U.S. patent application number 13/643487 was filed with the patent office on 2013-05-30 for method for the preferably continuous packaging of products.
This patent application is currently assigned to TRITON GMBH. The applicant listed for this patent is Herbert Bader, Volker Heinz, Bernhard Hukelmann, Fritz Kortschack, Ralf Niepelt, Stefan Topfl. Invention is credited to Herbert Bader, Volker Heinz, Bernhard Hukelmann, Fritz Kortschack, Ralf Niepelt, Stefan Topfl.
Application Number | 20130133294 13/643487 |
Document ID | / |
Family ID | 44751599 |
Filed Date | 2013-05-30 |
United States Patent
Application |
20130133294 |
Kind Code |
A1 |
Kortschack; Fritz ; et
al. |
May 30, 2013 |
METHOD FOR THE PREFERABLY CONTINUOUS PACKAGING OF PRODUCTS
Abstract
The invention relates to a method for the preferably continuous
packaging of products, in particular foods, with or without an
already stabilized inherent shape such as fresh meat, meat products
and sausage products, sausage meat emulsion or similar products by
encasing them on all sides with single-layer or multilayer films
that can be fed from the web. According to the invention flexible
films that can be deformed without the action of heating and are
self-resetting, are used as bottom web films, wherein the bottom
web films are temporarily deformed by the action of pressure in
order to form troughs for receiving product. The respective product
is introduced as portions into the trough and fixed there, wherein
it is fixed by a top web film or covering film, optionally
supported by a restrainer. When the action of pressure is released,
preferably the bottom web film performs its resetting process and
encloses the product thereby at least in part in such a manner that
unwanted air inclusions are removed and also a certain product
compaction occurs. Then, sealing between top and bottom web films
is performed.
Inventors: |
Kortschack; Fritz; (Berlin,
DE) ; Heinz; Volker; (Quakenbruck, DE) ;
Topfl; Stefan; (Osnabruck, DE) ; Hukelmann;
Bernhard; (Quakenbruck, DE) ; Bader; Herbert;
(Nordwalde, DE) ; Niepelt; Ralf; (Gronau-Epe,
DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kortschack; Fritz
Heinz; Volker
Topfl; Stefan
Hukelmann; Bernhard
Bader; Herbert
Niepelt; Ralf |
Berlin
Quakenbruck
Osnabruck
Quakenbruck
Nordwalde
Gronau-Epe |
|
DE
DE
DE
DE
DE
DE |
|
|
Assignee: |
TRITON GMBH
Berlin
DE
NORDENIA TECHNOLOGIES GMBH
Gronau
DE
DEUTSCHES INSTITUT FUR LEBENSMITTELTECHNIK E.V.
Quakenbrueck
DE
|
Family ID: |
44751599 |
Appl. No.: |
13/643487 |
Filed: |
March 31, 2011 |
PCT Filed: |
March 31, 2011 |
PCT NO: |
PCT/EP2011/054984 |
371 Date: |
January 7, 2013 |
Current U.S.
Class: |
53/461 |
Current CPC
Class: |
A22C 17/0093 20130101;
B65B 25/065 20130101; B65B 11/06 20130101; B65B 9/04 20130101 |
Class at
Publication: |
53/461 |
International
Class: |
B65B 11/06 20060101
B65B011/06 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 27, 2010 |
DE |
10 2010 018 435.7 |
Sep 13, 2010 |
DE |
10 2010 045 192.4 |
Claims
1. Method for the continuous packaging of foods with or without an
already stabilized natural shape, by encasing them on all sides
with a single-layer or multi-layer film which can be fed from a
web, characterized in that flexible films are used as lower film
and/or upper film, which are deformable without the influence of
heat and are self-restoring, wherein at least one of the films is
temporarily deformed by the influence of pressure so as to form a
trough for receiving a product, wherein the respective product is
introduced in portions into the trough and fixed there, the fixing
being accomplished by the associated upper film or cover film,
wherein as soon as the pressure influence stops the respective film
performs its restoring process, thereby enclosing the product at
least partially, wherein the product is enclosed in such a way that
undesired air inclusions are removed, and sealing between the upper
film and the lower film is performed subsequently.
2. Method according to claim 1, characterized in that for
deaeration purposes the upper film is connected to the lower film
section-wise in a first step, and completely and tightly in a
second step.
3. Method according to claim 1, characterized in that a rinsing
and/or filling process with a protective gas is carried out after
or during the deaeration process.
4. Method according to claim 1, characterized in that the pressure
influence is realized by generating a negative pressure at the
outer side of the lower film.
5. Method according to claim 4, characterized in that the
generation of the negative pressure and thus the shaping is
supported by a selective pressure gas supply to the inner side of
the film.
6. Method according to claim 3, characterized in that the rinsing
and/or filling process is accelerated by applying a vacuum in the
area of the temporarily deformed film.
7. Method according to claim 1, characterized in that means for the
direct or indirect electrical heating of the products received in
the temporarily deformed film are provided on or in one of the
films used.
8. Method according to claim 7, characterized in that the products
respectively located in the deformed film are resistance-heated
and/or high-frequency-heated, wherein the step of heating can be
carried out both immediately after the packaging and before the
later product removal.
9. Method according to claim 7, characterized in that a support
mold is used during the thermal treatment.
10. Method according to claim 1, characterized in that the
temporarily deformed film for the formation of troughs is realized
by vacuum molds that move along with the film tape.
11. Method according to claim 1, characterized in that the upper
film and/or cover film used is made of a flexible material, in
particular a material analogous or similar to the lower film.
12. Method according to claim 7, characterized in that the means
for heating comprise contacts in the area of the sealed seam.
Description
[0001] The invention relates to a method for the preferably
continuous packaging of products, in particular foods with or
without an already stabilized natural shape, such as meat products
and sausage products, sausage meat or similar products, by encasing
them on all sides with a single-layer or multi-layer film which can
be fed from a web, according to the preamble of patent claim 1.
[0002] A method for the surface treatment, simultaneously
portioning and shaping as well as preserving foodstuffs, such as
meat and sausage products or similar products, is known from WO
2005/099465 A1.
[0003] According to the teaching of this document the product is at
first compacted between two shaping, at least partially structured
plates. Next, the product is separated into shaped sections by
mechanically contacting corresponding portions of the shaping
plates. Subsequently, the product is controllably heated,
preferably by the shaping plates, in order to form a natural skin
on the surface of the product, which has a reduced a.sub.w-value as
well as both product shape stabilizing and sterilizing properties.
Afterwards, the product is packaged into envelopes, while the
enveloping or casing material are simultaneously sterilized by
thermal influence.
[0004] A method for the production and shaping of foods, such as
meat and sausage products, is known from DE 198 07 794 C2. To
protect the foods against recontamination they are enveloped with
films prior to the final preservation. According to the method for
the continuous production of sausages described in U.S. Pat. No.
6,135,869 upper and lower films are employed, which are subjected
to preshaping. The shaping is accomplished by structured
rollers.
[0005] In the method for the production of ham products according
to DE 198 59 830 A1 a mold open at one side is used, i.e. a mold
which is formed of a trough sealed on the end side and open at the
top side, and having a rounded bottom. After filling the mold by
pressing on injected and kneaded pieces of meat the filled mold is
covered with a lid which lies on the filling material and is
subjected to a vacuum. After the return to normal pressure
conditions the filling material is cooked, and the correspondingly
cooked ham product is then removed from the mold.
[0006] Further known are deep-drawing techniques, also using
deep-drawing sheets. These sheets are typically formed of several
layers. A lower film unwound from a reel is heated and shaped. The
shaped packages are then transported further and filled in the
filling area. An upper sheet, which is also unwound from a reel,
then serves to seal the shaped and filled packages. In the sealing
station the package is subjected to a vacuum and, if necessary,
replaced by a modified atmosphere. Heat and pressure seal the upper
sheet to the lower sheet. After cutting the package in lengthwise
and crosswise directions the finished packages are ready for
transport.
[0007] The cited methods according to the prior art all have the
disadvantage that the shaping of the packages and subsequently
filling them can only be done discontinuously, i.e. in cycles,
which results in a reduced productivity.
[0008] Moreover, the filling, for instance, of sausage meat into
preformed packages has the disadvantage that a complete filling
aiming at avoiding air inclusions is time-consuming, again
resulting in productivity constraints.
[0009] Based on the foregoing it is, therefore, the object of the
invention to provide a further developed method for the preferably
continuous packaging of products, in particular foods with or
without an already stabilized natural shape, such as meat products
and sausage products, sausage meat or similar products, which
avoids undesired air inclusions and allows, when used, a high
productivity.
[0010] The solution to the object of the invention is achieved by a
method according to the teaching of patent claim 1. The dependent
claims define at least useful embodiments and further
developments.
[0011] Accordingly, a method is provided for the preferably
continuous packaging of products, in particular foods with or
without an already stabilized natural shape, such as meat products
and sausage products, sausage meat or similar products, by encasing
them on all sides with a single-layer or multi-layer film which can
be fed from a web.
[0012] According to the invention a flexible film is preferably
used as lower film, which is deformable without the influence of
heat and is self-restoring, wherein preferably the lower film is
temporarily deformed by the influence of pressure so as to form a
trough for receiving the product.
[0013] This film is provided, for instance, with a thickness of
20-300 .mu.m, preferably 50-150 .mu.m, wherein the restoring
behavior of the film is characterized in that after an expansion by
at least 100% a remaining deformation of 60% and less is obtained.
Suited raw materials for the production of such a film are found in
the groups of the styrene block copolymers, such as
styrene-butadiene-styrene copolymer (SBS), styrene-isoprene-styrene
block copolymer (SIS), styrene-ethylene-butene copolymer (SEBS),
other thermoplastic styrene elastomers (TPE-S), elastic polyolefin
copolymer, thermoplastic polyolefin elastomers (TPE-O),
thermoplastic polyurethane elastomers (TPE-U), thermoplastic
polyamide elastomers (TPE-A), thermoplastic polyester elastomers
(TPE-E) or a mixture of these polymers. Such a film may be formed
both as monofilm or also as a multi-layer or coextrusion film.
[0014] In useful embodiments not only the restoring properties, but
also further properties may be integrated, e.g. barrier properties
with respect to gases, vapors or flavors. Suited raw materials are,
for instance, polyamides, ethylene vinyl alcohol (EVOH), polyvinyl
chloride (PVC), polyvinylidene chloride (PVDC) or comparable
substances which, ideally, are incorporated in one layer of the
above-described multi-layer or coextrusion films. The upper film,
too, may have the same or similar film properties, and may also be
deformed temporarily.
[0015] The respective product is then introduced, if applicable in
portions, into the trough and fixed there, the fixing being
accomplished by an upper film or a cover film, if necessary
supported by a hold-down device.
[0016] As soon as the pressure influence stops the flexible film
then performs its restoring process, thereby enclosing the product
at least partially such that undesired air inclusions are removed.
Subsequently, a sealing between the upper film and the lower film
is performed. In the above explanation it is assumed that at least
the lower film has self-restoring properties. Of course, also the
upper film, or the lower and the upper film, may have, quasi
kinematically reversed, such self-restoring properties.
[0017] The restoration may be supported by applying a vacuum.
[0018] For deaeration purposes the cover film or upper film may be
connected to the lower film section-wise in a first step, and
completely and tightly in a second step. In one embodiment the
upper film and/or the lower film may have a perforation.
[0019] A rinsing and/or filling process with a protective gas may
be carried out after or during the deaeration process.
[0020] The pressure influence for the temporary deformation in
order to create the trough for receiving the product is preferably
realized by generating a negative pressure at the lower side of the
lower film. It is also possible, however, to proceed analogously to
the above description and/or exclusively obtain a deformation of
the upper film.
[0021] The generation of the negative pressure can be supported by
a selective pressure gas supply to the side of the film facing the
product, so that an improved shaping is realized.
[0022] The rinsing and/or filling process may be accelerated by
applying a vacuum in the outer area of the temporarily deformed
film.
[0023] According to another embodiment of the invention it is
assumed that the product to be packaged is placed on a relatively
rigid plate, tray or carrier, and is enveloped by a self-restoring
film which is deformable without the influence of heat and which,
in this case, is regarded as the upper film. Analogous to the
aforementioned sealing of the upper and lower films, the upper film
can be connected completely and tightly to the rigid plate, tray or
a carrier. The enveloping process can here by optimized by the
negative pressure influence. The enveloping process can also be
realized in a protective gas atmosphere.
[0024] It can be learned from the foregoing that not necessarily
only the lower film is temporarily deformable by the influence of
pressure, but that also a deformable, self-restoring upper film or
cover film may be employed if a solid or rigid lower film or a
so-called tray is used.
[0025] At least one of the films used has suitable means for the
direct or indirect electrical heating of the products received in
the temporarily deformed film. These means may be external contacts
enclosed by the films.
[0026] The possibility of directly or indirectly electrically
heating products received in a packaging, casing or similar means
can be employed independently of the use of a special
self-restoring film as described herein. Thus, it is possible, for
instance, to provide metallic caps for heating and pasteurizing
cold cuts, which contact the product in question and realize a
conduction of a current, and heating, through the product volume.
Heating the respective product and material to be treated may also
be accomplished by continuous, e.g. strip-type contacts, which are
located in the packaging or run along a sealed seam.
[0027] In another embodiment contacts are provided on or in at
least one of the films, which are electrically conductive and
create a direct electrical contact to the product so as to realize
the desired heating. Providing fixed contacts for the selective
heating or for pasteurization on an electrical basis, too, is
encompassed by the invention.
[0028] The products respectively located in the deformed film may
be resistance-heated and/or high-frequency-heated, wherein the step
of heating can be carried out both immediately after the packaging
and before the later product removal, i.e. by the consumer. Due to
the fact that the packaging is already formed of a flexible film an
expansion of the product when heated prior to use or consumption is
unproblematic.
[0029] A support mold may be used during the thermal treatment.
[0030] The temporary deformation for the formation of troughs is
realized by vacuum molds that move along with the lower film
tape.
[0031] It is based on the invention to carry out a continuous,
active removal of air inclusions by suction from the filled
packages immediately before they are sealed or refilled with a
protective gas.
[0032] This removal by suction can be realized through the film
which is perforated in the sealing area, the films so far only
being connected section-wise, but also through suction holes in a
cover plate or cover device. The cover device is here adapted to
allow the films to slide along the cover device without damaging
the film material.
[0033] In order to prevent a distortion of the films as they slide
along underneath the aforementioned cover device for the removal by
suction, it is possible to fix the film edges of the filled troughs
by a circumferentially sucking negative pressure device.
[0034] The invention will be explained in more detail below by
means of an embodiment.
[0035] In the method according to the invention a flexible film is
used, which has a great elasticity without being influenced by heat
and great restoring forces.
[0036] This film material can be deformed, similar to a membrane,
by pressure or negative pressure, with the deformation being
restored, i.e. canceled, as soon as the acting force stops.
[0037] If a trough was formed in the film material by means of a
negative pressure the supplied product is introduced into this
trough. As soon as no more negative pressure is applied the film
adapts to the material to be packaged, with the material provided
in the trough being held in the trough by means of pressure, e.g.
by a joined upper film and/or a hold-down device positioned above
the upper film.
[0038] Low-weight materials to be packaged, e.g. pasty materials,
uncooked or slightly cooked scalded sausage or frying sausage, can
be held in the deformed lower film by a cover film. Undesired air
inclusions can escape through perforation holes or perforation
slots provided, for instance, in the sealing area of the film. To
this end, the upper film is initially connected section-wise to the
lower film in a first sealing step, whereby not yet all holes in
the sealing zone area are finally closed.
[0039] Due to the restoring force of the lower/upper film the
filled in material is uniformly distributed in the package, and air
inclusions are pressed out.
[0040] According to the exemplary embodiment it is also possible to
support the removal of the air inclusions by actively sucking them
off through the perforation holes. It is sensible if the vacuum,
which originally created the trough for receiving the product to be
packaged, is canceled during this step of removing the air
inclusions. In a subsequent complete sealing step all holes that
are still present will be closed permanently.
[0041] Goods which should be stored in an environment with as
little oxygen as possible are prepared prior to the sealing by
actively sucking it off and, where appropriate, introducing an
oxygen-free filling gas.
[0042] In a modification of the method the removal by suction is
purposefully carried out immediately before the sealing process of
the upper film and the lower film, i.e. not through the film
perforated in the sealing area.
[0043] According to the invention it is also possible to produce
packages that comprise a gas blanket used to prolong the keeping
quality of the packaged material or also for the design of the
package. To this end, a gas is introduced into the package
immediately before the sealing, whereby it is useful to apply a
negative pressure to the lower film again while this gas is flowing
in. FIGS. 1 and 2 exemplarily show the mechanical behavior
resulting from a hysteresis measurement of the preferably used film
material.
[0044] Products which are made durable by high pressure or thermal
influence may be subjected to a further treatment in the sealed
package because the flexible properties of the film allow an
expansion or compression, in particular during a high-pressure
treatment of the product during the treatment, without causing
damage to the film material.
[0045] A thermal treatment of the products can be realized by
applying an electric field or supplying a current, for which
purpose the films are provided with a conductive coating having
corresponding contact areas. Also, it is possible to embed
conductive materials in the sealed seam of the package. Provided
contacts may also be used at a later time to heat up the package
content before the consumption thereof.
[0046] The packaging technique as introduced has the advantage that
no clocked processes are necessary, as all work steps are carried
out continuously.
[0047] Due to a permanent sealing, vacuum molds moving along in
order to produce the troughs for receiving the product and the
supply of the upper film the filling with the product to be
packaged can quasi be carried out in parallel with the shaping.
[0048] Upon the termination of the packaging process the packages
are separated in a manner known per se, where appropriate in
connection with labeling or the introduction into a shipping carton
or the like.
* * * * *