U.S. patent application number 15/648286 was filed with the patent office on 2017-10-26 for food packaging assemblies comprising composite materials.
The applicant listed for this patent is Bradley Farrell, Cristi Stitz, Jennifer Stitz. Invention is credited to Bradley Farrell, Cristi Stitz, Jennifer Stitz.
Application Number | 20170305634 15/648286 |
Document ID | / |
Family ID | 59848116 |
Filed Date | 2017-10-26 |
United States Patent
Application |
20170305634 |
Kind Code |
A1 |
Farrell; Bradley ; et
al. |
October 26, 2017 |
Food Packaging Assemblies Comprising Composite Materials
Abstract
Food packaging assemblies of this invention comprise composite
materials for food contact applications. Such composite materials
include an absorbent layer and a non-absorbent layer, the absorbent
layer having a textured surface for absorbing and trapping liquids,
for example, oil, grease, or water, and the non-absorbent layer
having an oleophobic surface that acts as an oil and grease
specific liquid barrier. The material further includes one or more
lamination layers. The lamination layer acts as a general liquid
barrier between the absorbent layer and non-absorbent layer. This
additional liquid barrier enhances the liquid repelling effect of
the non-absorbent layer to more effectively trap liquids in the
absorbent layer, thereby preventing liquids from seeping through
the material onto an external surface.
Inventors: |
Farrell; Bradley; (Burbank,
CA) ; Stitz; Jennifer; (North Hollywood, CA) ;
Stitz; Cristi; (Los Angeles, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Farrell; Bradley
Stitz; Jennifer
Stitz; Cristi |
Burbank
North Hollywood
Los Angeles |
CA
CA
CA |
US
US
US |
|
|
Family ID: |
59848116 |
Appl. No.: |
15/648286 |
Filed: |
July 12, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15611738 |
Jun 1, 2017 |
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15648286 |
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13626811 |
Sep 25, 2012 |
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15611738 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A01M 1/20 20130101; A01C
1/044 20130101; A01C 1/046 20130101; A23V 2002/00 20130101; B65D
2585/366 20130101; A23L 5/11 20160801; A01M 21/043 20130101; B65D
81/264 20130101; A23L 5/273 20160801; A23L 5/10 20160801 |
International
Class: |
B65D 81/26 20060101
B65D081/26 |
Claims
1. A pizza box assembly comprising: a pizza box liner disposed in
the pizza box, the pizza liner comprising: a composite material
having an absorbent surface positioned face up in the pizza box and
a non-absorbent surface positioned face up in the pizza box, the
composite material is disposed in the pizza so that the absorbent
layer directly contacts a bottom or top surface of a pizza disposed
in the pizza box and the non-absorbent layer directly contacts one
or more pizza box surfaces; one or more side panels positioned near
the midpoint of the right and left sides of the liner, the side
panels extended vertically from the absorbent surface of the liner,
the side panels extending a distance from the absorbent surface
that is slightly less than the height of a side wall of a pizza box
so that the side panel can be disposed in the pizza box between a
bottom surface and the top of a side wall of the box; two or more
rear panels positioned near the midpoint of the back side of the
liner, the rear panels further stack on top of each other so that
the bottom rear panel is positioned below the top rear panel, the
bottom rear panel extended vertically from the absorbent surface of
the liner, the bottom rear panel extending a distance from the
absorbent surface that is slightly less than the height of a rear
panel of a pizza box so that the rear panel can be disposed in the
pizza box between a bottom surface and a hinge above a rear wall of
the box, the top rear panel extended out from the bottom rear panel
toward the center of the absorbent surface, the top rear panel
extending a distance above the rear wall of the pizza box so that
the top rear panel contacts the top of the pizza box when the box
is closed.
2. The pizza box assembly of claim 1, wherein the top rear panel of
the pizza liner further comprises a printable surface that pops out
from the rear wall of the pizza box when the box is opened, the
printable surface is configured to receive an hold ink so that
advertisements and other messages may be printed on the top rear
panel and displayed when the box is open.
3. The pizza box assembly of claim 1, further comprising a scored
edge at the base on at least one panel of the pizza box liner.
4. The pizza box assembly of claim 3, wherein the scored edge marks
a pre-folded path for assembling the pizza liner from a flat
configuration.
5. The pizza box assembly of claim 1, further comprising one or
more front edges cut into one or more corners of the front side of
the pizza liner, the edges distort the rectangular shape of the
pizza liner at the front side so that the liner may be disposed in
pizza boxes having a front wall with one ore more corners folded in
toward the center of the pizza box.
6. The pizza box assembly of claim 5, further comprising a pizza
box liner having one or more front panels positioned near the front
edges, the front panels extended vertically from the absorbent
surface of the liner, the front panels extending a distance from
the absorbent surface that is slightly less than the height of the
front wall of a pizza box so that the front panels can be disposed
in the pizza box between a bottom surface and the top of the front
wall of the box.
7. The pizza box assembly of claim 1, wherein the pizza liner is
removable from the pizza box to allow the liner and the box to be
disposed separately.
8. The pizza box assembly of claim 1, wherein the pizza liner
further comprises one or more half circle tabs positioned on top of
the side panels.
9. The pizza box assembly of claim 8, wherein the half circle tabs
are positioned on the side panels to align with one or more holes
in the side wall of the pizza box, in this configuration, the half
circle tabs are accessible through the holes in the side wall of
the box and provide a surface to mainplate the pizza liner when the
box is partially or fully closed.
10. The pizza box assembly of the claim 1, wherein the pizza liner
is disposed in the main body of the pizza box opposite the pizza
box top.
11. The pizza box assembly of claim 10, further comprising a second
pizza liner attached to the underside of the top of the pizza box,
the second pizza liner is positioned to absorb liquid from the top
surface of the pizza when the pizza box is closed.
12. A food bag assembly comprising: an inner surface for receiving
take out food, the inner surface comprising an absorbent layer; an
outer surface for handling the bag, the outer surface comprising a
nonabsorbent layer; and one or more liquid barriers between the
inner surface and the outer surface, the liquid barriers repel
liquid and thereby prevent absorbed liquid in the absorbent layer
from reaching the non-absorbent layer, wherein the inner surface,
the outer surface and the liquid barriers are included in one sheet
of composite material.
13. The food bag assembly of claim 12, further comprising an outer
surface with an absorbent layer laminated to the nonabsorbent
layer.
14. The food bag assembly of claim 13, wherein the absorbent layers
contained in the inner surface and outer surface of the food bag
have a surface texture comprising a system of ridges and valleys,
the ridges are configured to adsorb liquid from a food surface and
facilitate absorption of liquid by the absorbent layer, the valleys
are configured to absorb liquid into the main body of the absorbent
layer, the valleys further configured to trap and hold absorbed
liquid in the absorbent layer.
15. The food bag assembly of claim 12, further comprising a first
scored edge running down the middle of the side portions of the bag
assembly and a second set of scored edges extended out from the mid
point of the bottom of the bag toward the front and back surfaces
of the bag assembly, the scored edges mark a pre-folded path for
assembling the food bag from a flat configuration.
16. The food bag assembly of claim 12, wherein the food bag is
dimensioned to receive lasagna, fries, nachos, burritos, tacos,
fried rice, stir fry, macaroni and cheese, pasta, fried noodles,
fried chicken, hot dogs, burgers, bbq, popcorn, dounuts, tater
tots, corn dogs, biscuits, and other take out foods.
17. A baking sheet comprising: a top surface disposed face up in a
baking pan, the top surface for receiving food to be cooked on the
pan and comprising an absorbent layer; and a bottom surface
disposed face down in a baking pan, the bottom surface for
contacting the baking pan and comprising one or more liquid
barriers, wherein the top surface and bottom surface are included
in one sheet of composite material.
18. The baking sheet of claim 17, further comprising a scored edge
set back some distance from the outer edge of the baking sheet, the
scored edge marks a pre-folded path for assembling the baking sheet
from a flat configuration.
19. The baking sheet of claim 18, wherein the scored edge is set
back at least one quarter inch from the outer edge of the baking
sheet.
20. The baking sheet of claim 17, wherein the liquid barriers
included in the bottom surface comprise at least one of a
lamination layer, a non-absorbent layer, or some combination.
Description
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/611,738, filed Jun. 1, 2017, and entitled
"Composite Materials for Food Contact Applications" which is
continuation-in-part of U.S. patent application Ser. No.
13/626,811, filed Sep. 5, 2012, and entitled "Disposable
Pizza-Blotting Composite and Box", the contents of which are
expressly incorporated herein in their entirety.
TECHNICAL FIELD
[0002] In general, the present disclosure relates to composite
materials. In particular, composite materials that absorb and trap
liquids are described herein.
BACKGROUND
[0003] Many people enjoy "take-out" food as a convenient and
economical meal. Many of these foods are messy to eat including
fries, pizza, nachos, burritos, tacos, fried rice, stir fry,
macaroni and cheese, pasta, fried noodles, fried chicken, hot dogs,
burgers, bbq, popcorn, cookies and other baked goods. Liquids
including oil, grease, and other organic liquids and water and
other polar liquids staturate many take out entrees and drip from
conventional food packaging to ruin clothing, aplothstry, and the
experience of eating.
[0004] Despite the mess, many types of take out food are increasing
in popularity, for example, pizza. In addition to the mess of pizza
grease, high amounts fat, cholesterol, and sodium make eating pizza
unhealthy. Accordingly, there exists a long felt, but unresolved
need for a composite material to make food packing that removes
fats, grease, oils, and other excess nutrients from the surface of
meat, cheese, and dough.
[0005] Conventional methods of making take out food healthier
include using napkins and other paper products to blot excess oil
and grease from a food surface before eating. This approach,
however, is ineffective because the oil and grease bleeds through
the napkin and transfers to the hands of the consumer, thus
requiring the use of additional napkins. It is also inefficient
because conventional paper products are not optimized to absorb and
trap grease. Therefore, others have failed to use conventional
methods and materials to minimize the adverse health effects of
eating take out foods while also improving the eating
experience.
[0006] Excess waste is another problem associated with conventional
materials used in food contact applications, for example food
packaging. Although catchy, colorful, and excessive packaging helps
drive sales, it creates unnecessary waste. Worse, many conventional
food packaging assemblies are layered and comprise multiple
materials, for example, food packaging that comprises a plastic
layer enclosed within another paper box outer container. Layering
packaging with multiple materials is excessive and makes food
packaging more difficult to recycle because of sorting.
Accordingly, others have failed to create materials fit for food
contact applications that form a single composite material and
reduce overall waste.
[0007] According to the federal Environmental Protection Agency
(EPA), food containers and packaging make up over 23% of all
material reaching landfills. To encourage less waste production,
the EPA asks businesses, communities, and households to eliminate
waste before reusing or recycling. Waste reduction is important
component of a sustainable society because it reduces the amount of
raw materials extracted in the manufacture of a product and reduces
the water, energy, oil and other resources need to manufacture,
transport, sell and consume the product.
[0008] Due to wasteful and ineffective conventional materials for
food contact applications, food packaging comprises most of the
litter polluting US roadways, waterways, and beaches. Conventional
materials, for example, plastic food packaging are non-compostable,
non-biodegradable, and do not readily disintegrate. Instead
discarded food packaging accumulates in the environment harming
wildlife and disrupting ocean dependent industries including
shipping, fishing, tourism, and other ocean dependent industries.
Therefore, wasteful and ineffective food packaging materials is a
recognized problem.
[0009] Conventional materials for food contact applications also
contain substances that are harmful to human health. Expanded
Polystyrene (EPS, often called STYROFOAM, a product manufactured by
DOW CHEMICAL COMPANY) is one harmful material often found in food
packaging materials including, for example, takeout containers,
drink cups, and plates. EPS is made from non-biodegradable
petroleum-based polymer materials and does not break down. Instead,
in the presence of sunlight, it photodegrades into small pieces.
Additionally, reach shows harmful chemicals leach from EPS
containers that contact hot, greasy, or acidic food. All discarded
EPS either takes us space in a landfill or ends up polluting land
and waterways because it does not naturally compost or biodegrade.
In the ocean, EPS breakdowns into its monomer styrene, a human
carcinogen. Accordingly there exists a long felt, but unresolved
need for materials fit for food packaging applications that do not
contain EPS.
[0010] Many communities have passed laws banning the use of EPS. In
California, 65 ordinances have passed either prohibiting
restaurants from using EPS or requiring the use of compostable or
recyclable containers. Maine bans the use of EPS for serving
individual portions of food or a beverage at a facility or function
of the State or of a political subdivision unless containers are
recycled. Additionally, communities in Massachusetts, New Jersey,
New York, Oregon, Texas, Washington and Washington D.C. have all
banned EPS, in food service applications. Lastly, in 2015, New York
City passed an ordinance banning all types of ESP food waste and
foam packaging peanuts. Accordingly, the presence of EPS in food
contact applications is a recognized problem.
[0011] Perfluorinated chemicals or PFCs are another class of
harmful materials commonly found in conventional materials used in
food contact application. The adverse human health impacts of PFCs
have been well documented over the last decade. Research shows that
even extraordinarily small doses of Teflon, PFOA, and other PFCs
can be harmful to human health. For example, a 2006, report from
the U.S. Environmental Protection Agency (EPA) Science Advisory
Board said PFOA is "likely to be carcinogenic to humans."
Additionally, in 2012, an independent science panel funded by
DuPont reported "probable links" between PFOA exposure and
testicular and kidney cancer, thyroid disease, pregnancy-induced
hypertension and preeclampsia, ulcerative colitis and high
cholesterol. More recent research finds that even the smallest
doses of PFOA, PFOS, and other PFCs are harmful, because most
Americans already have elevated levels of perfluorinated chemicals
in their blood stream due to prolonged exposure. Accordingly, there
exists a long felt, but unresolved need for materials fit for food
contact applications that do not contain PFCs.
[0012] Despite the well documented health hazards of PFCs,
companies such as DUPONT and 3M have not always been forth coming
about the risks of perfluorinated chemicals. In 2001, 3M stopped
producing its Scotchgard chemical after admitting to the EPA it
withheld decades of damning internal studies on PFCs' health
hazards. Additionally, court documents from a West Virginia class
action case against DuPont revealed the company had also covered up
unfavorable internal studies. In 2006, the EPA fined DuPont a then
record $16.5 million and the company agreed to phase out PFOA by
2015. Accordingly, others have failed to create materials fit for
food contact applications that do not contain PFCs.
[0013] In an effort to protect consumers, FDA banned PFOA from food
packaging. Other PFC substances, for example, TEFLON
(perfluorooctanoic acid or PFOA) were phased out of food contact
applications after being linked to cancer and reproductive and
developmental harm. The agency, however, continues to allow the use
of other PFCs with slightly different chemical structures in food
packaging applications. The FDA has approved 20 types of PFCs for
coating paper and paperboard used to serve food. Despite regulatory
approval, concerns about the health impacts of PFCs persist due to
insufficient testing, particularly of new PFC compounds. DuPont
even filed documents with the EPA, reporting GenX, one of their
next-generation PFC chemicals used to coat food packaging, could
pose a "substantial risk of injury," including cancerous tumors in
the pancreas and testicles, liver damage, kidney disease and
reproductive harm.
[0014] Other companies have tried to avoid materials containing
PFCs. BURGER KING, for example, stopped using paper coated with
fluorinated chemicals in 2002. MCDONALD'S also pledged to move away
from PFOA coatings. On the production side, the manufacture of PFOA
by DUPONT and seven other companies in the U.S. ended ahead of
schedule in 2011. Additionally, the FDA officially banned the use
of three PFOA-based chemicals in food packaging in January 2016.
The FDA also added two new PFOS-based chemicals to its ban in
November 2016 after receiving a petition from 3M indicating that
production ended almost 15 years earlier. Therefore, the presence
of PFCs in materials used for food contact applications is a
recognized problem.
[0015] Despite the FDA's ban, tests indicate many conventional
materials used in food contact applications, for example, food
packaging used by some fast food outlets, are still coated with
grease resistant PFOA, PFOS, or related chemicals. Alternatively,
many chains are using papers coated with next-generation PFCs
hoping they are "safer". In 2014 and 2015, tests undertaken by
non-profit research organizations, along with federal and state
regulatory, and academic institutions studied wrappers for
sandwiches and burritos, bags for fried foods, chips, and pastries,
pizza and chicken boxes, and other paper and paperboard items used
to serve food from twenty seven fast food chains and other
restaurants in the U.S. The study revealed that of the three
hundred twenty seven samples collected between 2014 and 2015 from
fast food outlets in Boston, San Francisco, Seattle, Wash., D.C.,
and Grand Rapids (MI), 40 percent tested positive for fluorine, an
indicator of PFCs. Further tests on smaller numbers of samples
found the overwhelming majority of food packaging contains PFCs.
More specifically some samples were found to have traces of PFOA,
the former Teflon chemical. In these studies, PFCs showed up in
food packaging used at many of the most popular and well-known fast
food restaurants, including: ARBY'S, BURGER KING, CHIC-FIL-A, DAIRY
QUEEN, DUNKIN DONUTS, JIMMY JOHNS, PANERA, STARBUCKS, QUIZNO'S, and
TACO BELL. Accordingly, others have failed to create materials for
food contact applications that do not contain PFCs.
[0016] PFC-based coatings on food packaging materials present a
serious health risk because the hot, fatty foods served in PFC
packaging soak up the chemicals in contact with the food. By eating
food served in PFC packaging, consumers often consume PFCs and
other chemicals. A 2008 FDA study found that "fluorochemical paper
additives do migrate to food during package use," and oil and
grease "can significantly enhance migration of a fluorochemical
from paper." Additionally, a 2009 EPA study identified food contact
paper as a key pathway for PFCs to enter the body. Therefore, there
exists a long felt, but unresolved need for materials for food
contact applications that contain no PFCs.
[0017] Oil and grease contamination is another problem associated
with conventional food preparation techniques that use conventional
materials for food contact applications including cooking.
Contamination from oil and grease is one of the biggest threats to
clean municipal water in the United States. To maintain clean
water, the National Pretreatment Program (NPP) implements the Clean
Water Act requirements to control pollution in Publically Owned
Treatment Works (POTWs). As part of the NPP, the EPA requires State
and local governments to control pollutants that complicate POTW
treatment processes or contaminate POTW sewage sludge. These
requirements typically mandate eliminating the discharge of Fats,
Oils, and Grease (FOG) from food service establishments (FSE). More
specifically, the NPP regulations prohibit "solid or viscous
pollutants in amounts which will cause obstruction" in the POTW and
its collection system. The EPA's Report to Congress on combined
sewer overflows (CSOs) and sanitary sewer overflows (SSOs)
identified that "grease from restaurants, homes, and industrial
sources are the most common cause (47%) of reported blockages". FOG
is a big problem for municipal water infrastructure because it
"solidifies, reduces conveyance capacity, and blocks flow." The
annual production of collected grease trap waste and uncollected
grease entering sewage treatment plants can be significant and
ranges from 800 to 17,000 pounds/year per restaurant. Accordingly,
FOG contamination of municipal water is a recognized problem.
[0018] In response to the overwhelming number of FOG caused
blockages identified in CSO/SSO Report to Congress, a growing
number of control authorities are establishing and enforcing more
FOG regulatory measures to control FOG discharge by FSEs. Federal,
State, and local governments are employing regulatory methods to
encourage FSEs to adopt best management practices. These regulatory
methods include frequent inspections, periodic grease pumping,
stiff penalties, and even criminal citations for violators, along
with `strong waste` monthly surcharges added to restaurant sewer
bills. Reported surcharges range from $100 to as high as $700 or
more. In light of this harsh regulatory environment, FOG discharge
is a serious problem for any restaurant that deep fries food or
prepares food containing high concentrations of FOG. Accordingly,
there is long felt, but unresolved need for a material used in food
contact applications, including cooking, that absorbs FOG and
prevents FOG contaminates from reaching the clean water supply.
[0019] Using conventional materials in food contact applications
also contaminations recycling and composting streams. Recycling is
an important component of a sustainable system of waste disposal
with some state and local recycling operations diverting as much as
25%-90%+ of waste away from landfills. Food packaging materials,
for example, pizza delivery boxes, made from recyclable materials,
including corrugated cardboard, become contaminated when fats,
oils, and grease from cooked meat, cheese, and dough are absorbed
into the material. The oily substances are incompatable with the
water based process of making pulp from recycled paper and thereby
cause otherwise recyclable food packaging materials to become
landfill waste. Due to the costly problems associated with grease
contamination of pulp including paper plant shutdowns for equipment
maintenance and cleaning, the vast majority of food packaging is
not recycled. Accordingly, FOG contamination in the recycling
stream is a recognized problem and there exists a long felt, but
unresolved need for a composite material fit for food contact
applications that protects recyclable food packaging materials from
FOG.
[0020] It is estimated that up to 20% of all municipal solid waste
in the US is food waste. Composting currently offers the best
opportunity to divert food waste away from landfills because
alternatives including animal feed and bio-digestion are high
regulated and relatively unproven at scale. Unfortunately, as with
recycling, contamination is the largest force undermining current
composting efforts. Incorporating FOG and other materials that do
not break down in the composting process increases costs and
decreases the quality of the end product, humus, the organic
component of soil. Additionally, food packaging contaminates in the
composting stream, require many commercial composting operations to
invest in state-of-the-art depackaging and screening equipment
before they can accept food waste. Accordingly, there exists a long
felt, but unresolved need for a composite material used in food
contact applications that is compostable in large-scale composting
operations.
[0021] Regulations have been in enacted in many jurisdictions to
encourage food waste diversion through composting. For example,
state governments in Connecticut, Massachusetts and Vermont have
laws prohibiting landfill disposal of food waste from large
commercial food waste generators. Similarly, municipal governments
in New York City and Austin, Tex. have programs for diverting
large-scale food scraps from hotels, hospitals, and other large
generators. To divert residential waste, these jurisdictions offer
curbside organic composting. Other regulatory schemes require large
food waste generators, such as restaurants and grocery stores, to
separate and divert food waste from trash. For example, San
Francisco and Seattle both have mandatory requirements for food
waste diversion for all generators including residential and
commercial establishments. An alternative approach incentives waste
diversion. In San Diego and Charleston County, South Carolina,
separating food waste from other trash significantly reduces the
tipping fee for waste collection.
[0022] Despite increased regulation and the environmental and
practical benefits of composting food waste including less crowded
landfills, lower overall trash production, and cheaper trash
disposal, only about 10% of commercial establishments currently
process food waste. BioCycle Magazine, the premier resource for
compost and organics news, reported that of the approximately 5,000
compost operations across the country, only about 500 of them are
accepting food waste. The greatest opportunity for expansion of
food waste composting, therefore, lies in large-scale operations.
Accordingly, others have failed to develop and implement
compostable materials for food contact applications in order to
establish composting as an effective technique for diverting food
waste.
[0023] Greenwashing and other methods of disseminating
disinformation about a product to present an environmentally
responsible public image is a common and effective form of false
advertising associated with environmentally friendly products.
Clear testable standards can reduce the impact of greenwashing by
making composting practices more transparent and easier to
understand. There are many words to describe products that break
down under various conditions, for example, compostable,
biodegradable, degradable, and photogradable. As more materials for
food contact applications become marketed as recyclable,
biodegradable, compostable, bio-digestible, and/or photogradable,
standards for these materials must be clear and easily enforced to
avoid contamination across the spectrum of disposal streams.
Accordingly, there is a need for a compostable food packaging
material that meets internationally accepted composting standards,
for example, Europe's EN 13432 found in European Directive
94/62/EC, the American Society for Testing and Materials D6868, and
the Australian Standard AS4736-2006.
[0024] Obesity steming from overconsumption of take out foods and
other foods high in fat, cholesterol, and sodium is one of the
biggest public health problems in the United States. According to
the Center for Disease Control, more than one-third of adults
(36.5%) and 17% of youth in the United States are obese. The World
Health Organization (WHO) reports that obesity is associated with a
"greatly increased risk" of diabetes, gall bladder disease,
hypertension, dyslipidemia, insulin resistance, breathlessness, and
sleep apnea; a "moderately increased risk" of coronary heart
diseases, osteoarthritis, hyperuricemia, and gout; and "slightly
increased risk" of cancers, reproductive hormone abnormalities,
polycystic ovary syndrome, impaired fertility, low back pain,
increased anesthetic risk, and fetal defects as a result of
maternal obesity. According to a WHO report obesity is on the rise
in the US and worldwide with the number of obese adults now
estimated to be over 300 million. This represents a 33% increase
from 200 million in 1995.
[0025] Unhealthy dietary habits leading to overconsumption of fat,
cholesterol, and sodium is a leading cause of the growing global
obesity epidemic. According to studies conducted by the National
Institute of Health (NIH), overconsumption of food rich in fat
leads to weight gain because fat has low satiety properties and
high caloric density. Epidemiological evidence uncovered by the NIH
suggests a high-fat diet promotes the development of obesity and
indicates a direct relationship between the amount of dietary fat
and the degree of obesity. The American Journal of Clinical
Nutrition has also published evidence indicating a causal
relationship between dietary fat intake and obesity. This work
states there is ample research from animal and clinical studies,
from controlled trials, and from epidemiologic and ecologic
analyses to provide strong evidence that dietary fat plays a
leading role in the development and treatment of obesity.
Accordingly, a high-fat diet resulting from overconsumption of take
out foods is a well recognized problem.
[0026] Results from 28 clinical trials studying the effect of
reducing the amount of energy from fat in the diet further confirm
lowering dietary fat is a leading treatment for obesity. Many
publications including a recent article in the Journal of the
American Dietetic Association Data demonstrate the positive impact
absorbing unhealthy nutrients from take out foods has on dietary
fat. The paper includes data, complied by Iowa State University
from the U.S. Department of Agriculture's Nutrient Database,
suggesting fat from meat contributes a significant portion of the
calories and fat in many unhealthy diets. Iowa State University's
Dr. Garden-Robinson notes that draining fat from ground beef and
other meats after cooking significantly reduces fat and calorie
content. Therefore, there is a long felt, but unresolved need for
materials used in food contact applications that absorb FOG from
food surfaces.
[0027] In addition to high dietary fat, elevated levels of dietary
sodium can cause serious health concerns. Harvard University's
School of Public Health reports kidneys in most people with high
sodium diets have trouble processing excess sodium in the
bloodstream. As unfiltered sodium accumulates, the body holds onto
excess water to dilute the sodium. This increases the amount of
fluid surrounding cells and the volume of blood in the bloodstream.
Increased blood volume puts more pressure on blood vessels while
making it more difficult for the heart to circulate blood. Over
time, the extra work and pressure stiffens blood vessels and
accelerates heart aging. Deteriorating blood vessels and cardiac
tissue, in turn, leads to high blood pressure, heart attack,
stroke, and heart failure. As the leading cause of heart disease,
high blood pressure is a serious medical condition. It accounts for
two-thirds of all strokes and half of all cases of cardiac disease.
There is also evidence suggesting that high amounts of dietary salt
damages the heart, aorta, and kidneys independent of increasing
blood pressure and volume.
[0028] A recent study in Archives of Internal Medicine provides
more evidence that high salt diets have negative effects on health.
In this study, people with the highest sodium intakes had a 20
percent higher risk of death from any cause than people with the
lowest sodium intakes. Besides contributing to high blood pressure,
consuming high amounts of sodium can also lead to stroke, heart
disease, and heart failure. Research also shows that reducing
sodium lowers cardiovascular disease and death rates over the long
term. Research also shows that higher intake of salt, sodium, or
salty foods is linked to an increase in stomach cancer. The World
Cancer Research Fund and American Institute for Cancer Research
concluded that salt, as well as salted and salty foods, are a
"probable cause of stomach cancer." A diet high in sodium is also
linked to osteoporosis, the bone-thinning disease. The amount of
calcium that your body loses via urination increases with the
amount of salt you eat. If calcium is in short supply in the blood,
it can be leached out of the bones. Some studies have shown that
reducing salt intake causes a positive calcium balance, suggesting
that reducing salt intake could slow the loss of calcium from bone
that occurs with aging. Accordingly, excess sodium in the
bloodstream resulting from elevated dietary sodium is a well
recognized problem. Advanced food packaging materials that make
food healthier by absorbing unhealthy substances are one solution
to this problem. Therefore, there exists a long felt, but
unresolved need for materials used in food contact applications
that absorb sodium from food surfaces.
[0029] In addition to elevated levels of FOG and sodium, high
dietary cholesterol can cause serious health problems. There are
two types of cholesterol, one considered "good" and the other
considered "bad". High-density lipoprotein (HDL), or "good,"
cholesterol picks up excess cholesterol and takes it back to ones
liver. Low-density lipoprotein (LDL), or "bad," cholesterol
transports cholesterol particles throughout your body. LDL
cholesterol builds up in the walls of your arteries, making them
hard and narrow. Many factors determine a person's cholesterol
levels including genetic makeup, inactivity, obesity, an unhealthy
diet, diabetes and smoking.
[0030] According to the Centers for Disease Control and Prevention,
73.5 million adults (31.7%) in the United States have high
low-density lipoprotein (LDL), or "bad," cholesterol. Fewer than 1
out of every 3 adults (29.5.degree./o) with high LDL cholesterol
has the condition under control and less than half (48.1%) of
adults with high LDL cholesterol are getting treatment to lower
their levels. People with high total cholesterol have approximately
twice the risk for heart disease as people with ideal levels.
Nearly 31 million adult Americans have a total cholesterol level
greater than 240 mg/dL.
[0031] According to the Mayo Clinic, high cholesterol can cause
atherosclerosis, a dangerous accumulation of cholesterol and other
deposits on the walls of your arteries. Once coronary arteries that
supply the heart with blood become affected by cholesterol buildup,
chest pain and other symptoms of coronary artery disease may occur.
This buildup often combines with calcium and other bioavailable
substances to form plaques, which can tear or rupture arteries and
other blood vessels. After tearing, a blood clot often develops at
the plaque-rupture site. This clot can block the flow of blood or
breaking free and plug an artery downstream. Such blockages are
very dangerous because they frequently stop blood flow to part of
the heart causing heart attacks. Similar conditions in the brain,
lead to blocked blood flow to neural tissue and stroke.
Accordingly, cholesterol accumulation on artery walls resulting
from elevated dietary fat and cholesterol is a well recognized
problem.
[0032] Despite the well-documented danger of high fat, sodium, and
cholesterol diets, many unhealthy food options exist. These take
out food options are staples of many diets because fresh food such
as fruits and vegetables are less convenient, more expensive and
less accessible. Since eliminating take out food is not a realistic
option for many people, a multi-billion dollar pharmaceutical
industry has been developed to help people many the symptoms
associated with maintaining an unhealthy diet. For example, many
prescription drugs help lower cholesterol and treat other symptoms
of obesity including diabetes, high blood pressure, and heart
disease. Although many of these drugs are temporarily effective
there are often significant costs and potential side effects
associated with this path of treatment. Therefore, there exists a
long felt, but unresolved need for materials used in food contact
applications that absorb fat, sodium, and cholesterol from food
surfaces.
SUMMARY OF INVENTION
[0033] The invention included herein comprises a composite material
for food contact applications. The composite material includes an
absorbent layer and a non-absorbent layer, the absorbent layer
having an oleophilic surface for absorbing and trapping liquids,
for example, oil, grease, or water, and the non-absorbent layer
having an oleophobic surface that acts as an oil and grease
specific liquid barrier. The material further includes one or more
lamination layers. The lamination layer acts as a general liquid
barrier between the absorbent layer and non-absorbent layer. This
additional liquid barriers enhances the liquid repelling effect of
the non-absorbent layer to more effectively trap liquids in the
absorbent layer, thereby preventing liquids from seeping through
the material onto an external surface.
[0034] The composite material may be used as a food packaging
material that absorbs fat, calories, cholesterol, sodium, and other
substances from the surface of greasy take out foods. Food
packaging made from the material also prevents contamination in the
recycling stream by preventing FOG and other liquids absorbed from
a food surface from contacting food packaging assembles made from
recyclable materials, for example, corrugated cardboard. The
material is also flourine-free, EPS free, non-biotoxic, and safe
for food contact applications. As used herein, "fluorine free"
refers to materials that are composed of raw materials and
ingredients that are free from perfluorooctanoic acid (PFOA, CAS
335-67-1), ammonium perfluorooctanoate (CAS 3825-26-1),
perfluorooctane sulfuic acid (PFOS, CAS 1763-23-1), potassium
perfluorooctane sulfonate (CAS 2795-39-3), ammonium perfluorooctane
sulfonate (CAS 29081-56-9), lithium perfluorooctane sulfonate (CAS
29457-72-5), diethanolamine (DEA) salt (CAS 70225-39-5),
perfluorooctanesulfonyl fluoride (CAS 307-35-7), perfluorinated
carboxylic acids (PFCAs), for example, perfluorononanoic acid (CAS
375-95-1), perfluorodecanoic acid (CAS 335-76-2),
perfluoroundecanoic acid (CAS 4234-23-5), perfluoroundecanoic acid
(CAS 307-55-1), perfluorododecanoic acid (CAS 307-55-1),
perfluorotridecanoic acid (CAS 72629-94-8), perfluorotetradecanoic
acid (CAS 376-06-7),
hexacosafluoro-13-(trifluoromethyl)tetradecanoic acid (CAS
18024-09-4), perfluorohexadecanoic acid (CAS 67905-19-5),
perfluorooctadecanoic acid (CAS 16517-11-6), and perchlorate (CAS
14797-73-0). As used herein, "non-bioxtoxic" refers to materials
that are composed of raw materials and ingredients that are free
from heavy metals including Arsenic, Barium, Cadmium, Chromium,
Lead, Mercury, Selenium, and Silver, and substances listed as
carcinogens by the Occupational Safety and Heath Administration
(OSHA). As used herein, "safe for food contact applications" refers
to materials that comply with the Federal Food and Drug Cosmetic
Act under applicable sections and provisions of Title 21CFR
including parts 175: Adhesives and Components of Coatings, 176:
Indirect Food Additives: Paper and Paperboard Components, and 178:
Adjuvants and Production Aids or the FCN Program. As used herein,
"food contact applications" refers to producing, manufacturing,
packaging, processing, preparing, treating, cooking, packing,
transporting, or holding foods.
[0035] In at least one example, the material is 100% compostable
according to international composting standards. As used herein,
"degradable" refers to materials that disintegrate over a number of
years, but do not have a defined amount of time or conditions under
which they degrade. As used herein, "biodegradable" refers to
materials that break down through processing by a
naturally-occurring organism, for example, a bacteria, fungi, or
algae. Biodegradable does not require the material to break down in
a certain period of time, nor under the conditions found in the
composting process. Degradable and biodegradable materials do not
meet all composting standards therefore contaminate the composting
stream. Therefore, it is important for food service establishments
and consumers to easily recognize the difference between degradable
and biodegradable materials and compostable materials in order to
avoid introducing contaminants into the compost stream. As used
herein, "compostable" refers to materials that contain no heavy
metal content, disintegrate in less than 84 days and completely
biodegrade in less than 180 days. The European Standardization
Committee's (CEN) EN13432 lays down criteria for what can or cannot
be described as compostable and what can be called biodegradable.
The US Standards ASTM D6400-99 and ASTM D6868-11 sets out similar
standards. European Standard EN13432 is the basis of the
International Standards Organization (ISO) Standard ISO14855. These
standards ensure compostable materials break down in industrial
composting conditions. Materials that meet either the European or
US Standard will break down effectively in virtually every
commercial composting system. The Australian Standard AS4736-2006
is closely based on EN13432, with the exception of a worm
eco-toxicity test not required by the other standards.
International composing standards require compostable materials to
meet the following criteria:
[0036] "Biodegradability"--measured by metabolic conversion of the
material to carbon dioxide to at least 90% in less than six months.
(90% is used to account for sampling error, not to allow for
non-biodegradable material).
[0037] "Disintegrability"--there should be fragmentation below a
certain size with no visible contamination (screened at 2 mm after
180 days with less than 10% original mass)
[0038] Absence of negative effects on the final compost using a
plant grow test and physical/chemical analyses
[0039] Chemical/physical parameters identical to compost without
the test materials after degradation--pH, salinity, volatile
solids, Nitrogen, Phosphorous, Magnesium and Potassium.
[0040] Composite materials of this invention are configured for use
as food packaging and cooking materials in restaurants, homes,
fast-food kitchens, food trucks, event concessions, and other food
services. When used as cooking materials, for example, cookware
liners, the composite material helps FSEs keep FOG discharge within
the EPA reported range of local limits (50 mg/L to 450 mg/L). By
soaking up FOG from foods containing meats, dairy, and other FOG
producing ingredients before, during, and after the cooking
process, the material can be used by FSE to reduce FOG discharge
and eliminate the threat of FOG caused sewer blockages and
overflows. In one example, food packaging made from the composite
material soaks up FOG while the food is in storage. In another
example, baking sheet covers and other cookware liners made from
the material absorb grease as it is secreted during the cooking
process. In another preferred embodiment, the composite material is
applied to cooked food either directly or through integrations with
an existing food packaging assembly such as pizza boxes, chip and
popcorn bags, and sandwich wrappers to absorb grease after cooking.
Using the composite material in all food contact applications, FSEs
preparing greasy take out foods such as pizza, hamburgers, tater
tots and French fries, corn dogs, doughnuts, or biscuits can
eliminate FOG discharge and dispose FOG in a sustainable way.
[0041] The composite material may also be incorporated into
conventional food packaging assembles to reduce FOG contamination
of recycling and composting streams. Once FOG and other liquids are
absorbed in the absorbent layer, the lamination layer and
non-absorbent layers act as liquid barriers to prevent FOG from
seeping through the composite material and into food packaging.
These structures for absorbing and trapping grease allow the
composite material to protect recyclable food packaging materials,
for example, pizza boxes and take out food containers, from excess
FOG in greasy take out foods. Accordingly, communities, food
services, and other organizations seeking to divert waste away from
landfills through recycling can use to composite material to absorb
excess FOG and prevent FOG contamination of recyclable food
packaging materials.
[0042] Similarly, compostable embodiments of the composite material
makes food waste diversion through composting easier by eliminating
the need to disaggregate food packaging from food waste. In at
least one example, the composite material is incorporated into a
compostable food packaging assembly that completely breaks down
under industrial composting conditions. The compostable
characteristics of the composite material have been proven using
laboratory precision and perfected under actual conditions through
test kitchen and actual biodegradation experiments. The composite
material contains no volatile matter or heavy metals and is
fluorine free, non-biotoxic, and safe for food contact
applications. The material also has a flash point greater than
400.degree. F. and is safe for high temperature cooking
applications.
[0043] Embodiments of the composite material described herein, may
have their characteristics and properties certified by at least one
of federal, state, and local governments, environmental
organizations, and other third parties. Environmental claims,
including the composite material's ability to reduce chemical and
FOG discharge and FSE water consumption by alleviating dishwashing
can be certified by the federal or state FDA. This certification
distinguishes products made from the composite material from
conventional products having a bigger FOG footprint in order to
educate the market and encourage firms to competitively develop
sustainable food packaging and cooking technologies. Specifically,
the EPA may certify an embodiment of the composite material removes
a defined amount or range of FOG from the water supply in
accordance with the Clean Water Act, the National Pretreatment
Program (NPP), a Federal Final Rule (FR), or a provision of the
Code of Federal Regulations (CFR).
[0044] Additionally, governments and other third party
organizations may promulgate measures requiring FSEs, food
packaging manufactures, and paper companies to use or provide food
packaging and cooking materials that reduce FOG discharge, for
example, materials for food contact applications made from the
composite material described herein. Such measures would promote
better management of FOG discharge by FSEs that frequently cook
meats, cheeses, baked goods, and other dishes with butter, oil, or
shortening.
[0045] Embodiments of the composite material may also be certified
as a 100% compostable material by a third party organization. Many
organizations can certify the compostable properties of materials
including government organizations, for example, US state and
federal agencies, including the Food and Drug Administration (FDA),
Environmental Protection Agency (EPA), Federal Trade Commission
(FTC), and the Department of Agriculture (USDA). Third party
organizations such as the American Society for Testing and
Materials (ASTM), the U.S. Composting Council (USCC) Certification
Commission, the Biodegradable Products Institute (BPI), DIN CERTO
(a German based company), Vincotte (a Belgium based organization),
and Cedar Grove Composting (a Seattle, Wash. based company).
[0046] To convey the compostable certification to consumers
encountering the composite material in the marketplace, embodiments
of the composite material may be marked with a logo or
certification seal used by certifying third party. The material can
also be advertised and marketed as certified compostable through
product packaging, press releases, and commercials. Additionally,
print and web publications such as Planet Natural and BioCycle
magazine can also publish a list of certified compostable
materials. Enforcement organizations such as the FTC, in the US,
are in place to verify products marked--and marketed as--certified
compostable meet the requirements of the certification. Currently,
under the FTC's current legal framework for combating unfair and
deceptive trade practices, if a product is tested and does not
conform to the certification, the product can be pulled from the
market and the company selling the product can face legal damages
as well as bare the cost of creating and operating court ordered
internal quality control measures. In addition to compostability,
other properties of the composite material described herein may be
certified by a government authority or third party organization.
These properties include the composite material's safety features,
for example, the material's EPS, fluoride, and heavy metal free
composition, the material's ability to reduce recycling stream and
composting stream contamination, the material's ability to reduce
water use by eliminating water needed to clean FOG from baking
sheets, skillets, grills, and other cookware, and the material's
ability to reduce water pollution by eliminating FOG discharge from
kitchen operations through absorbing FOG during the cooking
process.
[0047] Embodiments of the composite material described herein make
take out food healthier by absorbing fat, sodium and cholesterol
from the surface of take out food during preparation,
transportation, and consumption. By soaking up excess nutrients
from foods like meat, chicken, and fried foods, for example, fried
cheese, fried vegetables, French fries, onion rings, and corn dogs,
the material provides a cost-effective and efficient way of
reducing the negative health impacts of convenient take out foods
supplied by fast food restaurants, sit down restaurants, pubs,
cafeterias, food trucks, and other food service operations at
fairs, sporting events and festivals.
[0048] To convey the health effects and nutritional impact of the
composite material, to consumers in the marketplace, the composite
material may be certified by third party organizations including
the federal FDA. In one example, the estimated amount of nutrients
absorbed by the composite material is listed in the food's
nutrition facts and nutritional labeling in compliance with Chapter
7 of the federal FDA's food labeling guide in accordance with the
Food, Drug, and Cosmetic Act. Health claims relating to the
performance of embodiments of the composite material including, for
example, "heart healthy", "lower fat", "lower sodium", "lower
cholesterol", "healthier food", and corresponding logos may also be
certified by a third party organization. In one example, the third
party organization is the federal FDA and the certification is
granted in compliance with Chapter 8 of the federal FDA's food
labeling guide in accordance with the Food, Drug, and Cosmetic Act.
Health claims in this example may comply with the criteria set
forth in a Federal Statute, Final Rule (FR), or provision of the
Code of Federal Regulations (CFR), for example, 21CFR 101.9(k)(l),
101.14(c)-(d), and 21CFR 101.70.
[0049] In one example, the absorbent layer, the non-absorbent
layer, and the one ore more lamination layers are joined to form a
composite having a basis weight between 5 lb and 55 lb.
[0050] In one example, the composite material is dimensioned to
cover all or a substantial portion of a pizza's surface. In this
example, the composite material may be fixed to a pizza box
assembly with the non-absorbent layer is secured to the interior
top or bottom surface of the pizza box. In this embodiment, the oil
and grease-blotting composite is positioned against the bottom
surface of a pizza box to absorb oil and grease from below, leaving
the upper surface of the pizza undisturbed and appetizing. It has
been found that positioning the composite below the pizza in this
position, with the absorbent side up, is highly effective in
extracting oil and grease from the pizza. Furthermore, the
non-absorbent layer at the bottom of the composite substantially
prevents oil and grease from reaching the cardboard of the box,
preserving the ability of the box to be recycled after use.
Alternatively, oil and grease blotting composite layers may be
placed both above and below the pizza to extract oil and grease
from both directions.
[0051] In a further embodiment, the non-absorbent layer may be an
insulating oil and grease resistant paper or metallic foil that
reflects heat back toward the pizza or other food item, thereby
minimizing the dissipation of heat through the box.
[0052] More specifically, in an embodiment, the invention comprises
a disposable food-blotting composite having an absorbent layer
comprising a physiologically safe cellulosic fibrous mat material
with at least one oleophilic surface; a flexible, non-absorbent
layer underlying the absorbent layer, the non-absorbent layer
including a malleable polymeric material having at least one
oleophobic surface; one or more flexible lamination layers or
coatings having at least one oleophobic surface, the flexible
lamination layer for covering at least one surface of the abosrbant
layer, the non-absorbent layer or both; wherein the absorbent
layer, the non-absorbent layer, and one or more lamination layers
are joined to one another to form a composite and wherein the
composite is dimensioned to cover a substantial portion of a
surface of an item of food with the absorbent layer configured to
contact the item of food in use.
[0053] Alternatively, a pizza box assembly according to the
invention may include a pizza box having a top and an inner
receptacle covered by the top; a pizza-blotting composite including
an absorbent layer comprising a physiologically safe material
having at least one oleophilic surface; a flexible, non-absorbent
layer containing a malleable material having at least one
oleophobic surface; and one or more flexible lamination layers or
coatings having at least one oleophobic surface, the flexible
lamination layer for covering at least one surface of the abosrbant
layer, the non-absorbent layer or both; wherein the absorbent
layer, the non-absorbent layer, and the at least one lamination
layer are joined to one another to form a composite and wherein the
composite is dimensioned to cover a substantial portion of a
surface of a pizza with the absorbent layer facing the pizza in
use, and wherein the non-absorbent layer is attached to the bottom
interior surface of the pizza box.
[0054] Alternatively, the composite material may be dimensioned to
fit, converted into, or otherwise incorporated into other food
packaging assemblies, for example, bags, napkins, trays, boxes,
plates, bowls, cups, and other dishes, wrappers, sheets, liners, or
cartoons. In an alternative example, the composite material is used
as an absorbent pad for cleaning up pet extriment, for example,
urine and feces. Absorbent pads comprising the composite material
may also be used for protecting machinery, for example, car and
motorcycle lifts, from oily substances, for example, motor oil,
brake fluid, and engine lubricant. The composite material may also
be used as a cleaning pad for cleaning oily substances from tables,
countertops, workstations, car interiors, and other surfaces.
[0055] Composite materials used in these applications comprise an
absorbent layer that absorbs liquid and non-absorbent layer that
forms a liquid barrier to prevent liquid from seeping through the
material. In these examples, composite materials may further
include one or more lamination layers that form additional liquid
barriers and optionally, pockets of space between the absorbent and
non-absorbent layers. The pockets can be configured to store a
variety of materials including air, absorbed liquid, air freshener,
additional cleaning chemicals, plant nutrients, seeds, fertilizer,
pesticides, and herbicides.
[0056] Alternatively, the composite material may used as a seed
mat. In this example, the seed mat comprises an absorbent layer
that absorbs liquid and a non-absorbent layer that forms a liquid
barrier to control the diffusion of inregation water and/or
fumigation gases. One or more absorbent or non-absorbent layers may
be infused with seeds, fertilizer, plant nutrients, pesticides, and
herbicides, and other substances formulated to promote plant heath
and growth. Optionally, the composite material may further include
one or more lamination layers that form additional liquid barriers
and optionally, pockets of space between the absorbent and
non-absorbent layers. The pockets can be configured to store a
variety of materials including air, absorbed liquid, plant
nutrients, seeds, fertilizer, pesticides, herbicides, and other
substances formulated to promote plant health and growth.
[0057] In this example, the non-absorbent layer may be water
resistant in order to form a water barrier between the planted
seeds and an external surface. This configuration seals water
inside the material so that it can be absorbed by the seeds for
germination and plant growth. In this example, the composite
material is compostable and safe for in-ground planting. Enclosing
seeds in the composite material removes the need for farming
plastic. It also prevents birds from eating the seeds and keeps
plants warm in cold weather.
[0058] A method of the invention for extracting oil and grease from
a food item after cooking includes i) obtaining a composite sheet
having an absorbent layer of a physiologically safe material having
at least one oleophilic surface; a flexible, non-absorbent layer
underlying the absorbent layer, the non-absorbent layer including a
malleable material having at least one oleophobic surface; and one
or more flexible lamination layers or coatings having at least one
oleophobic surface, the flexible lamination layer for covering at
least one surface of the abosrbant layer, the non-absorbent layer
or both; wherein the absorbent layer, the non-absorbent layer, and
the at least one lamination layer are joined to one another to form
a composite and wherein the composite is dimensioned to cover a
substantial portion of a surface of an item of food with the
absorbent layer facing the item of food; ii) placing the composite
sheet above, below, or both above and below the item of food after
it is cooked; and iii) discarding the composite sheet after oil and
grease from the food item have been absorbed by the absorbent
layer.
[0059] An alternative method of using the composite material to
absorb nutrients from a food surface includes: i) obtain a take out
food, ii) within 5 minutes of purchasing the food, insert the
composite material between the food packaging holding the food and
at least one food surface so that the pad is between the food
surface and the food packaging, iii) close the food packaging and
weight 30 minutes, iv) remove the first composite material pad and
apply a second pad to the food surface by pressing down lightly to
assure contact between the food and the composite material, v)
remove both pads after 2 minutes of contact by the second pad, vi)
remove any loose material from the pads, and vii) dispose of the
two pads of composite material.
[0060] The composite material may be configured to absorb grease
from food, cooking oil, hydrocarbons, lubricants, or any other type
of oil substance. The composite paper may also be configured to be
recyclable, compostable, biodegradable, or otherwise configured for
sustainable use. By combining the oil resistance necessary to
prevent oil from spoiling otherwise recyclable food packaging with
the disposal advantages of paper, for example, compostability and
biodegradably, the composite paper described herein offers a
comprehensive and sustainable solution to cardboard spoilage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] A full and complete description of the present storage
system is provided herein with reference to the appended figures,
in which:
[0062] FIG. 1 is a top plan view of one embodiment of a pizza liner
comprising of a composite material.
[0063] FIG. 2 is a cross-sectional view of the pizza liner of FIG.
1, as taken along line II-II of FIG. 1.
[0064] FIG. 3 is a perspective view of a pizza box assembly
containing the pizza liner of FIG. 1.
[0065] FIG. 4 is a perspective view of a sheet of a composite
material. One aspect of the drawing includes a magnified view of
the composite material.
[0066] FIG. 5 is a cross-sectional view of the sheet of composite
material in FIG. 4, as taken along line 47 in FIG. 4.
[0067] FIG. 6 is a perspective view of a second embodiment of a
pizza liner comprising a composite material.
[0068] FIG. 7 is a plan view of the pizza liner of FIG. 6.
[0069] FIG. 8 is a perspective view of a pizza box assembly
containing the pizza liner of FIG. 6.
[0070] FIG. 9 is a perspective view of a third embodiment of a
pizza liner comprising a composite material.
[0071] FIG. 10 is a plan view of the pizza liner of FIG. 9.
[0072] FIG. 11 is a perspective view of a pizza box assembly
containing the pizza liner of FIG. 9.
[0073] FIG. 12 is a perspective view of a food bag assembly
comprising a composite material.
[0074] FIG. 13 is a perspective view of the food bag assembly of
FIG. 12 containing popcorn.
[0075] FIG. 14 is a plan view of the food bag assembly of FIG.
13.
[0076] FIG. 15 is a plan view of a baking sheet comprising a
composite material. One aspect of the drawing includes baking pan
having the baking sheet disposed inside of the pan. Another aspect
of the drawing includes uncooked bacon on top of the baking
sheet.
[0077] FIG. 16 is a plan view of the baking sheet of FIG. 15 after
the bacon has been cooked on the sheet and removed from the baking
pan. One aspect of the drawing includes a perspective view of one
corner of the baking sheet after the corner has been peeled back
away from the baking pan. Another aspect of the drawing includes a
plan view of a baking sheet having a scored edge.
DETAILED DESCRIPTION
[0078] Reference is now made to the drawings for illustration of
various embodiments of the composite material and food packaging
assemblies. It should be understood that the composite material may
be made in any shape, as needs dictate. The composite paper
material may also be integrated into any type of food packaging,
for example, bags, trays, boxes, plates and other dishes, wrappers,
foils, or cartons. Further, it should be understood that the
material described herein is equally well suited for absorbing oil
from any greasy food including, for example, pizza, lasagna, fries,
nachos, burritos, tacos, fried rice, stir fry, macaroni and cheese,
pasta, fried noodles, fried chicken, hot dogs, burgers, bbq, bacon,
sausage, and popcorn.
[0079] FIG. 4 is a sheet of composite material having an absorbent
layer 40 joined to a non-absorbent layer 49. The layers 40, 49 may
be joined by any suitable means, including, but not limited to,
gluing, laminating, seaming, embossing, quilting, and surface
bonding. In laminated embodiments, a degradable laminate may be
applied to at least one surface of the absorbent layer,
non-absorbent layer, or both. The lamination layer may be placed
between the absorbent layer and non-absorbent layer or added to an
exterior surface of the absorbent layer or non-absorbent layer. In
one example, the absorbent layer 40 has a surface texture 48
configured to enhance the layer's ability to absorb liquid. In some
examples the surface texture 48 is optimized to absorb viscous,
oleophilic liquids, for example, fats, oils, and grease. In other
examples, the surface texture 48 is optimized to absorb low
viscosity, oleophobic liquids, for example, water.
[0080] One aspect of FIG. 4 includes a magnified portion 42 of the
composite material sheet. The magnified portion 42 provides a high
resolution view of a portion of the composite material sheet 41 to
display one embodiment of the surface texture 48 in greater detail.
In this example, the surface texture 48 includes a system of ridges
43, 46, shown by dark black lines, and valleys 44, 45, shown by the
white space between the dark black lines. The ridges 43, 46 extend
out from the surface of the composite material to form a network of
narrow line segments elevated from the main body of the absorbent
layer 40.
[0081] When applied to a greasy food surface, the ridges 43, 46
contact the surface before the main body of the absorbent layer. In
this orientation, the ridges 43, 46 adsorb and absorb liquid from
the food surface. Adsorbed liquid is absorbed into the absorbent
layer by flowing from the ridges 43, 46 to the valleys 44, 45 in
the main body. The valleys 44, 45 are wider than the ridges 43, 46
and have a greater capacity for holding liquid. In embodiments with
polar liquids, for example, solutions having strong intermolecular
forces and/or intramolecular forces, such as, hydrogen bonding or
van der Waals interactions, the ridges 43, 46 may provide a
capillary force for absorbing liquid from the food surface. The
rates of adsorption and absorption, the flow rate of liquid from
the ridges to the valleys, and the amount of capillary force
necessary to absorb liquid from a food surface are dependent on the
properties of the liquid, for example, viscosity and surface
tension, and the absorbent layer, for example, porosity, ridge
width, valley width, ridge height, and surface texture pattern.
[0082] In a preferred embodiment, the network of ridges 43, 46 and
valleys 44, 45 is continuous across at least one full surface of
the composite material so that the adsorbent and absorbent
properties provided by material and surface texture of the
absorbent layer pulls liquid across the surface of the composite
material. Absorbent layers having a continuous network of adsorbent
ridges 43, 46 extending out from an absorbent main body wick liquid
away from saturated areas and distribute it to unsaturated
portions. By distributing liquid more evenly throughout the
absorbent layer, the surface texture prevents absorbed liquid from
pooling on the surface of the composite material, thereby
increasing the layer's overall liquid carrying capacity and local
absorbance and absorbance capacity.
[0083] In one example, the ridges 43, 46 are in a loop like
configuration with ridges 43, 46 on the head of the loop being
spaced further apart than ridges 43, 46 on the neck of the loop.
The wide valleys 44, 45 at the head of the loop are optimized for
absorbing and holding liquid and while the high concentration of
ridges 43, 46 at the narrow neck of the loop are optimized for
adsorbing liquid. In other configurations, the surface texture 48
may include a continuous network of ridges 43, 46 laid out in
straight or wavy line patterns and separated by valleys 44, 45
consistently or irregularly spaced between the ridges 43, 46.
Additionally, the ridges 43, 46 may also overlap in a square,
rectangular, curved, or diamond pattern with valleys 44, 45
dispersed between the ridge pattern.
[0084] FIG. 5 is a cross sectional view of the composite material
sheet of FIG. 4, as taken along the dashed line 47. In this
example, the composite material has three layers, a absorbent layer
52, a lamination layer 56, and a non-absorbent layer 57. The
absorbent layer 52 includes a surface texture comprising a network
of ridges and valleys 54. By attaching to ridges on one side of the
absorbent layer 52, the lamination layer 56 seals the gap between
the ridges and valleys on one side of the absorbent layer 52. The
seal created by the lamination layer 56 is shown by a series of
semi-circular bubbles 55 that protrude into the gap between the
valleys 54 and ridges on the top side of the absorbent layer 56.
The seal creates a network of pockets 50 between the top surface of
the surface texture on the absorbent layer 52 and the bottom
surface of the lamination layer 56. When the composite material
contacts liquid, absorbed liquid is stored in the network of
pockets 50 so that it does not drip or seep out of the absorbent
layer 52. By compressing absorbed liquid into the network of
pockets 50, the lamination layer 56 horizontally displaces absorbed
liquid across a wider surface area. The horizontal displacement
created by the network of pockets holds liquids in the composite
material and prevents pooling. Additionally, by compressing
absorbed liquid in the network of pockets 50, the lamination layer
56 creates a wicking effect that draws absorbed liquids across the
surface of the absorbent layer 52 away from saturated areas with
full pockets into unsaturated areas with empty pockets.
[0085] The lamination layer 56 joins the absorbent layer 52 to the
non-absorbent 57 layer. In this example, the lamination layer 56
also provides a liquid barrier between the absorbent layer 52 and
the non-absorbent layer 57. The lamination layer 56 comprises a
non-biotoxic water based polymer emulsion coating with a flash
point greater than 400.degree. F. The lamination layer 56 may be
applied as a surface coating to at least one of the absorbent layer
52 or non-absorbent layer 57. In one example, the lamination layer
56 forms a liquid barrier between the absorbent layer 52 and the
non-absorbent layer 57. This liquid barrier traps liquid in the
absorbent layer 52 and prevents absorbed liquids from seeping
through top layers of the composite material into the non-absorbent
layer 57. The lamination layer 56 allows the composite material to
trap liquid in the absorbent layer 52 better than conventional
materials because it forms a first liquid barrier that is augmented
by a second liquid barrier, the non-absorbent layer 57. The
sequence of liquid barriers prevents absorbed liquid held in the
absorbent layer 52 from penetrating the composite material.
Accordingly, materials in contact with the non-absorbent layer 57
are isolated from absorbed liquids held in the absorbent layer
52.
[0086] In this example, the lamination layer prevents all liquids
from passing through the absorbent layer 52 to the non-absorbent
layer 57. In other embodiments, the lamination layer 56 may be
configured to selectively trap certain types of liquid, for
example, water based or oil based solutions, while allowing liquids
with particular physical or chemical properties to pass through the
absorbent layer.
[0087] Typical oil and grease and aqueous barrier coatings selected
for the lamination layer 56, often comprise a higher polymer binder
level compared to conventional print and binder coatings. Such
coatings contaminate recycling streams by rendering otherwise
recyclable materials not recyclable because complex, sticky polymer
coatings are difficult to breakdown in conventional acidic pulping
processes. When in a strongly acidic environment, for example, in a
solution with a pH lower than 2, the coatings tend to clump and
form "stickies", and other particles that are larger than the
acceptable size for paper making from recycled materials.
[0088] Conventional coatings also often comprise petroleum based
polymers. Such coatings contaminate composting streams because they
do not readily disintegrate in industrial scale composting
processes. The high content specialty polymers, for example, a
petroleum based polymer binder, present in these coatings makes
meeting the >1% non-biodegradable composition requirement for
the ASTM D6868-11 compostability standard extremely
challenging.
[0089] In addition to the environmental concerns associated with
conventional coatings, "blocking" is another common problem
associated with coated paper materials. Blocking occurs when layers
of coated paper material stick together either in the real or after
being rewound into rolls. Blocking in the reel is especially
problematic when residual heat from dryers dissipates slowly due to
the large mass of the reel. Higher temperatures on the reel in turn
can cause conventional coatings to stick or even melt as a result
of thermal instability.
[0090] The lamination layer 56 described herein improves upon
conventional liquid barrier coatings because it is non-blocking,
recyclable, and compostable. In one example, the lamination layer
56 is made out of non-biotoxic materials that are safe for food
contact applications and meet the >99% biodegradable composition
requirement of the ASTM D6868-11 standard. Additionally, when
placed between an absorbent layer 52 and a non-absorbent layer 57,
the lamination layer 56 causes absorbed liquids to wick across the
surface of the absorbent layer 52. This wicking effect is produced
by applying an impermeable, semi-permeable, or oleophilic
lamination layer 56 to an absorbent layer 52 with an uneven surface
texture. In this example, the absorbent layer 52 is a crepe paper
with ridges, valleys, and other small structures extending out
from--and protruding into--the main body of the absorbent
layer.
[0091] The lamination layer 56 may further contain a binding agent
that increases the lamination strength of the lamination layer 56.
Increasing the layer's lamination strength causes the laminated
surface of the non-absorbent layer to better adhere to the
absorbent layer 52. In one example, applying the lamination layer
56 to the absorbent layer 52 and waiting a period of one to five
seconds before joining the non-absorbent layer 57, improves the
thermal degradation properties of the composite material. This
method of combining the layers into a composite gives the
lamination layer 56 time to set-in and partially fill the valleys
on the surface of the absorbent layer 52, thereby creating a
uniform surface to join the non-absorbent layer 57. Pressing the
non-absorbent layer 57 to a smooth surface of lamination layer 56
fortifies the bond between the layers of the composite thereby
increasing the flash point of the composite and minimizing paper
curl. The lamination layer 56 may also be applied as a print
coating or can otherwise serve as a substrate for ink printing.
[0092] To further enhance the composite material's ability to trap
liquid, the non-absorbent layer 57 forms a second liquid barrier.
This additional liquid barrier prevents any liquid passing through
the lamination layer 56 from penetrating the composite material. In
one example, the non-absorbent layer 57 is an oil and grease
resistant paper material that repels fats, oil, and grease. In
other examples, the non-absorbent layer 57 is a water or liquid
resistant paper material that repels at least one of water, water
based solutions, or any type of liquid. Additionally, the
non-absorbent layer 57 may also comprise plastics and other
synthetic materials, for example, petroleum-based polymer materials
including high density polyethylene (HDPE), low density
polyethylene (LDPE), linear low density polyethylene (LLDPE), ultra
low density polyethylene (ULDPE), polyhydroxyalkanoate (PHA),
polyglycolic acid (PGA), polyethylene terephthalate (PET),
polypropylene (PP), polystyrene, and polyvinyl chloride (PVC).
[0093] In the configuration shown in FIG. 5, the exposed surface of
the absorbent layer is applied to a liquid surface. Liquid is
adsorbed by the network ridges extending from the surface of the
absorbent layer 52 and absorbed into the valleys comprising the
main body of the absorbent layer. Absorbed liquid is then stored in
the network of pockets 50 and spread evenly throughout the network
of ridges and valleys 54. The lamination layer 56 seals one side of
the absorbent layer 52 forming a first liquid barrier on the top
side of the absorbent layer 52. The liquid barrier traps liquid in
the absorbent layer and enhances the wicking effect of the
absorbent layer by compressing liquid into the network of pockets
between the absorbent layer and lamination layer. The non-absorbent
layer 57 attaches to the top of the lamination layer 56 and
provides a secondary liquid barrier to prevent any liquid that
passes through the lamination layer 56 from penetrating the
composite material.
[0094] Accordingly, the composite material makes food healthier and
less messy by absorbing high calorie nutrients from the surface of
greasy take out food into the absorbent layer. A sequence of two
liquid barriers, one formed by the lamination layer and one formed
by the non-absorbent layer, further traps liquid in the absorbent
layer to prevent absorbed liquid from penetrating the composite
material. By trapping and holding liquid absorbed from food
surfaces, the composite material can prevent liquid contaminants
from reaching cookware, food packaging assemblies, sewer systems,
and the hands of individuals eating food.
[0095] FIG. 1 is a pizza liner embodiment 10 comprising a composite
material having an absorbent layer 12 joined to a non-absorbent
layer 14. As illustrated, the composite 10 has a perimeter edge 16,
which results from the joining of the absorbent layer 12, and the
non-absorbent layer 14. The composite 10 is dimensioned to cover a
substantial portion of a surface of a pizza or other take out food
and, accordingly, may be provided in a number of different sizes to
accommodate foods of different sizes.
[0096] The absorbent layer 12 may be made of any suitable material
that is capable of absorbing liquid in significant quantities. Such
materials include, but are not limited to, bi-component
micro-fibers, biodegradable fibers, bleached fibers, cellulosic
fibers, sulphite bleached fibers, and kraft bleached fibers. The
material of the absorbent layer 12 may include materials that are
oleophilic, meaning that they have an affinity for oils and grease
but not water. The absorbent layer 12 is FDA approved for food
contact applications including manufacturing, packaging,
processing, preparing, treating, cooking, packing, transporting, or
holding foods. The layer is low-linting, such that absorbent layer
12 does not leave lint on food after contact.
[0097] In one example, the absorbent layer 12 is a grade of crepe
paper having 94% biobased content and containing 5% water and up to
1% synthetic and non-bio based materials. Further, the absorbent
layer 12 is fluorine free, non-biotoxic, and safe for food contact
applications. The surface of the absorbent layer may also be
textured to better absorb and trap liquid. In one example, the
textured surface includes a continuous network of ridges and
valleys covering the entire front and back surface of the absorbent
layer 12. The ridges are narrow elevated segments extending out
from the surface of the absorbent layer 12 that adsorb liquid from
food surfaces. The valleys are wider low lying areas between the
ridges that trap and hold absorbed liquid the main body of the
absorbent layer.
[0098] The paper material comprising the absorbent layer further
meets the 99% biodegradable composition requirement of the ASTM
D6868-11 compostablility standard. The absorbent layer may comprise
one or many sheets of 5 lbs to 70 lbs basis weight paper having a
thickness of 1.0 mil to 7.0 mils and a Sheffield porosity of 150 to
300 units. The absorbent layer further has an autoignition
temperature greater than 400.degree. F. and a moisture percentage
between 5.0% and 7.5%. The low moisture percentage minimizes paper
curl and the autoignition temperature above 400.degree. F. allows
the material to be used in high temperature cooking
applications.
[0099] As shown in FIG. 2 and FIG. 5, the non-absorbent layer 14
may be made of any suitable non-absorbent material that forms a
liquid barrier. In this example, the non-absorbent layer 14
comprises a material that is not permeable by oils or grease. Such
materials include oil and grease resistant papers (OGR), oleophobic
fiber webs, polymeric films, and liquid barrier coatings.
Advantageously, when the non-absorbent layer 14 is made of a
flexible OGR paper, the composite 10 may have a desirable degree of
malleability, such that the composite may be crumpled after use for
convenient disposal without the user having to contact the
oil-soaked absorbent layer 12.
[0100] In one example, the non-absorbent layer is an oil and grease
resistant (OGR) material having a kit level between 3 and 8. The
non-absorbent layer is further fluorine free, non-biotoxic, and
safe for food contact applications. The non-absorbent layer has a
flash point above 400.degree. F. so it can be used in high
temperature cooking applications. The non-absorbent layer 14 may be
laminated to at least one surface of the absorbent layer 12 to form
a liquid barrier between the absorbent layer in contact with a food
surface and the non-absorbent layer in contact with an external
surface, for example, a cooking surface, a customer holding food,
or a recyclable material, such as, corrugated cardboard. The liquid
barrier may repel water, polar liquids, oil, grease, organic,
non-polar liquids, and mixtures thereof. The liquid barrier allows
a first portion of the composite material to absorb and trap liquid
and a second portion to prevent liquid from seeping through the
first portion.
[0101] In a preferred example, the non-absorbent layer 14 is a
compostable OGR paper material having over 90% biobased content.
The non-absorbent layer meets the 99% biodegradable composition
requirement of the ASTM D6868-11 compostability standard and
contains no petroleum based polymers. In another example, the
non-absorbent layer 14 is a liquid barrier coated material that
repels OGR, water, and other liquids. The non-absorbent layer 14
may include petroleum-based polymer materials including, high
density polyethylene (HDPE), low density polyethylene (LDPE),
linear low density polyethylene (LLDPE), ultra low density
polyethylene (ULDPE), polyhydroxyalkanoate (PHA), polyglycolic acid
(PGA), polyethylene terephthalate (PET), polypropylene (PP),
polystyrene, and polyvinyl chloride (PVC).
[0102] In one example, the absorbent layer 12 is a crepe paper
comprising cellulosic fibers and the non-absorbent layer 14 is an
OGR paper. More specifically, the absorbent layer 12 is a crepe
paper made of four to six layers of cellulose wadding having a
basis weight of 5 to 70 pounds. The material may be virgin material
that is biodegradable and recyclable. The sheets of wadding may be
"pinned" together initially in an embossing type process to form a
friction connection that creates a self-supporting sheet of
absorbent material. An example of such absorbent material is the
cellulose sheeting sold by PREGIS CORPORATION under the trademark
CUSHION PACK.
[0103] The absorbent layer 12 is backed by the non-absorbent layer
14 and optionally coated by a lamination layer. The non-absorbent
layer 14 may be an OGR paper or polymeric film, such as
polyethylene, that is glued, attached by a lamination film, or
otherwise affixed to the absorbent layer to form the composite 10.
In one embodiment, the non-absorbent layer is laminated 10 to
provide additional oil and grease resistance.
[0104] The composite material may also disintegrate naturally and
be biodegradable, non-toxic, and compostable under American Society
for Testing and Materials (ASTM) or Biodegradable Products
Institute (BPI) standards, for example, the ASTM D6400 testing
criteria for plastic and the ASTM D6868 testing criteria for coated
paper products.
[0105] For use as an oil and grease absorbing food packaging
material, the composite 10 is placed against a pizza or other food
item from which oil or grease is to be absorbed with the absorbent
layer 12 in contact with the food item. The composite 10 may
contact either an upper or lower surface of the food, as desired,
to extract oil or grease without adversely affecting the food. In
the case of pizza, which is commonly placed in a box for
transportation, this leads to at least the following two potential
positions of the composite 10 relative to the box.
[0106] FIG. 3 illustrates a pizza box assembly 30 that includes a
pizza box 20 and the pizza liner 10 shown in FIGS. 1 and 2. The
pizza box 20 is a standard collapsible box used commonly in the
industry, having an inner cavity or receptacle 22 for holding the
pizza such that the absorbent layer 12 faces the inner receptacle
22. The composite 10 may be attached to the interior top 24 of the
box 20 by any suitable means, including adhesives. In one aspect,
the composite 10 may be removed after use and the pizza box 20 may
be recycled.
[0107] FIG. 6 illustrates an alternative pizza liner embodiment
comprising the composite material of FIG. 4 and FIG. 5. The pizza
liner includes an absorbent layer 60 laminated or otherwise
attached to a non-absorbent layer 62. In this configuration, the
pizza liner has an absorbent layer 60 on top of a non-absorbent
layer 62 so that the absorbent layer 60 contacts the pizza and the
non-absorbent layer 62 contacts the pizza box. In this example, the
pizza liner is rectangularly shaped and dimensioned to fit inside
of a rectangular pizza box.
[0108] The pizza liner includes two side panels 63, 65 configured
to hold the pizza liner in place and prevent the sides of the pizza
from contacting the sides of the pizza box. Further, the pizza
liner includes two rear panels 66, 68. The bottom rear panel 68
prevents the back surface of the pizza from contacting the hinge of
the pizza box and holds the pizza liner in place so it does not
slide backward in the pizza box. Additionally, the bottom rear
panel 68 props up the top rear panel 66 making it more visible when
the pizza box is open. When the pizza box is closed, the top panel
66 prevents the top of the pizza from contacting the top of the
pizza box.
[0109] The top rear panel 66 further includes a printable surface
for placing advertisements, designs, and other printed writing or
symbols. By providing a printable surface inside the pizza box, the
top panel 66 allows advertisements to be seen when the pizza box is
open. Since most consumers of pizza eat pizza from an open box, the
top panel 66 offers an improvement over the current state of the
art for advertising on a pizza box, attaching a paper flyer to the
outer surface of the top of the pizza box. The base of the side
panels 64, bottom rear panel 69, and top rear panel 67 includes a
scored edge allowing the pizza liner to be shipped flat and conform
to the shape shown in FIG. 6 when placed inside a pizza box without
additional folding. The scored edges 64, 67, and 69 allow a pizza
box assembly including a corrugated cardboard pizza box and the
pizza liner of FIG. 6 to be assembled in less than one second.
[0110] FIG. 7 is a plan view of the pizza liner embodiment of FIG.
6. The pizza liner includes an absorbent layer 70 surrounded by two
side panels 72, 74, a top rear panel 76, and a bottom rear panel
78. The plan view illustrates a front edge 71 cut into both front
corners of the pizza liner. The edges 71 are configured to
accommodate rectangular pizza boxes having the front corners folded
in to accommodate a lid with a tapered ends, as shown in FIG. 8.
Scored edges 73, 75, 77, and 79 at the base of each of panel are
also visible in the plan view illustration.
[0111] FIG. 8 illustrates a pizza box assembly including the pizza
liner example of FIG. 6 and FIG. 7. In this example, when the box
is closed, each side panel 83 is configured to come between its
corresponding side wall 80 on the top of the pizza box 88.
Accordingly, the side panels prevent the sides of the bottom and
top of the pizza box from contacting a pizza disposed inside the
box. The pizza liner is removable from the pizza box to allow the
liner and the box to be disposed separately. In use, the pizza
liner absorbs fats, grease, oil and other liquids on the surface of
the pizza and prevents the liquids from contacting the pizza box.
When the pizza is consumed or removed from the box, the liner may
be composed or otherwise disposed of and the pizza box, now without
any absorbed grease or oils because of the protection provided by
the liner, can be recycled or composted. Accordingly, the pizza
liner makes food healthier by absorbing liquefied high calorie
nutrients from a pizza surface while also allowing the pizza box to
be disposed in a more sustainable way by protecting the box from
grease, oil, and other contaminants.
[0112] FIG. 9 and FIG. 10 illustrate a third preferred pizza liner
embodiment. Similar to the pizza liner of FIGS. 6-8, the liner
includes an absorbent layer 90 laminated or otherwise attached on
top of a non-absorbent layer 91, side panels 94, a bottom rear
panel 98, a top rear panel 96, and scored edges at the base of each
panel 97, 99, and 103. This example further includes two front
panels 92 and half circle tabs 95 on the top of the side panels 94.
Similar to the side 94 and rear panels 96, 98, the front panels 92
prevent the front surface of the pizza from contacting the front
portion of the pizza box. The front panels 92 also hold the pizza
liner in place so that it does not move forward when disposed
inside the pizza box. The half circle tabs 95 provide a structure
to manipulate the side panels 94 when the pizza box is closed.
[0113] FIG. 11 illustrates a pizza box assembly including the pizza
liner example of FIG. 9 and FIG. 10. Similar to FIG. 8, the
assembly includes a pizza box having a bottom portion 118 for
disposing a pizza, a top portion 111 having a front portion with
tapered ends 119, and side panels 110 positioned behind the liner's
side panels 114. The assembly further includes a pizza liner having
side panels 114, a bottom rear panel 116, a top rear panel 115 with
a printable surface for placing advertisements, designs, and other
printed writing or symbols, front panels, and scored edges at the
base of the front, side, and rear panels.
[0114] The liner also includes a half circle tab 113 at the top of
each side panel 114. In this example, when the box is closed the
liner's side panels 113 may be re-positioned in front of the side
walls 110 on the top portion of the pizza box by inserting one or
more fingers into a pair of semi-circular holes on the side walls
of the pizza box (not pictured) and moving the half circle tabs 113
on the liner's side panels 114 forward. Displacing the liner's side
panels 114 by inserting one or more fingers to poke the half circle
tabs 113 ensures the liner will not get crushed by the box top when
the pizza box is closed. Accordingly, using the half circle tabs
113 to keep the liner intact and in position, enables the pizza
liner to function as a device for preventing liquid from contacting
the pizza box and for absorbing liquid from the pizza surface.
[0115] The pizza box assemblies of FIG. 3, FIG. 8, and FIG. 11 may
also include an additional liner comprising the composite material
attached to the underside of the top of the pizza box. The liners
may be circular or rectangular shaped and dimensioned to cover the
entire area of the inside of the pizza box or, alternatively,
dimensioned to cover a substantial portion of the pizza. In a
preferred embodiment, a pizza box liner comprising a composite
material is disposed in the inner receptacle of the pizza box at a
location beneath the pizza. When the pizza in the box is cut or
"scored" oil and grease from the pizza is efficiently wicked to the
underside by the absorbent layer without disturbing the upper
surface of the pizza as can occur when a composite material is
applied to the upper surface of the pizza. Therefore, an
arrangement wherein the liner is disposed in the inner receptacle
of the pizza box so that the absorbent layer contacts the bottom
surface of the pizza operates advantageously in a surprisingly
efficient manner to extract undesired oil and grease.
[0116] In use, when a pizza liner comprising the composite material
is positioned beneath the pizza, the pizza may be cut prior to or
after being placed on the composite. Due to the durable nature of
the composite material, it is not normally severed when a rolling
cutter is used on the pizza. Placement of a pizza liner comprising
the composite material beneath the pizza enables excess oil and
grease to pass downwardly to the composite for efficient absorption
by the absorbent layer. Absorbed oil and grease cannot pass beneath
the composite, however, because the non-absorbent layer and
lamination layer act as liquid barriers. The bottom of the pizza
box therefore remains oil and grease-free, enabling it to be
recycled. Similarly, the front, rear, and side panels of the pizza
liner protect the side, front, rear, and top walls of the pizza box
from oil, grease, and other contaminants.
[0117] As illustrated in FIGS. 3, 8, and 11, pizza liners
comprising the composite material may be square or any other
suitable shape to cover the bottom of the pizza box. Particularly
when the composite is placed beneath a pizza or other food item, it
may be desirable to cover the entire bottom of the container in
which the food item is placed. Alternatively, pizza liners
comprising the composite material placed beneath a pizza may be
circular and dimensioned to match the outline of the pizza.
[0118] In other instances, such as when pizza or other food items
are consumed on the premises of a restaurant, the composite can
still be used under the food to absorb oil and grease. In any case,
once the pizza is finished, the composite may be folded inwardly
onto itself without touching the grease-saturated absorbent layer
by grasping the non-absorbent layer.
[0119] As shown in FIG. 2, when food packaging assemblies
comprising the composite material are used to blot a pizza or other
food item from above, the non-absorbent layer 14 may have a
flexible tab, string, or other physical feature 32 enabling the
user to lift the composite material away from the food without
touching the saturated absorbent layer 12. The weight of the
absorbed oil and grease then causes the composite material 10 to
hang downwardly with the grease-impermeable non-absorbent layer 14
on the outside, facilitating disposal of the food packaging
assembly without getting oil or grease on the user's hands.
[0120] When the non-absorbent layer 14 is metallic, a thick paper,
or some combination, the composite 10 also serves an additional
purpose of retaining heat within the pizza by reflection in either
an up or down direction, depending on the position of the
composite.
[0121] In another form, separate liners comprising the composite
material 10 may be provided above and below a pizza with the
absorbent layer 12 facing and in contact with the surfaces of the
pizza to absorb oil and grease from both the top and the bottom of
the pizza. Alternatively, the top and bottom layers of the
composite material 10 may comprise a single sheet of the composite
that extends underneath the pizza and is folded over to also engage
the top of the pizza to absorb oil and grease from the top and
bottom of the pizza simultaneously.
[0122] The foldable nature of the composite enables it to be
packaged in a compact and inexpensive package, which may be in the
form of a sealed plastic, paper, or foil-backed pouch, as
illustrated in FIGS. 12-17. In this form, the composite is suitable
for distribution with a take-out pizza or other food item for
convenient use by the consumer in extracting oil and grease from
the food item. In situations where a food packaging assembly
comprising a composite material is used to distribute pizza,
popcorn, burgers, or other take out foods, a stand alone sheet or
napkin comprising the composite material may also be provided for
manual use by the consumer to further reduce the quantity of oil
and/or grease consumed.
[0123] FIGS. 12-14 illustrate a bag assembly comprising a composite
material. In one example the bag assembly is used to distribute
take out food. FIG. 12 illustrates an empty bag assembly having an
inner surface 121 comprising an absorbent layer. The inner surface
121 is configured to absorb liquid, for example, fats, grease, oil,
water, or some combination from the surface of food disposed in the
bag. The bag assembly further includes an outer surface 120. In one
example, the outer surface 120 comprises an absorbent layer for
absorbing fats, grease, oil, water and other liquids from hands
used to pick up and eat food disposed in the bag assembly. In this
example, the bag assembly includes a liquid barrier 122 positioned
between the inner surface 121 and the outer surface 120. The liquid
barrier 122 traps liquid absorbed from the food surface in the
absorbent layer of the inner surface 121 to prevent liquid absorbed
by the inner surface 121 from reaching the outer surface 120.
Similarly, the liquid barrier 122 traps liquid absorbed from hands
used to pick up and eat the food in the outer surface 120 to
prevent liquid absorbed by the outer surface 120 from reaching the
inner surface 121. In this example, the liquid barrier 122
comprises a lamination layer, a non-absorbent layer, or some
combination.
[0124] The composite material described herein may be converted
into bag assemblies, such as, square bottom bags and pinch bottom
bags, as well as other food packaging assembles, for example, tray
liners, sandwich and burger wrappers, basket liners, French fry and
hash brown pouches, napkins, bowls, plates, trays, and boxes. The
bag assembly of FIG. 12 is a square bottom bag further comprising
scored edges running down the middle of the side portions of the
bag assembly 123 and out from the mid point of the bottom of the
bag toward the outer surfaces 124. The scored edges 123, 124 allow
bag assemblies to be shipped flat and rapidly unfolded for use.
FIG. 13 illustrates the bag assembly with popcorn 130 disposed
inside the inner receptacle of the bag. Popcorn is one of many take
out foods that can be distributed in the bag assembly containing a
composite material. Other take out food suitable for distribution
in this bag assembly include, for example, pizza, hamburgers, tater
tots and French fries, corn dogs, doughnuts, and biscuits.
[0125] FIG. 14 is a top plan view of the bag assembly 140 that
illustrates popcorn 144 and other take out food items disposed in
the bag make direct contact with the absorbent layer 143 in the
inner surface. Additionally, this view displays the separate
components of this example including the inner absorbent layer 143,
the middle liquid barrier 142, and the outer absorbent layer
141.
[0126] FIGS. 15-17 illustrate a baking sheet 150 comprising a
composite material. In use, the baking sheet 150 may be placed in a
baking pan 151 and used to cook food at high temperatures. In this
example of FIG. 15, bacon 152 is placed on a baking sheet 150
disposed in a baking pan 151 and cooked at 450.degree. F. FIG. 16
illustrates the baking sheet after the bacon is cooked and removed
from the baking sheet. Dark colored areas 160, 165 on the top
surface 162 of the baking sheet show fat, oil, grease, water, and
other liquids that are absorbed into the baking sheet during and
after cooking. Absorbed liquids are trapped in the absorbent layer
so that the bottom surface 161 of the baking sheet 150 and the
surfaces of the pan 164 covered by the baking sheet are not
contacted by fats, oils, grease, water, and other liquids absorbed
from the food. The baking sheet 150 is further removable from the
baking pan so that it can be separately disposed. By preventing
liquids excreted by the food during and after cooking from
contaminating the baking pan 151, using the baking sheet comprising
a composite material as a baking pan liner allows the baking pan
151 to be reused without washing. Using the baking sheet to absorb
fats, oils, grease, sodium, and other high calorie nutrients from
the surface of the food further makes food healthier by reducing
consumption of high calorie nutrients contained in take out
foods.
[0127] The baking sheet may be dimensioned to be disposed in a
rectangular, square, or circular baking pan. Alternatively, it may
be distributed on a roll so it can be cut to size. In one example,
the baking sheet 167 has scored edges 168 around the outer surface
166 of the sheet. Scoring allows the outer edge 166 of the sheet
167 to be folded up to cover the side surfaces of the baking pan.
In a preferred example, the outer edge of the sheet 166 has a width
of a quarter inch beyond the scored edge 168. In this example,
grease would have to travel a quarter inch above the bottom surface
of the baking sheet 167 to contact the side surfaces or the rim of
the baking pan 151. In other examples, the outer edge 166 of the
baking sheet 167 is greater than a quarter inch. In these examples,
the outer edge 166 may fold over the entire side surfaces and/or
rim of the baking pan 151. In a preferred example, the outer edge
166 is wide enough to cover all surfaces of the baking pan 151. In
this example, none of the surface area of the baking pan 151 is
uncovered and open for contamination by liquid excreted from food
during cooking.
[0128] In use, a baking sheet 161, 162 comprising the composite
material is disposed in a baking pan 151. The absorbent layer is
positioned facing upward so that it can directly contact the bottom
surface of the food. One or more liquid barriers, for example, a
lamination layer or non-absorbent layer, are attached to the
absorbent layer so that the liquid barriers are positioned between
the absorbent layer and the surface of the baking pan 163, 164.
Food is then cooked on the surface baking sheet so that fats,
grease, oils, water, and other liquids excreted from the food
during cooking are absorbed by the baking sheet. Once absorbed,
liquid is then trapped in the absorbent layer by one or more liquid
barriers. These liquid barriers prevent absorbed liquid from
contaminating the baking pan surfaces 163, 164.
[0129] An example baking sheet comprising the composite material
illustrated in FIG. 5, includes a lamination layer 56 that forms
the first liquid barrier and is coated directly on the back surface
of the absorbent layer 52. A non-absorbent layer 57 forms the
second liquid barrier and is attached to the rear surface of the
lamination layer 56. In one example, the non-absorbent layer 57 is
an OGR paper material. In other examples, the non-absorbent layer
57 comprises a synthetic polymer based liquid barrier material, for
example, high density polyethylene (HDPE), low density polyethylene
(LDPE), linear low density polyethylene (LLDPE), ultra low density
polyethylene (ULDPE), polyhydroxyalkanoate (PHA), polyglycolic acid
(PGA), polyethylene terephthalate (PET), polypropylene (PP),
polystyrene, and polyvinyl chloride
Characterization
[0130] Samples of the embodiments described herein were tested for
compostability and absorbance. The chemical composition of the
sample embodiments was also discerned to evaluate the material's
safety for food contact applications. Compostability tests were
performed according to the American Society for Testing and
Material (ASTM) International test for standard specification for
labeling of end items that incorporate plastics and polymers as
coatings or additives with paper and other substrates designed to
be aerobically composted in municipal or industrial facilities or
the ASTM 6868. Tests were performed under laboratory conditions at
the University of Wisconsin-Stevens Point Institute for Sustainable
Technology in Stevens Point, Wis.
[0131] The ASTM 6868 is a set of testing criteria used by the
Biodegradable Products Institute (BPI) to certify compostable
materials and products such as food packaging. BPI relies on the
ASTM D6400 test for plastic and the ASTM 6868 test for coated paper
products or paper materials polymer binding agents. To pass ASTM
tests and become part of BPI's certified compostable program, a
product must: i) disintegrate quickly leaving no visible residue
that has to be screened out, ii) biodegrade fully or convert
rapidly to carbon dioxide water and biomass, iii) result in compost
that supports plant growth, and iv) not introduce high levels of
regulated materials into the soil.
[0132] The ability of samples to absorb fat, calories, cholesterol,
fatty acids, and sodium from the surface of cooked take-out pizzas
was tested using pizzas obtained from PIZZA HUT, DOMINO's, PAPA
JOHN's, LITTLE CAESARS, and SABARRO. Pizzas contacting samples
included thin crust pizzas, thick crust pizzas, meat lovers pizzas,
and veggie pizzas. Testing was performed under laboratory
conditions by COVANCE LABORATORIES, INC. of Madison, Wis.
Compostability
[0133] Disintegration and biodegradation methodology for this
experiment was based on a modified version of the ASTM method for
compostability tested without humidified aeration and carbon
dioxide capture (ASTM D5338). Industrial composition conditions
were simulated in a laboratory incubator set to 58.degree.
C..+-.2.degree. for 7 weeks in the Wisconsin Institute for
Sustainable Technology Compostability Laboratory at the University
of Wisconsin Stevens Point College of Natural Resources. The
composting vessels were 2-liter KIMAX glass bottles closed at the
top by a rubber stopper fitted with a hole running through the
center. An air-tight rubber sleeve was fitted around the threaded
mouth of the bottles to avoid sticky glass on rubber contacts
between the bottle and stopper. A plastic tube was inserted through
the stopper hole into the glass bottle to limit moisture loss while
providing for controlled gas exchange during composting.
[0134] There were two treatments tested in this example: a paper
composite material and untreated cellulose paper. A negative blank
of mature compost was also tested as a control. The untreated
cellulose paper and paper composite material were added to compost
in a 6:1 or 16% paper to dry compost ratio. Each treatment and the
control were replicated seven times with each vessel comprising a
complete, distinct sampling unit. There were twenty one vessels at
the beginning of the experiment, with three sampling units removed
at the end of weeks 1, 2, 3, 4, 5, 6, and 7. The vessels were
placed in the incubator in a complete randomized design.
[0135] The compost in this experience is municipal, deciduous left
compost (mature 2-4 months) sourced from Hsu's Compost and Soils in
Wausau, Wis. Hsu's leaf compost is certified through the United
States Composting Council (USCC) according to the Seal of Testing
Assurance (STA) program. The compost was composed of tree leaves
from municipal collection in the Wausau and Appleton, Wis. areas.
Each 2-liter vessel required required 615 g of as-received (moist)
compost. The compost was sieved using an 8 mm sieve to remove large
debris, which was then discarded. Mature compost was used based
upon the D5338 method for coated paper disintegration.
[0136] The paper composite material was prepared using an absorbent
crepe paper and a non-perfluorooctanoic acid (PFOA),
non-perfluorooctane sulfuic acid (PFOO), non-perfluorinated
carboxylic acid (PFCA), and non-perchlorate OGR paper from Expera
Specialty Solutions in Moisinee, Wis. The papers laminated together
using a non-hazardous water based polymer emulsion laminate
supplied from- and applied by-Prolamina Flexible Packaging
Solutions, a division of Proampac, in Neenah, Wis. The untreated
cellulose paper was also obtained from Expera Specialty
Solutions.
[0137] The paper treatments were incorporated into the compost by
cutting the paper and paper composite material, by hand, into 2
cm.times.2 cm squares according to the ASTM D5338. The squares were
then weighted in a beaker to discern the number of squares added to
each vessel to achieve the desired 6:1 (615 g: 98.4 g) compost to
paper ratio. Compost (615 g) was weighed into each of the twenty
one vessels and the pre-weighted paper was added. Distilled water
was added to bring the entire compost and paper matrix up to
60%.+-.2% moisture content. Between 101 mL and 110 mL of distilled
water was added to each vessel and moisture content of the initial
compost was determined gravimetrically by weighing samples from
each vessel and drying for 48 hours in a 105.degree. C. oven. The
compost, paper, and water were mixed thoroughly using 2-pronged
forks until a uniform matrix was produced. Each vessel was labeled
with the week of its removal, the treatment, and the paper
addition.
[0138] Each week during the 7 week active composting period, the
compost vessels were removed from the incubator and weighed.
Moisture was maintained between 50% and 60% through the 7 week
trial. Moisture additions were based on individual jar weight loss
and visual observations of compost and paper structure. Moisture
additions were made by adding distilled water to individual vessels
based on weight and additional water was mixed in using a flat soil
knife. Hand mixing was necessary to promote aeration and consistent
moisture distribution through the compost matrix. Mixing occurred
twice a week, once with moisture additions and once without.
[0139] During final sampling of vessels removed at various weeks,
the paper was separated from the compost using a series of 3 brass
sieves (8 mm, 4 mm, and 2 mm) and picked from the compost using
tweezers. Paper too large to pass through the 2 mm sieve was
weighted (including residual compost). Paper was further processed
by washing with de-ionized water over a 2 mm sieve. With much of
the residual compost removed, the paper was dried in an oven at
60.degree. C. for 6 hours. Final paper mass was recorded once dry.
Paper and compost, per vessel, from removed vessels, were stored
separately in quart sized ZIPLOC freezer bags. The remaining
vessels were returned to the incubator in a re-randomized order.
Samples from removed vessels were frozen and stored in a 0.degree.
C. walk-in freezer.
[0140] Results of the compostability testing are shown below in
Table 1.
TABLE-US-00001 TABLE 1 Start Final % Breakdown Material Weight
Weight Theoretical Carbon Composite Material 98.4 g 19.1 g 80.6
Untreated Cellulose Paper 98.4 g 19.9 g 79.8
[0141] After 5 weeks, the composite paper material and the
untreated cellulose paper were both ahead of the 90% breakdown
benchmark (72% breakdown). After 12 weeks, the % breakdown
theoretical carbon of the composite material was over the ASTM
D6868 90% benchmark for biodegradation and more than 90% of the
original material was lost to disintegration.
[0142] FIG. 6 illustrates the % breakdown of the composite material
and the untreated cellulose paper over the first 5 weeks of the
compostability testing. As shown in the figure, after 10 days, the
composite material was in-line with or exceeded the 90% breakdown
benchmark. Furthermore, after 35 days, the composite material out
performed both the 90% benchmark (by 8.6%) and the untreated
cellulose paper (0.8%) in biodegradation and disintegration.
Nutrient Absorbance
[0143] The composite material was evaluated for its ability to
absorb excess nutrients from the surface of greasy takeout foods.
Pads made from the composite material were placed in contact with
pizzas obtained from five popular take out pizza chains-PIZZA HUT,
DOMINO's, PAPA JOHN's, LITTLE CAESARS, and SABARRO in Madison, Wis.
Pads weight ranged from 11.8 g to 7.3 g so that pads of various
sizes could be evaluated for there ability to absorb nutrients from
different types of take out pizza. Thin crust, thick crust, "meat
lovers", and veggie style pizzas were tested. Absorbance
experiments were performed by Covance Laboratories, Inc. of
Madison, Wis. Samples very prepared in the field in a mobile
laboratory and nutrient extraction was performed under laboratory
conditions using the Soxhlet extraction method.
[0144] Samples were prepared by applying pads to the top and bottom
surfaces of the pizzas. Once in contact with the pizza, the
composite material absorbed nutrients from the pizza surface into
the pads. Soaked pads were stored on ice and transported to Covance
Laboratories for nutrient extraction and absorbance analysis.
[0145] Nutrients were absorbed form the pizzas using this method:
i) weigh composite paper material pad before use, ii) obtain a take
out pizza in corrugated cardboard pizza box from a take out
restaurant, iii) within 5 minutes of purchasing the pizza, insert
the pad underneath the bottom surface of the pizza so that the pad
is between the pizza surface and the cardboard box, iv) close the
pizza box and weight 30 minutes, v) apply a second pad to the top
surface of the pizza by pressing down lightly to assure contact
between the pizza and the composite material, vi) remove both pads
after 2 minutes of contact by the second pad, vii) remove any loose
toppings of pizza material from the pads, and viii) weigh each pad
separately immediately after use.
[0146] Nutrients were extracted from prepared samples using the
Soxhlet extraction method. The extraction was conducted under
laboratory conditions using the extraction method described in
Official Methods of Analysis of AOAC INTERNATIONAL, Method 960.39
and 948.22 published by AOAC INTERNATIONAL of Gathersburg, Md.
Excess nutrients were extracted from pads made from paper composite
material by: i) obtain pads applied to take food in the field, ii)
weigh pads into a cellulose thimble containing sea sand and dried
to remove excess moisture, iii) extract nutrients from pads using
penetne as a solvent for 5 hours, iv) evaporate pentene from the
extract, v) dry and weigh the extract for analysis.
[0147] Upon extraction, the composition of extracted nutrients was
determined by Inductively coupled plasma atomic emission
spectroscopy (ICP-AES). This technique produces an inductively
coupled plasma to excite atoms into emitting a electromagnetic
radiation response that is characteristic of a particular element
or combination of elements. Measured sodium and fat content of the
extract absorbed by the composite paper material pads was then used
to calculate the fat and sodium content of the nutrients absorbed
by the pad from the pizzas. The percent of the pizza's total sodium
and fat content absorbed by the composite material was determined
using the nutrient content analysis to provide an estimate for the
paper composite materials ability to remove fat and sodium from
take out foods.
[0148] Results of the fat absorbance analysis including are
displayed below in Table 2.
TABLE-US-00002 TABLE 2 Absorbed Absorbed Absorbed % Fat Sample
Nutrients Fat Calories Reduction Pad 1 11.80 g 10.49 g 94.4 Cal
9.5% Pad 2 9.60 g 9.09 g 81.8 Cal 8.8% Pad 3 9.10 g 8.12 g 73.1 Cal
7.4% Pad 4 10.60 g 7.97 g 71.8 Cal 6.1% Pad 5 11.10 g 9.42 g 84.8
Cal 8.1% Pad 6 8.60 g 6.88 g 61.9 Cal 5.6% Pad 7 8.60 g 6.48 g 58.3
Cal 5.0% Pad 8 9.60 g 8.70 g 78.3 Cal 8.0% Pad 9 7.30 g 6.77 g 60.9
Cal 6.4% Pad 10 8.90 g 8.29 g 74.6 Cal 7.9% Average 9.52 g 8.22 g
69.2 Cal 7.3%
[0149] Fat in this analysis includes saturated fatty acids,
monounsaturated fatty acids, polyunsaturated fatty acids, and trans
fatty acids. The fatty acids measured in this analysis include,
Butyric Acid, Caproic Acid, Caprylic Acid, Capic Acid, Lauric Acid,
Myristic Acid, Myristoleic Acid, Pentadecanoic Acid, Pentadecenoic
Acid, Palmitic Acid, Heptadecanoic Acid, Heptadecenoic Acid,
Stearic Acid, Oleic Acid, Linoleic Acid, Arachidic Acid, Gamma
Linolenic Acid, Elcosadienoic Acid, Behenic Acid, Erucic Acid,
Elcosatrienoic Acid, Arachidonic Acid, Arachidonic Acid, and
Lignoceric Acid. On average, 86.5% of all Absorbed Nutrients were
Fat leaving only 13.5% for sodium, cholesterol, an other nutrients.
% Total Fat was calculated assuming a pizza with 98 g fat per
serving.
[0150] Results of the sodium absorbance analysis are shown below in
Table 3.
TABLE-US-00003 TABLE 3 Absorbed Absorbed % Sodium % Daily Sample
Nutrients % Sodium Sodium Reduction Value Pad 11 10.2 g 0.56% 57.6
mg 1.0% 1.6% Pad 12 15.6 g 0.10% 15.3 mg 0.27% 0.64% Pad 13 34.6 g
0.07% 25.5 mg 0.45% 1.06% Average 21.0 g 0.24% 32.8 mg 0.57%
1.1%
[0151] Sodium measured in this analysis includes chloride and
sodium chloride salt. % Sodium Reduction was based on a total
sodium value of 5,610 mg per serving and % Daily Value was
calculated using a 3,400 mg sodium daily value.
Thermal Insulation
[0152] The composite material was evaluated for its ability to
thermally insulate food. Specifically, the material's tendency to
reduce heat loss from cooked food while inside conventional food
packaging was evaluated relative to a control sample. Temperature
data was gathered on large pizzas obtained from five popular take
out pizza chains-PIZZA HUT, DOMINO's, PAPA JOHN'S, LITTLE CAESARS,
and SABARRO in Madison, Wis. In order to isolate the thermal
insulation character of the composite material, pizzas were kept in
corrugated cardboard boxes throughout the experiment for both the
control samples and the samples containing the composite material.
Thermal insulation experiments were performed by COVANCE
LABORATORIES, INC. of Madison, Wis. Samples were prepared and
temperature data was collected in the field in a mobile laboratory
using an infrared thermometer.
[0153] Samples containing the composite material were prepared by
placing a first pad composed of the composite paper material under
the pizza and a second pad over the top surface of the pizza 10
minutes after obtaining the pizza. Temperature measurements were
made for the control samples 5 minutes after receiving the pizza
and 30 minutes after receiving the pizza. The total time for the
control experiment was 25 minutes. For the composite material
samples, temperature measurements were made 5 minutes after
obtaining the pizza (5 minutes before placing the sheet) and 30
minutes after applying the pads to the pizza. The total time for
the composite material experiment was 35 minutes. To obtain the
thermal insulation property, the initial temperature of the pizza
was subtracted from the final temperature of the pizza. Each
experiment was repeated seven times to collect data across multiple
trials.
[0154] Results of the thermal insulation experiments for the
control samples are displayed below in Table 4.
TABLE-US-00004 TABLE 4 Sample Initial Temperature Final Temperature
Temp. Difference Control 1 58.9.degree. C. 47.9.degree. C.
11.0.degree. C. Control 2 69.0.degree. C. 58.8.degree. C.
10.2.degree. C. Control 3 69.9.degree. C. 61.7.degree. C.
8.2.degree. C. Control 4 75.6.degree. C. 63.2.degree. C.
12.4.degree. C. Control 5 69.3.degree. C. 59.2.degree. C.
10.1.degree. C. Control 6 70.4.degree. C. 54.2.degree. C.
16.2.degree. C. Control 7 69.5.degree. C. 46.2.degree. C.
23.3.degree. C. Average 68.9.degree. C. 55.9.degree. C.
13.1.degree. C.
[0155] Results of the thermal insulation experiment for the
composite material samples are displayed below in Table 5
TABLE-US-00005 TABLE 5 Sample Initial Temperature Final Temperature
Temp. Difference Pad 1 61.6.degree. C. 54.4.degree. C. 7.2.degree.
C. Pad 2 59.0.degree. C. 54.4.degree. C. 4.6.degree. C. Pad 3
66.1.degree. C. 59.5.degree. C. 6.6.degree. C. Pad 4 64.4.degree.
C. 53.1.degree. C. 11.3.degree. C. Pad 5 67.2.degree. C.
53.8.degree. C. 13.4.degree. C. Pad 6 66.1.degree. C. 54.4.degree.
C. 11.7.degree. C. Pad 7 66.4.degree. C. 47.3.degree. C.
19.1.degree. C. Average 64.4.degree. C. 53.8.degree. C.
10.6.degree. C.
[0156] The preceding discussion merely illustrates the principles
of the present pizza-blotting composites and pizza box assemblies
containing such pizza-blotting composites. It will thus be
appreciated that those skilled in the art may be able to devise
various arrangements, which, although not explicitly described or
shown herein, embody the principles of the inventions and are
included within their spirit and scope. Furthermore, all examples
and conditional language recited herein are principally and
expressly intended to be for educational purposes and to aid the
reader in understanding the principles of the invention and the
concepts contributed by the inventor to furthering the art and are
to be construed as being without limitation to such specifically
recited examples and conditions.
[0157] Moreover, all statements herein reciting principles,
aspects, and embodiments of the invention, as well as specific
examples thereof, are intended to encompass both structural and
functional equivalents thereof. Additionally, it is intended that
such equivalents include both currently known equivalents and
equivalents developed in the future, i.e., any elements developed
that perform the same function, regardless of structure. Terms such
as "upper", "top", and "lower" are intended only to aid in the
reader's understanding of the drawings and are not to be construed
as limiting the invention being described to any particular
orientation or configuration.
[0158] This description of the exemplary embodiments is intended to
be read in connection with the figures of the accompanying
drawings, which are to be considered part of the entire description
of the invention. The foregoing description provides a teaching of
the subject matter of the appended claims, including the best mode
known at the time of filing, but is in no way intended to preclude
foreseeable variations contemplated by those of skill in the
art.
* * * * *