Note: Descriptions are shown in the official language in which they were submitted.
1~)940Z7
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BACKGROUND`OF THE INVENTION
United States Patent 3,100,712 discloses a specially designed
fiberboard shipping and storage container for cheese and a method and
apparatus for filling the container, removing the whey and excess moisture
and sealing the container for shipping and storage. A double wall container
is used lined with a water proof, air-impervious bag, the whey and moisture
are removed by applying pressure to the curd after it has been poured into
the container and by tipping the container over while applying pressure to
allow the excess whey and moisture to drain out, the bag is tied at the top
to seal the curd therein and a closure cap is applied to the top and strapped
thereto.
The objects of this invention are to provide for packaging curd
in a container which is less expensive to manufacture than that disclosed
in the aforesaid patent without sacrificing the advantages thereof and to
provide for better molding and more uniform removal of whey and excessive
moisture from the packaged curd.
SUMMARY OF THE INVENTION
The invention provides a method of processing cheese in a shipping
container for bulk shipment and storage purposes comprising molding a volume
of cheese curd in excess of the volume of the shipping container in which
it is to be packaged in a shipping container having a smooth interior surface
lined with a lining in the form of a water proof bag by successively, in the
order named, inserting a filling sleeve into the open end of the container
to increase the effective volume of the container sufficiently to accept an
excess volume of curd, inserting vacuum probes into the curd to draw off the
major portion of the whey and to reduce and compact the curd, removing the
vacuum probes, placing a smooth plate containing notched openings at its
peripheral edge against the end of the cheese curd, and applying pressure to
the plate by means of a hydraulic cylinder to further reduce and compact
the curd to the dimensions of the interior of the shipping container and,
while applying the pressure to the plate, rotating the container to a drain-
age position so that the residual whey expressed from the curd by the
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application of pressure can gravitate from the container through the notched
openings.
The invention also provides apparatus for use in carrying out the
above method comprising a multiple probe of five elongate probe elements, a
frame to which the probes are secured with one at the center and the remain-
ing probes arranged around the axis of the one at equal radial and circum-
ferential distances, said probes containing longitudinally distributed
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openings, conductors connecting the probes to a common vacuum by means of
which a lower than atmospheric pressure can be established at the openings,
and means for raising and lowering the frame relative to the container to
force the probes into the curd in the container and to remove the probes
therefrom.
As herein illustrated, the method comprises, with the aid of a
filling sleeve, extending the effective volume of a single wall container
reinforced peripherally at axially spaced intervals and lined with a water-
proof and air-impervious bag, filling the container extended by the filling
sleeve with a volume of curd greater than the volume of the container, mold-
ing and reducing the volume of the curd to the dimension of the container
by extracting the whey and excess moisture therefrom, removing the filling
sleeve, sealing the molded, compacted curd within the bag and applying a
closure to the open end of the container over the sealed end of the bag.
The container is a fiberboard structure of polygonal section and the rein-
forcement comprises strapping which encircles the container so as to prevent
lateral displacement of the side wall. Closures of corresponding polygonal
section are applied to the ends of the container and secured thereto by
strapping of the kind applied to the side walls. The whey and moisture are
removed with the aid of vacuum and pressure. Molding pressure is applied
by pressing a rigid peripherally notched plate against the exposed end of
the curd and tipping the container over so that the residual whey and
moisture drains gravitationally therefrom. Following vacuuming and pressing,
the container is righted, the top of the bag tied or heat sealed and the
closure at the tGp applied and strapped. After applying the top closure,
the container may optionally be inverted so that the tied or sealed end is
at the bottom to effect flattening at that end.
10940Z7
The invention will now be described in greater detail
with reference to the accompanying drawings, wherein:
~iGS, /~4 to /~
A FIG. 1 diagrammatically illustrate~ the steps followed
in filling the shipping and storage containers, processing the
curd therein and sealing the filled containers for shipment:
FIG. 2 is a perspective view of an empty container
open at both ends and provided at its ends with closure locking
tabs;
I FIG. 3 is an end view of the container blank before
¦being opened up in the form it would be supplied to a cheese
manufacturer;
FIG. 4 is a right cross section of the container
shown in FIG. 2;
¦ FIG. 5 is a plan view of an end closure blank with
closure locking tabs;
FIG. 6 is a perspective view of an end closure after
folding ready for application to the end of the container;
FIG, 7 is an elevation of an end closure of FIG. 6
with a pull sheet applied to its end surface;
ll FIG. 8 is a plan view of an end closure with pull
¦Itabs cut out of the structure of the side wall;
FIG. 9 is a perspective view of the end closure of
FIG. 8 after folding showing the pull tabs extending from
the side wall;
1 FIG. 10 diagram~atically illustrates the angular
¦~position of the pull tabs at the bottom end of the container
relative to the supporting surface on which the container
rests;
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i
I
FIG. 11 is a perspective view of a container of
alternative configuration, specifically of rectangular con-
figuration;
FIG. 12 is a perspective view of a filling sleeve;
FIG. 13 iS a perspective view of the lined container,
within the open end of which the filling tube is inserted,
resting on a cart with its open end under a filling spout;
FIG. 14 is a perspective view of a probe assembly;
FIG. 15 is an elevation partly in section of a single
probe;
FIG. 16 is a perspective view of a container with
¦ the probe assembly lowered into it with portions broken away;
FIG. 17 is an elevation of apparatus for applying
Il pressure to the curd to effect compaction and extrusion of
1¦ the whey and moisture;
¦ FIG. 18 is a view from the right side of FIG. 17
¦ showing the structure of FIG. 17 tipped over to a position in
. I which the open ends of the containers are below the closed
I ends for drainage;
I FIG. 19 is a perspective view of the pressure-
applying plate;
¦ FIG. 20 is a fragmentary section showing the inter-
engagem~nt of the locking tabs at the ends of the container
with the locking tabs on the closures;
j FIG. 21 is a perspective view of a rocker by means
I of which the filled and sealed container may be turned over
il end-for-end;
¦, FIG. 22 shows the way in which the rocker is used; and ¦
` FIG. 23 is a perspective view of a lift truck and
¦ of a container provided with the special pull tabs which enable
~ it to be handled without the use of grapples.
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FiGs 1~ Tc I G
A 11 Referring to the drawings, rIG. 1 shows in procession
the steps followed to fill a shipping and storage container
with curd cheese for shipping and storage. As therein shown
diagrammatically, the shipping container 10 comprises an open
end tubular structure 12 of fiberboard, corrugated board or
the like closed at its lower end by a lid 14 and open at its
¦ upper end. A bag 16 of moistureproof, air-impervious plastic
material, for example, a polyvinyl, is placed within the con-
I tainer with its upper open end 18 folded over the edge of the
I open upper end of the container and a rigid filling sleeve 20
¦ corres~onding substantially in diameter to the inside diameter
of the container is supported at the open upper end of the
¦l container within the open end of the bag for the purpose of
¦ extending the effective volume of the container by an amount
i such that a quantity of curd can be loaded into the container
and the extension e~ceeding the volume of the container so
that when the whey and moisture are removed therefrom, and
the curd compacted and molded by applying pressure, the volume
I can be reduced until it does not exceed the volume of the con- ¦
I tainer, but will just fill it.
¦¦ The first step performed at station lA is to fill
the container 10 and sleeve 20 up to substantially the level
of the upper end of the sleeve with curd. After loading,
I the container and sleeve are moved to station lB where
the whey and moisture are removed by an assembly of vacuum
¦~ probes by applying a vacuum thereto to thus compact, mold
¦l and reduce the volume of the curd to the diameter of the con-
tainer. Following evacuation, the container with the
sleeve still supported therein and with the reduced volume of
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curd is now moved to station lC where molding pressure is
applied by means of a plate 26 and ram 28 to the exposed
upper end of the curd in a direction axially downward
toward the bottom of the container to further mold the curd
¦ and to express any residual whey or moisture and to further
reduce the volume to that of the container and, while the
pressure is being applied, the container is tilted over as
shown at station lDto a position in which its upper end is
below the lower end where it is heId for a sufficient length
la of time to allow complete drainage of any residual whey and
moisture into a receptacle 29. Following such drainage, the
container is restored to its upright position at station lE,
the filling sleeve 20 removed, the pressure-applying plate 26
I raised and the open top of the bag 16 gathered over the upper
~1 end of the curd in such a fashion as to exclude air and tied
¦ as indicated at 30. Alternati-~ely, a vacuum may be applied
¦ to the open top of the bag as it is gathered and the open end
¦ sealed by a heat sealing process. Following tying or sealing
~ of the bag, a closure 14 is applied to the open upper end of
I the container and secured by strapping 34. As a final step,
the container with the lid strapped thereto is turned upside
down as shown at station lG, the purpose being to cause the
cheese to become f3at at the top.
By following the foregoing steps, a compact, well-
1¦ molded block of cheese may be formed,free of external surface
¦ irregularities and internal whey which, if present, contributes
to excessive mold.
¦ The shipping container 10 as shown in FIG. 2 is a
1 tubular structure of octagonal cross section open at its upper
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1.
¦ and lower ends. At the upper and lower ends of the structure,
there are extensions 36 which comprise end closure flaps hinged
at 38 so as to be foldable outwardly and downwardly for inter- ¦
engagement with similar closure flaps on the closure 14. The
¦ structure may be comprised of fiberboard, paperboard or rein-
forced corrugated board wherein the flutes run axially of
the structure and is desirably reinforced intermediate the
ends by axially spaced, peripherally disposed bands 40 of
metal or fabric strapping.
¦ The shipping containers are manufactured and supplied
to the cheese manufacturers as flat blanks 42, FIG. 3, and they
prepare the containers for filling with curd by opening the
~I blanks and applying a correspondingly shaped octagonal lid 14,
¦I FIGS. 5 and 6, to the lower end and securing it with a strap
1 40. The lid 14 as shown in FIGS. 5 and 6 has a flat end face
¦ 44 of octagonal configuration and extensions 46 hinged thereto
at 47. The extensions are divided to form side wall parts 48
and locking tabs 49. The closure is strapped to the lower end
~l of the structuxe by means of aband40 as disclosed, for example,
20 1l in the aforementioned patents. The container closed at one end
and open at the other is now placed closed end down upon a
wheeled dolly, the bag 16 inserted and its upper end folded
outwardly over the open end of the container and the filling
Il sleeve 20 inserted into the open end. The container is now
25 1I ready for filling. After filling the container as described
above, a lid 14 is applied to the upper end of the same
~¦ construction as that applied to the lower end and strapped.
Optionally, as shown in FIG. 11, the container may
i be of a rectangular cross-sectional configuration and, when
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Il
~¦ so constructed, it is desired to provide the four corners
with reinforcing strips 50 adhesively secured to the structure
I at the corners or stapled thereto.
¦ The containers employed for packaging the curd cheese
I for shipping and storage are of a ~olume to hold approximately
500 pounds of cheese. Consequently, movement of the filled
j containers after filling and for processing whereby the curd
I is molded and compacted and the whey and moisture removed
¦ and thereafter loading for transportation and unloading for
1I storage is a problem; first because the bulk mass of the curd
cheese is not solid andr hence, the containers cannot be
¦ picked up with grapples without deformation and second because
¦ the weight and bulk makes manhandling extremely difficult and
I can be injurious to those involved in the processing, loading
j and unloading operations. To avoid these problems, the container
¦ is provided with handling means at the ends which may be
grasped to slide the container along on the end on which it
rests. In one form, FIG. 7, the handling means are flat pieces
I 56 of reinforced fiberboard or cardboard or the like, preferably ¦
l moistureproof, which are of larger overall area than the end
face 44 of the lid 14 adhesively secured to the end face 44
so that portions 58 corresponding in number to the side of
the closure project from the side wall portion 48 all the way
¦l around. The handling means may be applied to both of the
¦ closures and should project no more than approximately one
Il inch from the peripheral wall of the lid. The piece 56 option-
¦¦ ally may be made of moistureproof sheet plastic. Alternatively,
i' as shown in FIGS. 8 and 9, the handling means may comprise tabs
46 cut from the side wall portion 48 of the closure at the
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several faces which project radially outward from the side
wall. In both instances, the peripheral portions 58 and the
peripheral tabs 46 lie substantially in the plane of the end
I face 44 of the closure. Because of the hinged connection of
¦ the tabs 46 to the end face of the closure, the latter have an
advanta~e in that they slope upwardly from the floor or other
supporting surface on which the container stands and thus
provide for éase of grasping, FIG. 10.
The loading plate and pull tabs at the ends of the
container are employed to pull the container onto a lift
truck such as shown in FIG. 23. The lift truck 64 shown is
of standard construction and is provided with a vertical grid
plate 66 which can be moved forwardly or backwardly relative
to the lift plate 65. At the bottom of the grid plate 66,
there are gripper jaws 68 which can be opened automatically
as they are moved forward to receive one of the portions 58
of the loading piece 56 or one of the tabs 46 and close upon
it, whereupon the grid plate is pulled back and the truck
I¦ simultaneously driven forward to draw the container onto the
¦ lift plate 65 for transportation in the conventional manner
¦ by the lift truck. The container is unloaded from the lift
Il plate 65 by forward movement of the grid plate with the jaws
¦l open and simultaneous backward movement of the truck.
}! The lift truck is generally employed after the curd
1, has been completely packaged and is ready for transportation
and is to be loaded onto trucks or has reached its des~ination
¦ and it is to be removed for stGrage. Prior to such time, a
hand-motivated cart 70 as shown in FIG. 13 is employed com-
Il prising a flat pallet 72 provided with wheels 74-74, a
caster 86 and a handle 78.
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ll
Referring now more in detail to the loading of the
curd into a container such as is described abo~e and to the
apparatus by means of which the vacuuming and compactin~
operations are performed, FIG. 13 shows a container 10 to the
lower end of which a closure lid 14 is strapped resting on the
cart 70 with its upper end below a spout 78 through which
curd 80 is delivered into the open upper end of the container.
As previously described, the upper end 18 of a moisture and
airproof bag is disposed in the container with its upper open
end folded outwardly over the upper open end of the container
I and the loading sleeve 20 is supported in the open upper end
¦I by means of pins 80 which rest on the upper edge of the con-
!1 tainer. Diametrically arranged handles 86-86 provide for
lowering the sleeve into place preparatory to the filling
operation and removing it after the filling operation has been
completed. At this particular point in the operation, the
sides of the container are laterally supported by the rein-
forcing strapping bands 40 so that the gravitation of depositing
l the curd in the container will not cause bulging. When the
container extended by the filling sleeve has been substantially
¦ completely filled as shown in FIG. 16 with the curd, it is
¦ trundled to the vacuum station lB for removal of the whey and
moisture.
,I The vacuum assembly as shown in FIGS. 14 and 15
l~ comprises a frame structure 81 of generally rectangular con-
figuration at the center of which there is fixed a centrally
located probe 83 and around which are fixed satellite probes
85, four in number, at substantially equal radial distances 1,
Il from the axis of the center probe 83 and equal peripheral
distances from each other about the center~ Preferably, the
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1l 1
¦ radial distance of the satellite probes from the center probe
¦ is approximately two-thirds of the length of the radius of
the container.
~ Each probe 83,85, FIG. ~, comprises a sleeve 86
¦ within which there is fixed an outer perforate tube 88 and an
¦ inner imperforate tube 90 with an annular space 92 therebetween.
The outer perforate tube 88 contains lengthwise thereo~ openings
94 and the inner imperforate tube contains at its lower end an
opening 96 which is in communication with the annular space
j 92. The lower end of each probe has a conical tip 98 and the
Il upper end is connected to a rod 100 which, in turn, is con- ¦
¦ nected to a piston located within an air cylinder 102, FIG. 16,
¦I mounted on a horizontal support 104 so as to enable raising
Ij and lowering the vacuum assembly vertically. Conductors
¦ 106-106 provide for supplying pressure to the opposite ends
of the cylinder to effect raising and lowering of the assembly.
The vacuum assembly is supported at an elevation sufficiently
high to permit the containers to be trundled by means of the
~ cart beneath it whereupon air is supplied to the cylinder to
¦ move the vacuum assembly downwardly and to cause the probes~
¦l to be forced downwardly into the curd within the containers.
The upper end of each probe is provided with a conductor 108
and these conductors are connected to a common source of
Ii vacuum such as a vacuum pump P by means of which a lower-than-
atmospheric pressure may be maintained at the openings 94
in the outer sleeves of the probes. A vacuum pressure of
approximate~y four pounds is maintained for a period of six
hours after the probes have been inserted into the curd so
as to remove the whey and moisture from the curd sufficiently
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1094027
to reduce the volume of the curd to substantially a level o~
the upper end of the container,thus to compact the curd and
mold it to the dimensions of the inside of the container.
A removal of approximately 90 percent of the whey can be
achieved in this manner with the advantage that the evacuation
of the whey and moisture is substantially uniform throughout
the cross-sectional area of the block and throughout its
length from top to bottom. Having removed the whey and fluid
by means of the probe assembly, the latter is elevated to
withdraw the probe from the curd, whereupon the container
with the curd compacted therein is moved by means of the
cart to station lC for application of pressure to the curd
Il exposed at the open end. The application of pressure at
¦I the end completes compaction, molding and expressing of the
1¦ residual moisture and whey, reducing the volume to no more
than that of the container.
The apparatus for applying conforming pressure and
extrusion of residual whey and moisture as shown in FIGS. 17
and 18 is adapted to receive one or more containers, three
20 A being shown. The compactor has a base plate 110, FIG. ~,
to which there are fixed at the opposite ends vertically
disposed posts 112-112. Along the rear edge of the plate 110,
. there is a horizontal rail 114 supported by vertical posts
1~ 116-116. A rectangular frame 118, FIG. 17, comprising spaced
1~ parallel side parts 120-120 and top part 122 is pivotally
l! mounted between the posts 112-112 on trunnions 126-126 bolted
to the upper ends of the posts 112-112 so that it can be tilted
about a horizontal axis in a position in which it is perpen-
dicularly upright as shown in FIG. 17 to a position in which
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it is inclined with its upper end lower than its lower end.
The frame is divided into three stalls by spaced parallel
parts 121-121 parallel to the side parts 120-120 and each
¦ stall has at its lower end a pallet 124 of sufficient trans-
~ verse width and depth from back to front to allow the cart
70 on which the containers rest to be rolled onto them between
the side parts 120-121-121-120. At the back side of the frame
118 there are semicylindrical cradle plates 128, one in each
¦ stall supported by vertically spaced bands 130-130 on the
¦ frame so as to be substantially concentric with the vertical
¦ axis of the container when moved onto the pallet for engage-
ment with the rear side of the container. The front side of
the container is supported by a harness assembly 132 comprising
l parts 134-134 hinged to the parts 120-121 for closing about
¦ the forward side of the container after it has been moved onto
I the pallet 124 into engagement with the cradle 128 to secure
- !I the container firmly in place. A pneumatic motor 136 is
¦I secured to the upper part 122 above each of the pallets 124
Il so as to be at the geometric center of the container resting
1l on the pallet~ Each motor 136 is provided with a ram 28
whi~h may be moved downwardly toward the top of the container.
In accordance with the method described heretofore, a pressure-
applying plate 26, FIG. 19, is placed against the exposed end
Ij of the curd within the container whereupon the ram 28 is lowered I
I to apply pressure to the end plate to thus compact the curd
¦¦ within the container and further conform it to the interior
configuration of the container. Such compaction effects an
extrusion of residual whey and moisture and to drain this
residual whey and moisture off, the frame and, hence, the
1: ,
1~)9402~7
~ container, ale tilted to the position shown in FIG. 18 80 that
¦ it discharges gravitationally into the receptacle 28 mounted
.f ~ on the base below. To allow for free drainage, the peripheral
edge of the pressure-applying plate 26 is provided with
notches 142, FIG. 19. To facilitate placing the pressure
plate in position and removing it, diametrically disposed
handles 86-86 are provided. The extruding pressure is applied
for a sufficient length of time to reduce the whey and moisture
content to not more than approximately 4 percent. The frame
¦ 118 is tilted by a piston and cylinder assembly 118a, FIG. 18.
~ Following application of pressure, the frame 118 is
¦ tilted back to its vertical position and the container trundled
i off the frame by means of the cart, whereupon the filling sleeve
1 20 is removed and the upper overlapping portion 18 of the bag
is drawn over the exposed end of the cheese as closely as
possible and knotted as shown at 30 at FIG. lE or, as also
suggested, may be heat-sealed while applying a vacuum. After
typing or sealing the bag, the lid 14 is applied to the upper
open end and strapped, whereupon the completely sealed container
is inverted, FIG. lG, to achieve a smooth flat surface of the
cheese at the sealed end.
¦ Inversion is accomplished by the use of a turning
¦ device 146, FIGS. 21,22, which comprises an elongate frame 148
I adapted, when standing upright, to encircle one side of the
¦ container as shown in FIG. 22. One end of the device is provided
¦ with a lifting lip 150 which can be inserted beneath the lower
¦ end of the container. The other end is provided with a retain-
ing member 152 so as to confine the container to the frame when
it is roc~ed on the arcuate runners 154-154 to its inverted
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I1 10940Z7
position. After sufficient time in the inverted position, the
turning device is restored to its original position to place
the container in an upright position and from this position it
may be transported by means of the lift truck referred to
¦ earlier for loading onto a truck for transportation and storage.
¦ From the foregoing, it can be appreciated that fresh
cheese curd may be formed into a smooth surface mold with the
moisture removed by first applying vacuum and then applying an
l axial force with the container in a drainage orientation. In
¦ the event that it is deemed necessary, further air and moisture
~ can be extracted by placing the container in a standard vacuum
¦¦ chamber. As thus treated, development of surface mold on the
cheese will be avoided by substantially complete removal of
~I moi~ture and the avoidance of surface crevices. Molding of the
I cheese within the sealed plastic liner within a cardboard-type
container constructed to provide the requisite strength and
moisture proofing which is of light weight and easily foldable
provides for optimum handling during processing.
I It should be understood that the present disclosure
¦! is for the purpose of illustration only and includes all modi-
¦ fications or improvements which fall within the scope of the
appended c1~ims.
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