manner that, as and when required, will
cause the piston to become magnetically attached thereto. A port
4912 is provided in the end cap 4906. Two manifolds marked manifold
4914 and manifold 4916 are fitted on opposite sides of the vacuum
tube 4900. The manifold 4914 has direct communication with the
vacuum tube through apertures 4918 and manifold 4916 has direct
communication with the vacuum tube through apertures 4920. Ports
are provided at each end of the manifolds. The manifold ports 4922,
4924, 4926 and 4928 are connected to a vacuum source and nitrogen
gas or any other suitable gas source, via a three-way valve such
that either gas, set at a selected and adjustable pressure, or
alternatively a vacuum source can be attached directly to the
manifold ports. The gas supply and the vacuum source can be
alternately attached to each manifold port, together or separately,
in any desired sequence and/or manner that will efficiently remove
residual oxygen from cell structure of packaging materials
contained in the vacuum tube 4900.
[0960] A plurality of vacuum tubes 4900 may be manufactured in
suitable quantities and arranged so as to be attached to an
apparatus such as shown in FIG. 267. The vacuum tubes 4900 are
arranged to allow the transfer of magazines 4908, therethrough
after removal of both end caps with the piston electro-magnetically
attached to end cap 4906. Alternatively the trays with flaps may be
transferred from the magazine 4908 directly there from. Empty
magazines can then be returned by automatic transfer to a known
location and as controlled by a programmable CPU or PLC
(programmable logic controller) attached to the magazine
assembly.
[0961] Referring again to FIG. 267, an apparatus is shown as vacuum
tube assembly, and includes a quantity of preferably 23,
horizontally and parallel disposed vacuum tubes, similar to 4900,
and each marked individually can be seen attached to a pair of
parallel and continuous chains that are in turn arranged to engage
with sprockets that are in turn arranged with suitable drivers. The
quantity of vacuum tubes, attached to the chains, may be varied
according to requirements.
[0962] An apparatus shown as magazine assembly, including a
quantity of preferably 23, to correspond to the number of vacuum
tubes horizontally and parallel disposed magazines, with each
magazine similar to magazine 4908, and each marked individually,
secured to a pair of parallel and continuous chains, that are in
turn arranged to engage with sprockets that are in turn arranged
with suitable drivers. The magazines are arranged so as to be
detachable from the magazine assembly.
[0963] The vacuum tube assembly and the magazine assembly are
arranged such that magazines can be automatically transferred
between the assemblies, as required. In this way a magazine that
has been loaded with trays with flaps can be selectively
transferred from the magazine assembly to a selected vacuum tube
location in the vacuum tube assembly
[0964] A quantity of preferably 4 thermoforming machines 4948,
4950, 4952 and 4954 are shown positioned adjacent to the magazine
assembly so as trays with flaps, produced by the thermoforming
machines, can be loaded directly into the magazines. Any suitable
quantity of thermoforming machines with interchangeable tooling to
suit any number of different sizes of trays with flaps can be
provided, as required, and located adjacent to the magazine
assembly.
[0965] Machines 4948, 4950, 4952 and 4954 include suitable
thermoforming machines that are arranged to thermoform trays with
flaps from suitable rolls of expanded polystyrene sheet provided on
rolls 4956 on spools 4958. Each thermoforming machine includes
ovens and forming and trimming (cutting) devices. Trays with flaps
are thermoformed, trimmed and ejected in horizontally disposed
stacks, such that the stacks extend onto shelves 4960 and 4962
arranged on each machine 4948 through 4954. Magazines 4900 can be
positioned adjacent to and in line with stacks on shelves 4960 and
4962 so as to facilitate loading of the trays with flaps directly
therein. Preferably, trays with flaps can be produced by
thermoforming machines 4948, 4950, 4952 and 4954 and loaded
directly into any selected magazine. Each magazine has an address
which is known and a computer a CPU (central processing unit) can
control the thermoforming machines in concert with the magazine
assembly. Any suitable quantity of thermoforming machines can be
arranged at positions adjacent to the magazine assembly. Each
thermoforming machine can be arranged to produce different sizes of
trays with flaps, as required, which can be arranged to be
transferred and loaded into suitable magazines with known
addresses.
[0966] Preferably, magazine assembly and the vacuum tube assembly
can be arranged to operate in concert and controlled by the
CPU.
[0967] Apparatus that is arranged to fold and bond trays with flaps
are shown and marked 4964, 4966, 4968, 4970 and 4972 and arranged
to fold and bond trays with flaps of different sizes, and
specification details, as required. The CPU is programmed with the
location of each machine 4964, 4966, 4968, 4970 and 4972 and
specification details of trays with flaps. Accordingly, the
apparatus can be programmed to operate in concert with the vacuum
tube assembly such that magazines can be transferred between the
apparatus and the magazine assembly by transfer of magazines to
magazine locations shown as magazine 4974, 4976, 4978, 4980, 4982
as required for subsequent folding and bonding. After folding and
bonding has been completed by any of the machines 4964, 4966, 4968,
4970 and 4972, finished trays are positioned onto the respective
conveyors 4984, 4986, 4988, 4990 or 4992 for transport thereon to
packaging machines.
[0968] The magazine assembly and/or the vacuum tube assembly can be
enclosed in a space that can have a suitable gas, such as nitrogen,
provided therein and temperature controlled at a suitable
temperature.
[0969] Apparatus shown in FIG. 267 is thus arranged to
automatically produce trays with flaps on the thermoforming
machines. The trays with flaps can then be transferred into
magazines that can be secured to the magazine assembly. The
magazines can be transferred from the magazine assembly to any of
the vacuum tubes attached to the vacuum tube assembly. Trays with
flaps can then be processed according to any suitable process and
as herein disclosed. The magazines can then be transferred to the
folding and bonding apparatus for further processing and subsequent
transfer to packaging machines for use in packaging perishable
goods.
[0970] The tray with flaps, folding and bonding machines 4964,
4966, 4968, 4970 and 4972, are arranged to fold and bond any trays
with flaps of different specification details. The CPU is
programmed with location of each machine 4964, 4966, 4968, 4970 and
4972, and specification details of trays with flaps stored in the
magazines. Accordingly, the vacuum tube assembly can be programmed
to unload trays with flaps into magazines 4974, 4976, 4978, 4980
and 4982, as required for subsequent folding and bonding. After
folding and bonding has been completed by any of the machines 4964,
4966, 4968, 4970 and 4972, finished trays are positioned onto the
respective conveyors 4984, 4986, 4988, 4990 or 4992 for transport
thereon to packaging machines.
[0971] The thermoforming machines 4948, 4950, 4952 and 4954 and the
tray with flaps, folding and bonding machines 4964, 4966, 4968,
4970 and 4972, the corresponding magazines 4974, 4976, 4978, 4980
and 4982 and conveyors 4984, 4986, 4988, 4990 or 4992 can be
enclosed in a space that can have a suitable gas, such as nitrogen,
provided therein.
[0972] The nitrogen gas can be produced by a suitably sized
nitrogen generator such as an on-site nitrogen supply,
incorporating a non-cryogenic air separation apparatus known as
Pressure Swing Absorption (PSA) Generators. Suitable PSA generators
are available from BOC Gases, a division of The BOC Group. Any
convenient source of gas supply may be used.
Apparatus for the Removal of Oxygen from Cell Structures
[0973] Referring now to FIGS. 262-265, an apparatus that is
intended to be used in the process of removal of any oxygen gas
that may be retained within the cell structure of expanded
polystyrene foam trays and flaps that are intended for use in
packaging perishable products such as red meats in a low residual
oxygen modified atmosphere package is shown. FIG. 262 shows details
of three identical vacuum tubes 4800 in various stages of the
process and at positions A, B and C. Each vacuum tube includes a
tube, open at one end and closed at the other. The vacuum tubes may
be manufactured from any suitable material such as aluminum,
stainless steel or a plastic material or a combination thereof. The
size and profile of the vacuum tubes can be arranged to suit and
accommodate any sizes of the tray with flaps. A piston 4802 fitted
with a seal between the piston and the internal surface of bore of
the vacuum tube, such as "O" rings appropriately attached to the
piston, can be located in the bore of each vacuum tube. The piston
is arranged so as to move easily within the confines of the vacuum
tube along the bore, with low friction and resistance between the
bore and the piston "O" rings. A port 4808 is provided in the
closed end of each vacuum tube and a cap 4810 is provided, when
required, to completely close and seal in an airtight manner, the
open end of the vacuum tubes. Two manifolds marked 4812 and 4814
are fitted on opposite sides of the vacuum tubes. The manifold 4812
has direct communication into the vacuum tube through apertures
4816 and manifold 4814 has direct communication with the vacuum
tube through apertures 4818. Ports are provided at each end of the
manifolds. The manifold ports 4820, 4822, 4824 and 4826 are
connected to a vacuum source and nitrogen gas or other suitable gas
source, via a three-way valve such that either gas, set at a
selected and adjustable pressure, or alternatively vacuum source
can be attached directly to manifold ports. The gas supply and the
vacuum source can be alternately applied to each manifold port in a
manner that will most efficiently remove the residual oxygen from
the cell structure.
[0974] Referring now to FIG. 264, a rear end elevation of the
apparatus is shown. As can be seen, four horizontally disposed
vacuum tubes 4800, are mounted to a frame 4830 which is in turn
attached to a main frame 4830 via pivot 4832. The main frame 4830
is rigidly attached to base of frame that is located fly on a
floor. A driver 4832 is provided and arranged to rotate the vacuum
tubes about pivot 4832. The drive can rotate the vacuum tubes,
attached to frame 4828, all together as a single unit, with an
intermittent motion such that during each intermittent motion the
frame 4828 with vacuum tubes 4800, moves through 90 degrees or a
quarter a single revolution. In this way vacuum tube 4800 at
position A would move to the position B. The vacuum tube at
position B would move to D and D to A. The apparatus is arranged so
as to allow automatic loading of a quantity of trays 4834 at
position A. At position B, the vacuum tube is arranged to be sealed
with trays 4834 therein and position 5100 is arranged so as to
allow unloading of the trays 4834 from vacuum tube 4800.
[0975] Referring again to FIG. 262, with vacuum tube 4800 at
position A, trays 4834 are shown being loaded into the vacuum tube
with a loading force. During the loading, a suitable gas such as
nitrogen can be provided through port 4808 of the vacuum tube at
position A, at a desired pressure so as to exert a desired level of
force against piston 4802, thereby holding the trays 4834 in a
firmly held, nested, disposition while submitting to the loading
force. The piston thereby moves toward the closed end of the
loading vacuum tube until the vacuum tube is filled with trays. Cap
4818 is then positioned into the open end of the vacuum tube
thereby sealing in an airtight manner with trays 4834 enclosed
therein. Immediately after closing and sealing the open end with
cap 4810, a vacuum source is attached to all ports 4820, 4822,
4824, and 4826. The vacuum source remains attached thereto for a
set period of time, sufficient to remove substantially all air from
the closed vacuum tube 4800. After evacuation of substantially all
air from the vacuum tube 4800 at position A, the vacuum source can
be disconnected from manifold 4812 and a nitrogen gas source
attached thereto, such that nitrogen gas is provided into manifold
4812 and through apertures 4816 so as to flood the vacuum tube at a
desired pressure. The nitrogen gas then flows across the surfaces
of trays 4834 and through apertures 4818 and into manifold 4814.
The vacuum source can then be disconnected from the manifold 4814
so as to allow pressure of nitrogen gas inside vacuum tube to be
increased to a desired pressure. The nitrogen gas can be maintained
at the desired pressure for a desired period of time sufficient to
allow exchange with and thereby removal of substantially all oxygen
that may be present in the cell structure of the trays with flaps.
Alternating and or pulsating vacuum and gassing of the vacuum tubes
can be arranged so as to provide rapid removal of the oxygen gas. A
gas analyzer can be attached to each vacuum tube and arranged to
determine the residual oxygen gas content inside the vacuum tube.
When the residual oxygen content of gas present inside the vacuum
tube has been reduced to a desirable level, the frame 4828 with
vacuum tubes 4800 attached, can be then rotated so that the vacuum
tube at position B is rotated to position 5100, the cap 4810 is
removed and the trays 4834 are extracted by providing nitrogen gas
through port 4808 at a suitable pressure so as to cause the piston
to move toward the open end of the vacuum tube and eject the trays
through the open end of the vacuum tube. Suction cups 4836 may be
used to intermittently remove a single tray at a time until the
vacuum tube is emptied.
[0976] Each vacuum tube 4800 can be provided with individual and
separate identification. Preferably, separate identification may be
arranged by way of a bar code attached to the vacuum tube, at a
convenient location or alternatively it may be by way of a chip,
embedded into a section of each vacuum tube.
[0977] The vacuum tubes 4800 may be arranged to accommodate any
size of tray with flaps. The trays with flaps may be pre-loaded
into an open magazine 4838, such as shown in FIG. 263, that is
arranged to fit inside any of the vacuum tubes 4800. Any suitable
quantity of open magazines may be provided and each one can be
arranged so as to have constant outer dimensions that allow close
and neat fitting within the vacuum tubes 4800, while the open
magazine internal dimensions are arranged to suit different sizes
of trays with flaps. Each magazine can be fitted with an individual
address or identifying mark such as a machine readable and
recognizable bar code or computer chip, embedded into the magazine
at any convenient location. The address of the individual open
magazine can thereby be identified. The open magazine can be loaded
with the trays with flaps and then stored in, for example, a
suitable racking system for a period of time, and when required for
use, the loaded open magazine can be automatically removed from the
racking system and transferred to the vacuum tube 4800 for
processing. Any convenient quantity of open magazines can be
manufactured and loaded with trays of various sizes, collectively
providing an open magazine. The racking system may be located
inside an enclosed storage space that may be filled with a desired
gas such as nitrogen. In this way the procedure of loading,
processing and then unloading the trays with flaps, in the vacuum
tubes 4800, that have been stored in the open magazine with
identifiable address, may be arranged in an automatic process.
Trays can be held within the magazine by a clip or a brush.
[0978] The vacuum tubes 4800 may be attached to any suitable
mechanism with the capability of positioning the vacuum tubes as
required, such as is shown in FIG. 262.
[0979] Referring now to FIG. 266, a plan view of various apparatus
constructed according to the present invention is shown. A pair of
horizontally disposed, parallel, continuous chains 4846 are
arranged on suitable sprockets 4848 mounted in a frame. The
sprockets are attached to a driver (not shown) that includes a
programmable servo motor arranged to drive the parallel chains, in
either direction, as required. Vacuum tubes 4800 are fixed to
continuous chains 4846 as shown and includes a quantity of
preferably 23 vacuum tubes, marked with individual addresses to
provide a vacuum tube assembly generally denoted by 4850. The
vacuum tubes are positioned with the closed ends toward the rear of
equipment layout and the open ends toward the front of the
equipment layout.
[0980] Thermoforming machines 4852 and 4854 are positioned adjacent
to the vacuum tube assembly so as trays produced therewith can be
loaded directly into vacuum tubes. Three tray with flap, folding
and bonding machines 4856, 4858 and 4860 are located adjacent to
the vacuum tube assembly.
[0981] Machines 4852 and 4854 include suitable thermoforming
machines that are arranged to thermoform trays with flaps from
suitable rolls of expanded polystyrene sheet provided on rolls on
spools 4864. Each thermoforming machine includes ovens forming and
trimming apparatus. Trays with flaps are thermoformed, trimmed and
ejected in horizontally disposed, and nested quantities onto shelf
4866 and 4868. Vacuum tubes 4870 and 4872 are positioned adjacent
to and in line with shelf 4866 and 4868 so as to facilitate loading
of the trays with flaps directly therein. In this way, trays with
flaps can be produced by thermoforming machines 4852 and 4854 and
loaded directly into the vacuum tubes. Each vacuum tube has an
address which is known, and a computer, with CPU (central
processing unit) can control the thermoforming machines in concert
with the vacuum tube assembly. Any suitable quantity of
thermoforming machines can be arranged at positions adjacent to the
vacuum tube assembly. Each thermoforming machine can be arranged to
produce different sizes of trays with flaps, as required, which can
be arranged to be transferred and loaded into vacuum tubes with
known addresses. Alternatively, the thermoforming machines may be
arranged so as to produce trays with flaps for loading into open
magazines for subsequent storage before processing on the vacuum
tube assembly.
[0982] The tray with flaps, folding and bonding machines 4856, 4858
and 4860 are arranged to fold and bond the trays with flaps of
different specification details. The CPU is programmed with
location of each machine 4856, 4858 and 4860 and specification
details of trays with flaps. Accordingly, the vacuum tube assembly
can be programmed to unload trays with flaps into magazines 4874,
4876 and 4878, as required for subsequent folding and bonding.
After folding and bonding has been completed by any of the machines
4856, 4858, and 4860, finished trays are positioned onto the
respective conveyors 4878, 4880 or 4882 for transport thereon to
packaging machines.
[0983] The tray with flaps, folding and bonding machines 4856,
4858, and 4860, the corresponding magazines 4878, 4880 or 4882 and
conveyors can be enclosed in a space that can have a desirable gas,
such as nitrogen, provided therein.
[0984] The desirable gas, such as nitrogen can be produced by a
suitably sized nitrogen generator such as an on-site nitrogen
supply, incorporating a non-cryogenic air separation devices known
as Pressure Swing Absorption (PSA) Generators. Suitable PSA
generators are available from BOC Gases, a division of The BOC
Group. Any convenient source of gas supply may be used.
[0985] FIG. 105 shows a cross section through an apparatus that may
be used for pumping pre-blended grinds into a profiled conduit
thereby providing an extruded stream of grinds for subsequent
slicing and production of patties. An enclosed housing 12 is shown
with a tapering screw 15 mounted therein. The external surfaces of
the tapering screw can be profiled to match the internal surface of
housing 12 such that these surfaces are in close but not touching
proximity and so that the screw 15 will scrape the internal surface
of the housing 12. The arrangement in FIG. 105 shows a single screw
but may alternatively be arranged with parallel sides that are not
tapered. The screw is most preferably tapered and may be mounted in
tandem and adjacent to a counter rotating, correspondingly
matching, second tapering screw (not shown) in parallel therewith.
Such a pair of matched and meshing screws can provide a means to
scrape all surfaces of the screws and all internal surfaces of
housing 12. As shown in FIG. 105, screw 15 is driven via a shaft 14
attached to a suitable driving motor (not shown) such as a servo
electric motor, which can drive the screw(s) in a direction
indicated by arrow 14 and at a variable speed. Pre-blended grinds
20 that have been processed as required in enclosed vessels (not
shown) that substantially excluded oxygen from contact thereto, are
provided by any suitable transferring mechanism into conduit 9
which is attached via a gas tight flange 11 to housing 12. Grinds
20 provided into housing 12 are substantially free of air or oxygen
and any voids contained therein can be substantially filled with
carbon dioxide. Grinds 20 can be transferred into housing 12 at a
controlled temperature below the freezing point of water such as at
29.5 degrees F. Housing 12 may be fitted with a suitable jacket and
insulation with conduits provided therein (not shown) through which
any suitable liquid, maintained at any suitable temperature, can be
transferred. A piston 16 is shown located within a cylinder 25,
which in turn, is mounted directly to housing 12. Piston 16 can be
directly coupled to a driving mechanism (not shown) that will
activate movement of the piston in a reciprocating manner with
directions of movement shown by double headed arrow 27. FIG. 107
shows piston 16, cylinder 25, grinds 20, and screw 15 and it can be
seen that the end of piston 16 is provided with a radius 26, that
matches the external radius of screw 15 such that when piston 16 is
in close but not touching proximity to rotating screw 15, the
external surface of piston 16 at 26 will be wiped by the outermost
edges of screw 15 as it rotates. In this way substantially no fat
or grinds can accumulate by sticking to the exposed surface of
piston 16, at 26. A single matching piston and cylinder assembly is
shown mounted to housing 12, however, more than one such matching
assembly may be mounted in radial disposition to housing 12. In
fact, for example, three or four such matching piston and cylinder
assemblies may be mounted around the circumference of housing 12
and arranged to operated simultaneously or as may otherwise be
required. Mounted to the exit end of housing 12, a conduit 18 is
fixed in a sealed and gas tight manner. Conduit 18 is shown with a
restriction therein, such that the internal diameter at the point
of entry is identical to the internal diameter of housing 12 and
the diameter of conduit 18 is tapered so as to reduce the cross
sectional area and therefore, when grinds are pumped there through,
back pressure is generated against the exposed end surface 26 of
piston 16. A flange 19 is shown at the exit end of apparatus shown
in FIG. 105 which may correspond with matching flanges of profiled
conduits (such as 45 in FIG. 106) that can be interchangeably
attached thereto, to provide a different profiles and size of
extruded streams of grinds pumped there through. An arrow 29 shows
the direction of flow of extruded stream of grinds 20.
[0986] In a preferred embodiment, grinds 20 are transferred into
housing 12 and carried in a forward direction, indicated by arrow
29, by rotation of tapered screw 15, in a continuous stream. During
transfer through housing 12, grinds 20 are compressed so as to
ensure any voids that may be contained therein are eliminated by
dissolving of CO2, contained in the voids, into said grinds. As
stream 20 is transferred in the direction shown by arrow 29, a cone
shaped conduit at 18 further restricts stream of grinds 20 and
compresses it into a substantially void free stream exerting a back
pressure that is proportionate to the velocity of stream 20 and the
restriction according to the diameter of conduit 18. Alternatively,
other suitable restrictive conduits or valves may be provided in
place of conduit 18. In order to provide a stream of grinds that
has been conditioned to a suitable temperature, housing 12 can be
temperature controlled by any suitable heat exchanging and
temperature controlling apparatus.
[0987] In a preferred embodiment, a mechanism is provided for
slicing beef patties from a continuous stream of grinds, allowing
slicing of individual patties to occur while the stream of grinds
is stationary relative to the knife. This can be achieved by moving
the slicing mechanism parallel with and at the same speed as the
stream of grinds and slicing while in motion followed by rapid
return of the slicing mechanism to an original position in
readiness for subsequent slicing. However, this can be difficult to
control and high production output is generally not possible. In a
preferred embodiment the stream of grinds 20 is halted at the time
of slicing. Most preferably the velocity of stream 20, at the exit
point 30 can be adjusted between a maximum rate of flow that is
substantially determined by the speed of rotation of screw 15, and
zero velocity by controlled activation of piston 16. This may be
achieved by activating piston 16, so that it moves, at a controlled
rate, away from the housing 12 and therefore increasing the
available volume within cylinder 25 that can be filled with grinds
transferred by screw 15 and momentarily at a rate equal to the
transfer of grinds through housing 12. This arrangement can provide
a momentary reduction of flow and halting of stream of grinds 20 at
exit point 30. In order to achieve this, and ensure that there is
no movement of said stream of grinds at exit point 18, the rate of
increase in available volume in cylinder 25 must be equal to the
volumetric rate of flow of stream of grinds 20. Therefore, by
activating piston 16 in a reciprocating manner, grinds can be
intermittently accommodated within space 31, in cylinder 25 and
then immediately expelled therefrom in a continuously repeated
cycle. In this way, velocity of stream of grinds 20, can be
intermittently varied between a maximum rate of flow and
substantially no rate of flow, by adjusting the flow rate provided
by rotation of screw 15 in concert with the cyclical reciprocating
motion of piston 16. Furthermore, additional piston and cylinder
assemblies may be installed to provide larger capacities of
volumetric variation in space 31 and to vary the quantity of grinds
extruded during each flow cycle from the exit end of conduit 18 at
30. Any quantity of grinds extruded during each piston 16 cycle can
be arranged to be equal to the desired weight of a single beef
pattie. This cycle rate may be arranged to exceed 500 cycles per
minute and, for example, if it is desired to produce quarter pound
beef patties, at this rate of 500 cpm, a total rate of production
would be equal to 125 lbs. of patties per minute.
[0988] Referring now to FIG. 106, a cross section through an
apparatus intended for use in slicing extruded streams of ground
meats, as described above in FIG. 105 to produce patties, is shown.
Any suitable cutting blade may be used to slice from a continuously
extruded section 40, such as a high-speed, band blade that is
driven by a suitable electric motor. Referring now to FIG. 105 and
FIG. 106, a temperature controlled conduit, 45, with flange 41, is
arranged so that it can be mounted directly to the flanges 19, of
apparatus shown in FIG. 105. An arrow 42 shows the direction of
flow of a stream of grinds 40 transferred from conduit 18, via
orifice 30 into conduit 45. Conduit 45 may be provided at any
suitable length 43, and can be arranged with temperature
controlling conduits 44 imbedded in the walls of conduit 45. Any
suitable liquid that will remain liquid at a selected temperature
may be transferred through conduits 44 at a flow rate that will
ensure temperature control of stream 40 as may be required. A knife
cutting blade 47 with suitably machined bearing attachment 54 is
shown mounted to a driving shaft 46. Conduit 45 is mounted at a
convenient angle and adjacent to revolving blade 47 such that as
blade 47 is rotated, patties can be sliced from stream of grinds 40
and deposited into stacks of sliced patties as shown at 51 and 52.
In this way, patties can be produced, stacked and transported to a
packaging station via conveyor belting 50 that is driven
intermittently by a drive roller 49 in a direction shown by arrow
52.
[0989] In order to minimize accumulation of fat and/or ice on the
internal surfaces of conduit 18, scrapers (not shown) may be
mounted, for example to the end of screw 15 to scrape internal
surfaces thereof. Additionally, internal conduit surfaces may be
treated with non-stick surfaces that are resistant to any such
build up of fat and/or ice. Furthermore, separate temperature zones
may be arranged such that, for example, housing 12 may be
maintained at 29.5 degrees F. and any suitable insulation provided
at the connection between conduits 18 and 45. In this way conduit
45 may be set at a much lower temperature such as 10 degrees F. so
as to cause a "crust" freezing of the external surface of stream of
grinds 40 and thus provide an improved condition for slicing by
knife 47. The intermittently varied velocity of stream of grinds 18
can be directly and correspondingly integrated with each revolution
of knife 47 such that during the knife cutting action of stream 40,
the velocity of stream 40 is reduced to virtually zero and then as
the knife rotates through an arc away from the stream 40 and toward
the next slicing of the subsequent pattie, the velocity of stream
40 can be accelerated then decelerated so as to be again in a
substantially stationary position for subsequent slicing by said
knife 47. Control of stream 40 flow rate is therefore provided by
the reciprocating action of piston 16.
[0990] Referring now to FIG. 108, a side elevation of an apparatus
assembled to continuously produce fine ground boneless beef 77,
from coarse ground boneless beef 61 in an enclosed system that
substantially excludes oxygen, is shown. Coarse ground beef 61 is
transferred through conduit 63 to fine grinder 65. Flanges 62 and
64 are fixed together to provide a gas and liquid tight seal there
between allowing continuous transfer of pressurized coarse ground
beef 61 to fine grinder 65. Ground beef 61 and 77 can be maintained
at a selected temperature such as 29.5 degrees F. Fine ground beef
77 is then transferred into vessel 70 from grinder 65, and allowed
to accumulate therein. A connection to vessel 70 from a gas source,
via a pipe 78 provides a conduit to deliver suitably pressurized
gas such as carbon dioxide into vessel 70 and to allow contact of
selected gas with grinds 77. Also, a conduit 79 allows controlled
release of excess gas that may accumulate in vessel 77, for example
via controlled pressure release valves (not shown) installed in
conduit 79. In this way a selected gas such as carbon dioxide can
be provided in any free space in vessel 70, at a constant, selected
gas pressure. Positive displacement pump 71, is driven via shaft
72, that in turn is driven by a servo electric motor (not shown) or
other such suitable variable drive motor and in such a manner as to
allow adjustment, as required, to the rate of pumping of fine
grinds 77 from vessel 70 into conduit 73. Pump 71, may also provide
a controlled pressure inducing feature by its pumping action of
fine ground beef 77 into conduit 73 thereby causing substantially
all gaseous voids, contained in 77, to be eliminated by dissolving
of any free CO.sub.2 gas contained therein. In this way, grinds 77
that may contain voids or spaces filled with CO.sub.2 can be
transferred to a solid stream of grinds 20 that is substantially
free of any voids. Solid stream of grinds 20 may be transferred in
the direction shown by arrow 74 to directly connect to conduit 9
shown in FIG. 105.
[0991] The aforementioned method and apparatus for the processing
meats refers not exclusively but most preferably to ground meats
that are can be pumped via a single or several positive
displacement pumps. In many other applications, production of meat
food products, that involve slicing of large pieces of beef, is
required. It has been determined, by the present inventor, that
preventing contact of the freshly cut beef surface with atmospheric
air can provide enhancement of storage life. Consumers, in general
will only buy red meat and therefore to accommodate the needs of
the consumer and the requirements of the meat packer, the present
invention is directed at providing an improved process whereby meat
is sliced by automatic apparatus, directly into an enclosure that
excludes air (and oxygen). Therefore, in another preferred
embodiment, apparatus shown in FIG. 109 and the following
disclosure, an apparatus that can slice primal beef portions
directly into an enclosure with an oxygen free gas therein, is
detailed.
[0992] Referring now to FIG. 109, a round cross sectional conduit
81 is horizontally disposed and mounted with an exit end 103
directly adjacent and above an end of a conveyor 94, that is
mounted at an elevating angle to the horizontal. The conveyor
elevating angle is set such that slices of meat will be urged
forward by the action of blade 92 as it rotates and descends,
slicing through the primal so that the sliced and separated portion
will fall gently onto the conveyor 94. Enclosure 98 can be filled
with carbon dioxide gas 99 or other suitable gas that is held at a
suitable temperature and gas pressure above ambient atmospheric
pressure and in such a manner to ensure that substantially no air
and most importantly, no atmospheric oxygen can enter enclosure 98.
The profile of conduit 81 may be chosen to suit any particular
product which may not be round and for example, a square or
rectangular profile may be chosen, however, in this instance a
round profile has been shown. A blade 92 attached to a shaft 91 is
conveniently mounted at the exit end 103 of conduit 81 such that
slices 94 can be cut from the end of primal 87 after emerging from
conduit 81. Blade 92 can be arranged to cut a single slice during a
single revolution of shaft 91. Therefore the intermittent
sequencing of firstly driving blade 92 for a single revolution to
cut a single slice, followed by the measured and controlled
movement of a primal such as 87 from the exit end 103 of conduit 81
can be arranged to automatically and continuously operate. Slices
94 can then be carried forward in a continuous or intermittent and
controlled action for further processing or packaging, along
conveyor 94 driven in the direction shown by arrow 96, by roller
93.
[0993] Plugs 82, 85 and 89 are shown in cross section and located
on the inside of conduit 81 between primal beef portions 87. Primal
beef portions 87 may have been previously processed and allowed to
set in a mold, after pre-rigor mortis harvesting from a slaughtered
animal, such that the cross sectional dimensions of the molded
primal corresponds substantially with the cross section of conduit
81. This method of molding primal cuts of meat has previously been
described in the inventor's earlier patent disclosures and while
the primal cuts can vary in size, molds can be arranged such that
only those dimensions shown by numbers 101 and 102 will
significantly vary. In this way, primal cuts of meat may be located
into the entry end of conduit 81 and in the direction shown by
arrow 100. After locating a primal 87, into the entry end of
conduit 81 a plug such as 82 is then loaded directly behind the
primal 97 followed by another primal and then another plug such
that a continuous sequence of primal cuts, each with a plug
interposed between. Each plug such as 82 comprises a profiled
"piston" with an iron core 88 enclosed in a plastics frame 85. Each
iron core 88 may be magnetized to such an extent that, when a
suitably mounted electromagnet is adjacent thereto a magnetic bond
is developed between the iron core 88 and the electromagnet that is
substantially unbreakable by any force that is likely to be applied
to either part in this apparatus application. Frame 85 is arranged
with one or more flexible lips 86 that can sealingly contact the
inner surface of conduit 81 and but allow plugs 82 to slide along
the internal surfaces of conduit 81, flexible lips 86 can thereby
provide a seal around the full perimeter of plug 82 with conduit 81
and can therefore act as a piston held captive within the conduit
81. A series of electromagnetic rings 83, are mounted to a drive
mechanism (not shown) and each electromagnet is "mated" with a
single plug such as 82, located on the inside of conduit 81. The
distance between each plug such as 82, and as shown in examples 101
and 102 can be electronically measured by proximity devices
conveniently mounted external to the conduit 81 and adjacent
thereto and in such a manner so as to allow measurement of any
distance between any two plugs. In this way, any particular primal
cut of beef can be measured and with suitable computer apparatus
arranged and connected to any suitable measuring arrangement such
as said proximity switches, a selected quantity of slices can be
automatically calculated and subsequently sliced as the primal
emerges from the exit end of conduit 81 by knife blade 92. It may
be preferable to remove a thin section of sliced meat from each end
of each primal and divide the balance into a quantity of slices
having a desirable thickness. Alternatively the length of each
primal, as shown in examples 101 and 102, can be divided into a
selected number of slices with a thickness automatically
calculated, accordingly. Alternatively, slices of a chosen weight
may be calculated by computer apparatus. In all cases, the primal
cuts can be automatically and intermittently transferred along
conduit 81 with each forward movement of electromagnets 83 which
carry plugs such as 82 forward simultaneously. In this way, the
thickness of any slice cut by knife 92 can be determined by the
distance of each forward movement of electromagnets 83. As plugs,
such as 82, are carried forward and emerge from exit end 103, the
operation of blade 92 can be arranged to allow the automatic
removal of each plug and subsequent transfer to the entry or
loading end of conduit 81 in readiness for its next use. Plugs can
be sanitized prior to next use as may be required.
[0994] Conduit 81 can be temperature controlled by any suitable
method which may be provided by circulating liquid, such as glycol,
through conduits provided within or in contact with the walls of
conduit 8, and the internal surface of conduit 81 may be treated so
as to resist "sticking" to anything passed there through. In this
way, primal portions of beef may be "crust frozen" during transfer
through conduit 81. One or more conduits, such as 97, may be
provided to connect a vacuum, gas or selected agent source directly
to conduit 81.
[0995] Perishable food products produced, in part or otherwise, in
the manner described herein may be placed in any suitable tray with
or without any suitable substance and over wrapped with any
suitable web of material such as pPVC and then placed in a master
container that may be manufactured from a substantially gas barrier
material or partial gas barrier material to provide finished
packages. Following this, finished packages may be stored in any
suitable storage room maintained at any suitable temperature until
required for sale, at which time finished may be removed, labeled
and displayed for sale in a retail outlet such as a
supermarket.
Electronic Method of Transacting Business
[0996] Referring now to FIG. 275, a schematic representation of an
apparatus for storing and processing goods in a meat processing
train resident in a meat processing plant, is illustrated.
[0997] A pressure vessel 8058 is connected directly to a supply
conduit 8002 in a gas and liquid tight manner, such that goods 8012
can be transferred through conduit 8002 and into vessel 8058 for
storage and processing therein. Vessel 8058 may be arranged in an
inclined disposition so as to reduce the depth of goods, measured
along a vertical, straight line inside the vessel, contained
therein. Vessel 8058 may also be arranged with a suitable blending
arrangement mounted therein in such a manner so as to allow
blending of any goods stored in or transferred through vessel 8058.
A fat, protein and water content measuring device 8004 is inserted
between conduit 8002 and valve 8006. The measuring device 8004 may
be mounted at the connecting point and directly between conduit
8002 and vessel 8058 to provide a means of isolating conduit 8002
from vessel 8058 in a gas tight manner. A tube 8060 connects vessel
8058 to a source of suitable gas or agent via a suitable valve (not
shown) to allow transfer of any suitable gas or agent, such as any
storage life enhancing gas, into vessel 8058. A port 8008 with
connection hose to a suitable vacuum generator is provided in the
wall of vessel 8058 at an upper location so as to allow evacuation
of gases from vessel if required. A connection to conduit 8016 is
provided at a lower location in the vessel 8058 such that any goods
transferred into vessel 8058 will tend to gravitate there toward,
irrespective of any mechanical transferring arrangement that may be
mounted inside vessel 8058. Conduit 8016 is connected directly to a
positive displacement pump 8022 via a liquid collection point
arranged to collect any purge 8018 or liquids that may accumulate
in vessel 8058 after normal release from goods therein, such as
purge associated with meats. A connection tube 8052 is coupled to
pump 8054 in such a manner so as to allow pumping of any
accumulated purge or liquids 8018 via tube 8056. Tube 8056 is
connected to a spray nozzle arrangement 8064 mounted on the
internal wall of vessel 8058 at an upper location of vessel 8058.
In this way purge 8018 can be sprayed in a spray 8010 onto the
upper surface of goods 8012 and thereby be returned to its source
within vessel 8058. Purge 8018 may reticulate downward and again
accumulate in 8016 and so be recycled by pumping again through tube
8052. Purge 8018 may also be treated with any suitable agent such
as suitable bactericide, prior to spraying at 8064 and thereby
reducing bacteria content and improving safety of the ground meat
product for human consumption. With the apparatus herein disclosed,
it can be seen that goods 8012 can be transferred via conduit 8002
through measuring device 8004 and valve 8006 and into vessel 8058
in a manner that substantially excludes ambient air. Measuring
device 8004 can provide a means to measure the quantity of fat
and/or water and/or protein in goods transferred there through. In
this way, the value of goods in vessel 8058, based on current
market pricing, can be immediately and automatically calculated as
it is transferred therein. A valve 8020 is mounted directly beneath
conduit 8016, which in turn connects to positive displacement pump
8022. Valve 8020 is arranged to provide a means to substantially
isolate vessel 8058 in a gas and liquid tight manner. Positive
displacement pump 8022 is arranged to pump goods, as may be
required, through fine grinder 8024 and subsequently extrude fine
ground goods, such as ground beef, directly into packaging trays,
such as 8028, that is positioned adjacent thereto. Alternatively,
any other processing arrangements such as pattie manufacturing
equipment, can be connected directly to the downstream and exit end
of pump 8022, and in such a manner so as to allow any selected
processing methods of goods. The exit end of pump 8022 may be
enclosed in an enclosure that is filled with an oxygen free and
suitable gas, selected for it's food product quality and storage
life enhancing properties.
[0998] Referring now to FIG. 276, a cross section of a portion of
the meat packaging system is illustrated. A pair of horizontal
conveyors 8072 carry a tray 8068 loaded with meat 8066. A space is
defined between the horizontal conveyers 8072, such that a ink jet
printer 8074 can reside between the conveyors 8072. The ink jet
printer 8074 can print a barcode with information such as weight
and date of packaging the meat product 8066.
[0999] Referring now to FIG. 287, a schematic illustration of a
system for transacting commerce over a communication network
according to the present invention is illustrated. The meat
processing equipment is resident within a meat processing plant
9000. The meat processing equipment can be the processing and
storage equipment illustrated in FIG. 275 or any of the equipment,
which can reside within a meat processing plant 9000, as described
in this disclosure. The meat processing plant is connected to a
communication system, such as the internet 9006, via a seller
computer 9004. A person of ordinary skill in the art will
appreciate that seller computer 9004 can include a plurality of
computers connected within a LAN environment. Furthermore, the
seller computer 9004 can be connected to one or a plurality of
operator terminals having a monitor, user interface and input
devices. Referring now to FIG. 288, the seller computer includes a
central processing unit 9012 (hereinafter "CPU"), network interface
9100, display 9104 and mass memory 9106. Residing within the mass
memory of the seller computer 9004 are instructions for providing a
graphical user interface (hereinafter "GUI"), a database 9110, and
an operating system 9112. The database may contain historical sales
data, traffic, weather, or road information to enable the
determination of an estimated delivery time to a buyer's designated
destination. Such historical information, when used in this manner
can provide a means of more accurate prediction of actual sales of
fresh meat products, for example ground beef and beef patties are
purchased and consumed by consumers at barbecues, more frequently
and in larger quantities during the hot summer week end and holiday
periods, when compared to colder periods when barbecues are a less
appropriate and popular recreational event. Referring again to FIG.
287, the seller computer is connected to the internet 9006, which
in turn is connected to one or a plurality of buyer computers,
9008, 9010, 9012. The buyer computers are used to place an order
specifying one or more specifications, such as quantity of meat,
type of meat, fat content, lean meat content, weight, size, or any
other of a plurality of specifications which is useful for
quantifying meat products. The seller computer 9004 receives
purchase orders via the internet 9006, with a central processing
unit receiving the order and processing the order to determine
which variables or parameters to manipulate in the meat processing
plant 9000 to fulfill the buyer specifications. The seller computer
9004 may vary the rate of production of a processing train or
adjust the content of fat in proportion to lean tissue by
controlling valves, pumps or direct a slicing or cutting machining
to cut a predetermined amount of product in differing sizes or
shapes. The seller computer 9004 can also contain instructions to
extract weather or highway and road information from other servers
9014 and 9016 connected to the internet 9006 to compute an
estimated delivery time at the buyer's designated destination. The
seller computer 9004 includes programmable instructions to direct
certain events to occur when the estimated delivery time to the
buyer's specified destination are in excess of the allowable amount
of time that meat can remain in a finished package without
undergoing significant oxidation such that it would become
unsalable. Meat packaged in a controlled atmosphere environment of
carbon dioxide according to the present invention can endure for
about 6-9 days after exposure to ambient atmospheric gas at 36
degrees F., without undergoing significant discoloration or
rancidity/oxidation. If however, the estimated time of delivery
will exceed this recommended amount, the seller computer 9004 can
direct that the buyer's order be packaged in a gas barrier master
container containing a substantially oxygen free gas. Packaging in
a master container extends the shelf-life of finished packages for
about an additional 6 weeks. However, if the estimated amount of
time necessary to deliver the buyer's order to the designated
delivery destination is less than the amount of time before
sufficient discoloration or rancidity/oxidation sets in, then the
buyer's order does not need to be packaged in a low oxygen gas
barrier master container, thus reducing the average cost per pound
of meat product because average packaging costs can be reduced.
Once packaged the meat is delivered to the buyer through
conventional channels, such as by refrigerated truck 9002, rail, or
ship to the buyer's designated destination. The memory of the
seller computer 9004 contains programmable instructions for
carrying out the present invention. One method carried out by
seller the computer 9006 is illustrated in FIG. 290. The method
includes an event for receiving buyer specifications 9300. The
seller computer will then execute a set of programmable
instructions designed to carry out the buyer's order in event 9302.
The seller computer may for instance issue instructions that result
in accelerating a pump and conveyor to increase the rate of
production, or open a valve to mix any number differing meat
streams of differing fat content to arrive at the buyer's
specification for fat content. Other instructions can direct a
cutting machine or slicing equipment, sealing station, weigh
station, counter, collating or order consolidation/assembly direct
from the packaging line or from packages held in storage, followed
by palletizing to meet the buyer's order. Further, the seller
computer will determine whether it will be necessary to package the
finished trays in a barrier master container, which can involve
calculating an estimated time of arrival to the buyer's designated
destination 9304, or estimated time of arrival at the point of sale
to a consumer, after delivery to a distribution center. The seller
computer can receive any desirable parameter and necessary
information to carry out the instructions either from a resident
database of previous buyer data or the seller computer may gather
the information from the internet from other computers 9014 and
9016. The seller computer may use weather information 9312 or
transportation information such as road or highway conditions 9310.
The seller computer contains instructions to package a buyer's meat
order in a master container 9306, when it is determined that an
unacceptable level of deterioration will occur to the packaged meat
if it is not packaged in a master container. The seller computer
will then instruct the packaging train to package, palletize and
ship the product to the buyer 9308. The seller computer can also
have access to the buyer historical data to use in computing the
quantity or type of meat which is purchased by buyers.
[1000] In another alternate embodiment of the invention, the buyer
can be invoiced from the measuring devices located upstream of the
vessels. For example, the measuring devices located after the
grinding heads can be used to invoice the buyer, while the meat is
still held in storage in the vessels. In this manner the product
can be specifically tailored to an individual buyer's
specifications.
[1001] Furthermore, the present invention can also provide for a
method of compensating for surge in the blending process. For
example, surge can be eliminated by excluding any gas in the meat
streams, but ground meat is elastic and can continue flowing at a
rate exceeding the pumping velocity after the pump has been slowed
or stopped. Alternatively, when the pumping velocity is
accelerated, the actual velocity may lag momentarily. The above has
an effect on blending accuracy, particularly, when the on-line fat,
water & protein measuring device is located upstream from the
continuous blender. As the meat streams (two or more) emerge from
their respective conduits directly into the blending conduit the
fat, water and protein (fat and lean) content of each stream
determines the velocity of the respective streams. The fat and lean
content is measured upstream therefore there is a set distance
(measured) between the point of measuring and the point of transfer
from the conduit to the blender. The pumping speed therefore must
be adjusted to compensate for this surge.
[1002] Referring now to FIG. 289, a buyer computer includes a
network interface 9200 for connecting to a communication system,
such as the internet, a processing unit 9202, a display 9204, a
mass memory 9206 including instructions for providing a GUI 9208
and an operating system 9210. Buyer computers may be located at
supermarkets, supermarket head quarters, or regional centers where
all sales data and information is collected directly from the
checkout bar-code reading apparatus located at each supermarket. A
person of ordinary skill in the art will readily appreciate that
one or more computers can be used by a buyer at a remote location
to enter purchase orders via the internet. Buyer computers can also
include hand held remote controlling devices. The information
gathered at the point of retail by buyer computers can be gathered
and sent to a remote or local regional buying center having another
buyer computer. The regional buying center can communicate with the
seller server to place an order via the internet. Furthermore, the
seller server computer can have access to the historical data
gathered by buyer computers as well.
[1003] Referring now to FIG. 277, an actual embodiment of a
pre-form web with flaps is illustrated. The pre-form web 8100 can
be shaped into a finished tray. The web can be constructed of any
suitable material such as PVC, PP or other suitable materials
herein disclosed in this specification. The method used to form the
web can be thermoforming or any other suitable methods. The web
8100 is constructed of a rectangular base 8102. The base is
surrounded by four upwardly extending walls 8104, 8106, 8108 and
8110. The walls may be outwardly reclined to facilitate the removal
of the web from a mold or the nesting together in a stack of
similar tray pre-forms (not shown). The walls are connected to the
base 8102 at a lower portion thereof and adjoining walls are
connected to each other thusly forming corner sections. In this
embodiment, the corner sections are made from the ends of the walls
being creased inwardly 8114 where the ends attach to an adjacent
wall. Thus, two ends of two walls form an inwardly extending
corrugation 8112 to give the web additional strength when finished
into a tray. Two walls 8102 and 8108 of the four walls on opposing
sides are formed with an upwardly extending region 8116 in the
center, and an angled shaped bottom edge 8118 to give the finished
trays the ability to be stacked atop one another without allowing
the sealing web of a lower tray to touch the base of the adjacent
stacked upper tray. While an angled bottom has been shown, the
shape may take an arcuate form. Furthermore, the base is configured
to have similar angled surfaces or arcuate shape that corresponds
to the shape of the lower portion of the side walls 8102 and 8108.
The upper edges of the walls 8104, 8106, 8108, and 8110 are
attached to flaps 8120, 8122, 8124 and 8126, respectively.
Referring now to FIG. 278, the flaps are joined to the upper edge
of the walls at a hinge 8128 to allow the flaps to rotate inwardly.
The finished tray 8130 will thusly include an outer 8132 and an
inner 8134 reinforcing wall made from the flaps. The flaps include
a tab 8136 connected to one edge of the flap which can be folded
inwardly as shown in FIG. 278 to press fit into a groove 8138
formed at the lower perimeter of the base 8102. The member formed
by the folded tab 8136 thus forms a securing device which is press
fitted into the corresponding base groove 8138 without the need for
bonding the flaps to the finished tray with adhesives thereto.
[1004] Referring now to FIG. 279, a mold 8200 for forming pre-rigor
mortis meat is illustrated. Pre-rigor mortis meat is moldable to
form any of a variety of desired shapes by placing quantities of
harvested pre-rigor meat into any one of a plurality of mold forms.
In one actual embodiment shown in FIG. 279, a mold 8200 is shaped
in an elongated form. The mold 8200 can be constructed of suitable
materials, some of which can be advantageously permeable to ozone
or any other suitable gas or substance. The mold 8200 has four
walls 8202, 8204, 8206, and 8208. The bottom wall 8206 of the mold
8200 can be configured to be angled or arcuate such as the base
shown in FIG. 277. However, any mold can be provided with a bottom
wall suitably configured to the shape of any of the trays herein
disclosed. This is provided in a mold so as to enable slicing of
the meat into portions of similar size and weight, which can
conform to the finished tray to utilize the space within the tray
in the most efficient manner. In this way substantially identical
slices of meat can be produced with virtually no trimming
requirement. Whenever trimming is required, a loss is incurred
since the portions trimmed off can only be used in a product, such
as grinds, of lower value than the sliced meat. Identical slices
can be sold in packages of "same weigh and same price", which is a
preferred supermarket strategy as opposed to randomly priced
packages that have individual package price determined by random
weight due to inconsistent size and weight of each slice of fresh
meat contained in a single package. Referring again to FIG. 279,
two walls 8204 and 8208 of the four walls form the vertical walls
of the mold 8200. The vertical walls 8204 and 8208 can be inclined
or reclined to match the configuration of any packaging tray walls.
The mold 8200 includes a top wall 8202 connecting the two vertical
walls 8204 and 8208 at a upper portion thereof. The mold 8200 also
includes a bottom wall 8206 connecting the vertical walls 8204 and
8208 at a lower portion thereof. Thusly formed, the mold 8200
resembles a hollow tube with a cross-section shape shown in FIG.
280. Although an irregular shaped polygon is shown as a profile
shape, the shape of the mold can be any suitable shape to resemble
a tray's dimensions. The bottom wall 8206 can be shaped to
substantially conform to the tray base as described above. The mold
8200 includes openings formed on opposite ends of the mold thereof.
A lip 8210 is formed within a short distance inward from a first
opening of the mold 8200. A plug 8212 fits within the opening and
is constrained to move toward the opening by the lip 8210. A second
plug 8214 is inserted in the mold 8200 from the opposite opening.
The second plug 8214 can be pressed to form the meat to a shape
substantially resembling the mold 8200. A chip 8216 or proximity
switch can be embedded within the plugs to determine the distance
from the first plug to the second plug. In this manner, the correct
size of the meat portions can be determined. Once the pressing
operation is completed, the shaped meat 8218 can be sliced
automatically or manually to suit the size of the finished trays.
In this manner, two dimensions are kept constant which will
consistently provide meat portions of constant size and weight that
can fit within the trays, while advantageously only varying one
dimension, which will most preferably be the length of the molded
portion. The shaped meat can contain an area of fat 2819.
[1005] In another alternate, the mold is provided with a port for
injecting desirable concentrations of gases or for evacuating
undesirable constituents, which can include gases or liquids.
[1006] Referring now to FIG. 282, an alternate embodiment of a
pre-form web with flaps is illustrated. The web 8300 includes a
base 8302 with four vertical walls 8304, 8306, 8308, and 8310
connected to the base 8302 at lower edges of the walls thereof. The
pre-form web 8300 is preferably constructed by injection molding or
other suitable methods, such as thermoforming. The walls may be
inclined to facilitate the removal of the web pre-form from a mold.
The base is connected to the walls at lower portions thereof, and
the walls are connected to each other at adjacent ends, thusly
forming corners 8312, 8314, 8316 and 8318 where the ends of walls
connected to each other and to the base 8302 meet. Opposing two
walls 8310 and 8314 of the four walls are formed with angled edges
at a lower central portion thereof to form an recess so that upon
stacking of finished trays, the goods are preferably not in contact
with a lower stacked tray. The base 8302 is likewise configured
with angled surfaces to correlate to the shape of the walls 8310
and 8314 so that the base 8302 is aptly suited to minimize contact
with the goods of a lower stacked tray. The upper edges of the
walls include flaps 8320, 8322, 8324 and 8326 suitably constructed
so as to inwardly rotate about a hinge around the perimeter of the
opening. Referring to FIG. 283, the flaps are constructed with a
number of surfaces 8328 and 8330 at desirable oblique or
perpendicular angles to impart strength to the flaps and the
finished tray in the form of a structural member. As with other
trays disclosed herein, the tray of this embodiment is intended to
be stackable atop one another. Referring now to FIG. 284, a portion
of a finished tray with goods 8332 placed therein and folded flap
8334 is illustrated.
[1007] Referring now to FIG. 285, another alternate embodiment of a
pre-form web for finishing into a tray is illustrated. The web in
this embodiment can be thermoformed of suitable materials disclosed
herein or by other suitable methods known in the arts. The web 8400
includes a rectangular base 8402 with four walls 8404, 8406, 8408
and 8410 attached at the respective four sides around the perimeter
of the base 8402. The walls contain ribs 8422 to add structural
rigidity and strength to a finished web. When the flaps are folded,
the flaps can be bonded to the ribs, which project outward, thusly
allowing bonding of the ribs to the flaps. In this manner, the flap
faces 8424 can be pre-printed with a barcode containing relevant
information or other product description. The walls are connected
to each other at adjacent ends thereof, respectively. The four
adjacent walls are joined to each other by corrugated sections
8412, 8414, 8416 and 8418 joining a first end of a first wall to a
second end of a second wall and so on. When the web 8400 is
finished into a tray, the corrugated sections will appear as shown
in FIG. 286. The corrugated sections are intended to impart
rigidity and strength to the finished tray 8420. For example, under
certain thermoforming or injection molding conditions, the lower
corners where the base and walls are connected, the web material
may be stretched or "thinned" out, thus creating a weak spot and a
potential source for leaks. By forming a web with corrugated
corners the weak sections of the finished tray are strengthened
accordingly.
[1008] In another alternate embodiment illustrated in FIG. 294, a
tray is constructed with flaps and having contoured ends to
substantially lie adjacent to a corner where the base and walls are
joined together, when the flaps are thusly folded. The flap ends
reinforce the corners of the finished tray by overlapping and/or
wrapping around the corner sections on the bottom and sides
thereof. One or two flap ends may be bonded to a corner to
reinforce the corners. In one actual embodiment, a tray 9700
includes four flap, flaps 9702 and 9704 include contoured end
portions 9706 and 9708, respectively, rounded to conform to a
rounded corner 9710 of the web base and walls. A first flap 9702 is
folded and bonded to the tray 9700 such that the rounded end
portion 9706 of the flap 9702 overlaps the corner area 9710. A
second flap 9704 has an end portion 9708 can be folded on top of
the first rounded flap end portion 9706 to doubly strengthen the
corner section 9710 of tray 9700, as illustrated in FIG. 295.
[1009] A method according to the present invention includes
grinding boneless beef directly into an enclosed chamber that has
been filled with a suitable gas such as CO2 and which substantially
excludes oxygen from contacting with said ground beef. Adjusting
temperature of said ground beef to a suitable temperature.
Processing and mixing ground beef (meat), in a vessel or series of
vessels substantially excluding oxygen, so as to blend and adjust
the relative quantities of fat and muscle in the finished product
to a desired ratio can take place, while maintaining the ground
beef at a suitable temperature. The ground beef can then be
extruded in a stream of grinds by pumping through an enclosed
conduit with an exit end and a selected cross sectional area and
profile that is substantially similar to typical beef pattie, at a
velocity that is adjustable while maintaining pumping at a
substantially constant rate. The stream of ground beef can be
pressurized in a conduit at a selected pressure and compressing any
voids such that CO.sub.2 gas contained therein dissolves into the
stream of ground beef, while continuing to maintain ground beef at
a suitable temperature. The velocity of the stream of grinds can be
adjusted so as to intermittently slow or stop it's flow as it
emerges from the exit end of the enclosing conduit and allow
slicing with knife means to provide single beef patties in stacks
of a chosen quantity. Intermittent slowing or stopping of flow may
exceed 500 cycles per minute. The processed meat is interfaced with
a packaging system which packages the fresh meat patties without
exposure to air while continuing to maintain at a suitable
temperature.
[1010] Referring now to FIG. 291, a schematic illustration of a
plant layout is shown. The plant layout includes a processing
stream or train, for processing meat. In one section of the plant,
sources of meat 9454, 9456, and 9458 are transferred to meat
grinders 9402, 9404, and 9406. A suitable supplier for meat
grinders is the Weiler Company, Inc. of Whitewater, Wis. The meat
grinders are connected to downstream pre-blending and transfer
equipment 9408, 9410 and 9412, which may include screw and/or belt
conveyers and pumps as the transfer equipment. The pre-blending and
transfer equipment may be supplied by the Weiler Co. and the
continuous blending equipment supplied by Case Ready Solutions, LLC
of Mercer Island, Wash. The pre-blending equipment is connected to
on-line measuring devices 9414, 9416, and 9418, respectively, for
measuring the amount of fat to lean meat ratio. The measuring
devices can be supplied by Epsilon Industrial of Austin Tex. or
Holmes/Newman of Fallbrook, Calif. The transfer equipment includes
positive displacement pumps supplied by the Weiler Company.
Downstream from the measuring devices, the meat is transferred to
continuous blending equipment, 9420 where the meat is blended in a
controlled or modified atmosphere, which substantially excludes
oxygen. At this point one or a plurality of meat streams can be fed
into the blending equipment to provide for meat grinds of a desired
constituency of fat and lean meat, therefore the continuous
blending equipment includes a product entry port for one or a
plurality of meat streams. The continuous blending equipment is
supplied by Case Ready Solutions, LLC and Wenger of Sabetha, Kans.
While a continuous blending process is preferred for consistency
and efficiency, the ground meat can be fed in batches with holding
vessels interspersed throughout the process, the meat can then
transferred to one or more vessels 9432, 9434, 9436 and 9440 for
temporary storage. One vessel 9438 may serve for rejects or off
spec product. Temperature control by injection of carbon dioxide
can be adjusted to between about 29 to about 38.degree. F., the
pressure is held to less than about 40 psi, in the continuous
blending equipment and vessels but the pressure is kept to less
than about 10 psi elsewhere throughout the equipment. Continuous
blending equipment 9420 can be horizontally disposed and elevated
to provide for a gravity feeding arrangement alternately and to
either of vessels 9432, 9434, 9436 and 9440. A quantity of any
specified blend of fat and lean grinds, sufficient to fill a vessel
is produced followed by a quantity of another specified blend of
fat and lean grinds, sufficient to fill a second vessel. Vessels
can be supplied by the Weiler and Company. Blended grinds are
transferred from each vessel by suitable conveying and transfer
equipment such as positive displacement pumps to meat portioners
9422, 9424, 9426, and 9428, where the meat is extruded and sliced
into desired portions by size or weight. Feeding may be continuous
or in batches as required. The packaging section of the plant
includes a conveyor system 9446, 9448, 9450, and 9452 for moving
unfinished webs through stations, where webs are finished into
trays and loaded with goods, such as portioned meats. After the
goods have been loaded into trays, the trays are sealed by a second
web, such as may be provided with the Hayssen model RT1800, 9442
and 9444, with the modifications described herein above. Further
packaging may include loading into master containers, depending on
the circumstances and palletizing, according to a buyer's
specifications. The processing of the ground meat is conducted in a
controlled or modified atmosphere having little to no exposure to
oxygen. Suitable gases are described in the specification. The
equipment is preferably automated and controlled by a computer
9460, such as equipment supplied by the Wenger Co. The computer can
be connected to one or more buyer computers via a communication
system, such as the internet, for automatically receiving and
filling orders from buyers, such as supermarkets.
[1011] Referring now to FIG. 292, a schematic representation of a
packaging area of a meat processing plant is illustrated. The
packaging area can include one or a plurality of processing trains.
In one embodiment, the packaging area 292 includes three sources of
webs 9502, 9504, and 9506 for processing the unfinished webs. A web
treatment train includes magazines 9508, 9510, and 9512 containing
the webs, gas treatment and sterilizing equipment, and bonding
equipment to produce the finished trays from the unfinished
pre-form webs. Under some circumstances, bonding equipment may not
be necessary for non-bonded trays which can be produced by using
pre-form webs not requiring bonding. There can be one or a
plurality of unfinished web streams, which can produce finished
webs of differing sizes as required. The equipment in this area can
be supplied by PMI Cartoning Inc. of Elk Grove Village, Ill., with
adhesives supplied by National Starch and Chemical (a division of
the ICI Group) of Bridgewater, N.J. The tray treatment section is
linked to conveyor and transfer equipment which moves individual
finished trays along a conveyor, while meat grinding, portioning
and loading apparatus, 9514, 9516 and 9518 processes the meat
stored in vessels 9520, 9522, and 9524 which is then loaded as
goods into the finished trays. The trays can then be weighed and
labeled with a bar code containing relevant information. The
weighing and labeling equipment can be supplied by the Herbert
Industrial of Haverhill, Suffolk, UK. The trays with goods are then
sealed with a second web. The finished packages continue to travel
on conveyors where the packages can be directed to a stacking
apparatus 9528, such as drop loaders, supplied by PMI Cartoning,
Inc. At the stacking apparatus, further equipment can produce
thermoformed cartons. Thermoforming equipment 9530 can be supplied
by Cott Technologies Inc. of La Puente, Calif. The finished
packages can then be loaded and stacked into the newly thermoformed
cartons. The auto carton equipment can be supplied by PMI
Cartoning, Inc. The cartons are then palletized in palletizing
equipment 9534 and made ready for shipment to a buyer's designated
delivery destination. For the majority of the meat processing, the
meat is excluded from substantial contact with oxygen to minimize
oxidation. Therefore desirable concentrations of gases are
continually being used to pad processing equipment. This equipment
can be supplied by the BOC Gases company. Other equipment is
developed to remove undesirable gases by using vacuum equipment.
Vacuum equipment can be supplied by the Kinney Co of New York or
the Reitschle vacuum pump manufacturing company of Germany.
Conveyor and or transfer equipment can be supplied by PMI
Cartoning, Inc. While three differing webs for trays may be
provided at the loading station, each master container is provided
with a manner of identifying an allocated destination. The master
containers are palletized to ship where they are needed by the
buyer or alternatively may be placed in storage. The computer
controller is provided with a set of instructions to manage, in
cooperation with the input provided for by an operator interface,
the processing and packaging of the meat goods.
[1012] Referring now to FIG. 293, a schematic illustration of web
treatment and welding equipment is shown. In one embodiment, the
equipment includes tray loading magazines 9602 and gas exchange
magazines and chambers 9604. A nitrogen gas generator 9612 is
provided to pad the equipment, providing an inert environment to
substantially exclude oxygen. The nitrogen generating equipment can
be supplied by the BOC company. The trays travel on a delivery
conveyor to an adhesive applicator and bonding equipment 9606,
where the trays are formed from webs and then bonded to produce the
finished trays. The adhesive applicator and bonding equipment can
be supplied by National Search and Chemical. Under some
circumstances, the trays can be formed without bonding, such as
from the pre-form web with tabs on the foldable flaps. The finished
webs are then delivered where needed on the meat processing train
where need by a delivery conveyor 9608. The section of the plant
for finishing trays is controlled by controller computer 9610. The
computer 9610 can be integrated with other sections of the plant to
provide for just in time delivery of finished webs.
[1013] The present invention provides an efficient method of
processing fresh red meat products at the point of animal slaughter
for subsequent case ready packaging and delivery to the consumer
via a typical supermarket or retail sale outlet. The consumer may
be located thousands of miles away from the point of slaughter
which often results in distribution and delivery that can require a
period of time exceeding 20 days.
[1014] Perishable food products produced, in part or otherwise, in
the manner described herein may be placed in any suitable tray with
or without any suitable substance and over wrapped with any
suitable web of material such as pPVC (or PE) and then placed in a
master container that may be manufactured from a substantially gas
barrier material or partial gas barrier material to provide
finished packages. Following this, finished packages may be stored
in any suitable storage room maintained at any suitable temperature
until required for sale, at which time finished may be removed,
labeled and displayed for sale in a retail outlet such as a
supermarket.
[1015] Referring now to FIG. 296, a schematic illustration of an
embodiment of a plant layout according to the present invention
comprising an automated system of pre-treating packaging components
and perishable goods such as ground meats is shown. The arrangement
as shown includes four production lines for the portioning,
loading, over-wrapping and assembly of barrier master container
packages. Four empty tray conveyors are shown as 9800. Trays are
transferred along conveyors 9800 to transverse conveyors 9802,
9804, 9806, and 9808. A continuous mixer 9810 is arranged to
deposit selected ground beef into any one of four silos 9812, 9814,
9816, and 9818. Each of silos 9812, 9814, 9816, and 9818 is
arranged with a positive displacement pump attached thereto such
that ground meat can be pumped via conduits (not shown) from silo
9812 to fine grinder 9820, from silo 9814 to fine grinder 9822,
from silo 9816 to fine grinder 9824, and from silo 9818 to fine
grinder 9816. A dump silo 9828 is provided such that any quantities
of material that are determined to be unsuitable for packaging can
be transferred therein. Fine grinders 9820, 9822, 9824, and 9826
are attached respectively to portioning equipment 9830, 9832, 9834,
and 9836. Empty trays transferred along conveyors 9800 are loaded
with ground meat portions from portioner 9830 at conveyor 9802,
from portioner 9832 at conveyor 9804, from portioner 9834 at
conveyor 9806, and from portioner 9826 at conveyor 9808. Conveyors
9838 transfer loaded trays from each loading conveyor 9802, 9804,
9806, and 9808 to weighing scales 9840, 9842, 9844 and 9846,
respectively. Labels with weight and product information as
required, are applied to the bottom of loaded trays, by bottom
label applicators 9848, 9850, 9852, and 9854, respectively. Loaded
trays are then over wrapped by flow packers 9856, 9858, 9858, and
9860, respectively. Automatic stackers 9862, 9864, 9866, and 9868
stack selected groups of loaded over wrapped trays which are then
transferred and automatically loaded by automatic loaders 9876,
9878, 9880, and 9882, into gas barrier containers formed in line on
horizontal thermoforming machine 9870. Conveyors transfer trays
from the flow packers to the automatic stackers. An automatic
carton erection apparatus 9872 is arranged to enclose each barrier
master container in a carton, which is then transferred to an exit
conveyor 9874. A central control panel 9884 is located conveniently
to allow control of the complete system. Continuous mixer 9810 and
silos 9812, 9814, 9816, and 9818 may be located in an adjacent room
separated by an insulated wall such that the contents of the silos
can be maintained at a selected temperature which maybe 34 degrees
F.
[1016] Referring now to FIG. 297, a schematic, cross sectional
illustration of a section of the plant layout according to the
present invention is shown in FIG. 299. The plant is located on a
factory floor, 5000, and at a convenient elevation from the floor,
in an enclosed, suitably ventilated room that is temperature
controlled at about 38 degrees F. A generally horizontally disposed
conduit is defined by an outer, substantially gas tight, enclosure
3001. Packaging components such as tray performs 3021 and web
materials 3011, and ground meat 3027 are transferred into the
conduit 3001 in such a manner so as to substantially exclude the
entry of atmospheric oxygen and a gas 3032 is provided in any space
inside conduit 3001 that is not occupied by equipment or goods. Gas
3032 is selected and may comprise any suitable gas such as carbon
dioxide or nitrogen and is maintained at a pressure above ambient
atmospheric pressure. A conveyor 3024 is conveniently mounted
within conduit 3001 and arranged to carry trays 3020 there through.
Tray pre-forms 3021 are stacked into profiled and vertically
disposed magazines 3023 and 3099. Magazines 3023 and 3099 are
arranged to have an outer wall that closely, but not touchingly,
follows the outer profile of the stacks of pre-form trays 3021,
contained therein. De-nesting mechanisms (not shown) are arranged
to remove a single perform from the bottom of a stack such as
contained in magazine 3023 and position it onto conveyor 3024. In
this way, gas contained within conduit 3001 can then fill the
cavity in tray perform and thereby substantially preventing any
atmospheric oxygen or other undesirable gases from entering into
the tray cavity. Tray pre-forms 3021 are then carried in the
direction shown by arrow 3031 to a position below the folding and
bonding arrangement not shown but housed within enclosure 3017.
During the folding and bonding of pre-form 3021 to form tray 3020
gas 3032 fills all cavities or interstitial voids contained in the
tray and in this way it is ensured that only a selected and
suitable gas is contained therein. Finished empty trays 3020 are
then placed by 3017 onto conveyor 3024 and carried forward to be
loaded with portions of ground meat 3027. A stream of selected
ground meat is transferred through conduit 3100 at a convenient
velocity and into fine grinder 3028 and in such a manner so as to
extrude a continuous and suitably cross sectional profiled stream
of ground meat 3101 onto conveyor 3024. Extruded stream 3101 is
extruded into conduit 3001 and onto conveyor 3024, mounted therein,
at a suitable velocity so that guillotine 3026 can cut portions of
substantially similarly sized ground meat sections there from.
Portions of ground meat 3027 are then transferred into trays 3020
which are there together transferred through conduit 3001 on
conveyor 3024. Conveyor 3024 can be arranged with upwardly disposed
"cleats" 3080 or a series of suitable enclosures to ensure that
when ground meat portions 3027 are loaded into trays 3020 the tray
is positioned precisely beneath the respective ground meat portion,
allowing accurate loading into tray 3020 to produce a loaded tray
with goods 3030. Loaded trays with goods 3030 are then transferred
through conduit 3001 toward over wrapping equipment arranged to
over wrap trays 3030. A roll of suitable over wrapping web material
3010 is conveniently mounted above conduit 3001 and is unwound by
transferring a single web of material 3011 through a slot like
conduit 3012. Gas contained in conduit 3001 at an elevate pressure
can pass over the surfaces of web 3011 while it passes through slot
like conduit 3012 and in this way ensure that substantially no
atmospheric oxygen is allowed to enter conduit 3012 or conduit
3001. Over wrapped and hermetically sealed trays 3102 are
transferred along conduit 3001 toward robot stacking arrangement
3014. Robot 3014 is enclosed in a housing that forms a part of
conduit 3001 and is programmed to stack trays 3102 into groups 3015
that are then loaded into gas barrier containers 3013. Gas barrier
containers 3013 can be formed in line and flushed with a suitable
gas prior to loading of stacks 3015 therein. Horizontal
thermoforming machine 3016 is conveniently located below robot 3014
and is arranged so that the thermoformed barrier containers 3013
are enclosed within an extension of conduit 3001 and thereby
ensuring that gas 3032 is in contact therewith and filling cavities
in barrier containers 3013.
[1017] Referring now to FIG. 298 the tray de-nesting apparatus
portion of FIG. 297, before the pre-form flaps have been bonded to
the tray walls, is shown in a cross sectional view. Vertically
disposed walls 3023 are arranged to closely conform to the outer
edge perimeter of the stacked pre-forms 3021. A narrow gap is
thereby maintained between the stack 3021 and magazine walls 3023
allowing the tray pre-forms to slide through the magazine without
restriction, as the lowest tray performs are progressively removed
and placed onto conveyor 3024. Gas 3032, from conduit 3001, is
exhausted through the narrow gap at 3040 and additional selected
gas such as 3032 can be injected through conduits 3022 at a
suitable pressure so as to substantially fill spaces between the
stacked pre-forms as they are gradually transferred through
magazine 3023.
[1018] Referring now to FIG. 299, a schematic illustration of an
embodiment of an specially arranged thermoforming apparatus is
shown according to the present invention. The apparatus shown in
FIG. 299 is intended to provide an alternative, preferred and
economical method of delivering trays to conveyor 3024 as shown in
FIG. 297. A wheel 3066 is mounted onto a shaft 3070. Wheel 3066 is
arranged to have 8 flat sides, onto which tooling 3067 can be
mounted. Wheel 3066 is attached directly to a sprocket (not shown),
which engages with a pair of continuous gripper chains 3073. Other
sprockets including idler sprockets 3075 and drive sprockets 3074
are mounted to maintain gripper chains 3073 follow a fixed and
generally horizontally disposed track. A roll of interchangeable
and thermo-formable material 3064 is located between chains 3073
and is unwound in a continuous web of material 3063. As web 3063 is
unwound from roll 3064 it is held by gripper chains 3073 at each
side edge and withdrawn, at a suitable rate, from roll 3064 by the
forward motion of chains 3073. Sprockets 3074 are attached to a
suitable drive motor with controller that progressively carries web
3063 between heat banks 3062. Heat banks 3062 are mounted in close
proximity above and below web 3063 and as gripper chain 3073
carries web 3063 there between is heated. The temperature of heat
banks 3062 is controlled and maintained within a selected range so
as to ensure that the temperature of web 3063 is at a
thermo-formable temperature as it passes from between heat banks
3062 and onto a face of wheel 3066. Rollers 3060 and 3061 are
arranged to contact the upper and lower surfaces of web 3063 and
apply a calendering pressure thereto. Rollers 3062 and 3061 are
maintained at a temperature as required. Eight sets of tools 3067
are mounted to wheel 3066. Each tool 3067 comprises a four-sided
tray cavity forming depression with a flat forming depression
adjacent to each side, such that a pre-form with four flaps can be
formed therein. Clamping fixtures with plugs or matching molds 3065
are arranged to conveniently be incorporated as required while the
pre-form being formed in matching tools 3067. Forming tool 3067 can
be arranged such that the flap forming sections of the tool can be
hinged so as to fold the flaps after cutting from web 3063, and
become bonded to walls of the tray cavity prior to ejection. In
this way, a pre-form tray can be thermoformed, cut from the web
3063, folded and bonded, and ejected by tools on wheel 3066. A
finished tray 3020 is then ejected and allowed to fall in the
direction as shown by arrow 3068, onto conveyor 3024. Enclosure
3001 is arranged to completely enclose the wheel assembly 3066,
clamping arrangements 3065 and conveyor 3024, and in such a manner
to ensure that all cavities between walls and flaps of tray 3020
are filled with selected gas 3032. Web 3063 may comprise a solid
extruded sheet of plastics material, extruded from any suitable
polymer, with an additive contained therein that will generate a
suitable gas such as carbon dioxide when heated to a
thermo-formable temperature. Web material 3063 may comprise a
polypropylene polymer with any suitable additive such as a filler
additive containing calcium bicarbonate that will release carbon
dioxide gas when heated, within the extruded polymer sheet, to a
thermo-formable temperature. In this way, an expanded polypropylene
sheet (EPP) of material can be formed immediately prior to use, and
ensuring that carbon dioxide gas fills the interstitial spaces
within the web material from which trays 3020 are formed.
[1019] Referring now to FIG. 300, a section of web 3063 is shown
with a thickness 3073, which may be for example 0.010 inches, prior
to heating. A section of web material 3071 is shown with thickness
3072 which may be for example 0.030 inches thick. As shown, web
3063 can be increased in thickness from 0.010 inches to 0.030
inches, by heating to a thermo-formable temperature.
[1020] Modifications may be made to the inventions as would be
apparent to persons skilled in the packaging arts. These and other
modifications may be made without departing from the ambit of the
invention, the nature of which is to be determined from the
foregoing description.
[1021] Any suitable substance, gas, blend of gases, solution or
agent may be substituted, included as an alternative or included
with any suitable gas or blend of gases that has been specified for
any use or application in this disclosure.
[1022] While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention.
* * * * *
References