PRODUCTS, METHODS AND APPARATUS FOR FRESH MEAT PROCESSING AND PACKAGING

PRODUITS, PROCEDES ET APPAREIL PERMETTANT DE TRAITER ET D'EMBALLER DE LA VIANDE FRAICHE

English Abstract

Published without an Abstract

French Abstract

Publié sans précis

Claims

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The embodiments of the invention in which an exclusive property or privilege
is claimed are defined as follows:
1. A method of packaging goods, characterized in that the goods are
packaged in a selected gas.
2. The method of Claim 1, comprising providing a base, placing goods
over said base, applying a web of oxygen permeable material over said goods,
and
locating said packaging in a master container by stacking directly one above
another
without any other packaging materials therebetween with a desired gas between
packaging which will enhance the keeping properties of said goods by
contacting the
surface of said goods and sealing said lid to said master container with said
gas
therebetween, said web of oxygen permeable material then holding said goods
relative to said packaging and being of a size permitting viewing of a major
portion
of an upper surface of said goods and allowing said gas to contact said goods
by
permeating said web.
3. The method as claimed in Claim 2, wherein said web is stretched over
a portion of said goods in each package and held to said packaging so said web
is
maintained stretched to firmly hold said goods to the packaging.
4. The method as claimed in Claim 2, wherein a machine readable
barcode is applied to said tray prior to applying said web on a portion of
said tray that
is visible after applying said web to said packaging whereby at a future point
in time
said barcode can be machine read and human readable information can be applied
to
the web.
5. The method as claimed in Claim 2, wherein said goods are meats and
said gas is typically 80% CO2 and more than 19% N2 and less than 0.03% O2.

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6. The method as claimed in Claim 2, comprising selecting.the height
from said bottom of said package to said lip of said gas permeable tray web to
be
higher than the height of said goods, and effecting sealing so said gas
permeable web
is not contacting the upper surface of said goods when said goods are on said
remaining web.
7. The method as claimed in Claim 1, comprising the steps of: providing
in a master container;
providing packaged trays having perforations to allow evacuation and
flushing of gases, wherein the trays are stacked inside the master container;
evacuating the master container and trays of ambient atmosphere;
flushing the master container and trays with a selected gas; and
hermetically sealing the master container.
8. The method as claimed in Claim 1, comprising;
providing sealing plates, wherein the plates have apertures for locating
trays;
wherein the apertures are sized smaller than tray dimensions, so as to
inwardly urge
the tray sidewalls, locating a tray with a flange a within the aperture; and
sealing a web material to the flange while the tray is in the inwardly urged
configuration.
9. The method as claimed in Claim 1, including the steps of:
providing a substantially gas barrier master container comprising a
rectangular cavity with a space enclosed by a base and four upwardly disposed
walls
terminating at a flange; said flange being displaced from said base in
distance equal
to a height and said cavity having a length and a width. Said height, length
and width
so arranged to allow enclosure of a volume of packaging trays that are
directly
stacked together in multiple layers and in a grouping. Said grouping having
height,

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length and width dimensions that are arranged such that said grouping of
stacked
trays will neatly fit within said space;
providing a range of different sized packaging trays each of which can be
stacked together and having dimensions substantially equal to said grouping;
wrapping a plurality of said trays with a web of suitable plastics material
and
enclosing goods therein;
stacking wrapped trays with goods arranged in a grouping into the master
container space so as to substantially fill the cavity so that a minimum free
space
remains and wherein said volume of free space is substantially similar or less
than
the total volume of goods contained in the master container cavity;
flushing the master container and free space with a volume of selected gas, so
as to displace substantially all air contained therein;
hermetically sealing a gas barrier lid material to the flanges of said master
container and over said space so as to hermetically seal said master container
with
trays, goods and selected gas in said space; and
placing said master container in a carton and sealing therein.
10. A method of processing goods, characterized in that the goods are
brought in contact with a selected gas to enhance the keeping qualities of the
goods.
11. The method as claimed in Claim 10, comprising:
placing meat portions in a pressure vessel that is substantially filled with
CO2
at elevated pressure to dissolve CO2 in liquids and oils; and
packaging the meat portions with an overwrap web such that the web is in
contact with a portion of the meat so as to hold toward the meat portion
toward the
base, such that when stacked below another similarly packaged tray, the met
does not
contact the underside of the tray above it.

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12. The method as claimed in Claim 10, comprising:
placing pre-rigor mortis meat in a perforated mold;
chilling the meat, but not allowing muscle fiber shortening to occur;
placing the molds with meat in contact with CO2;
storing the mold with meat to allow a quantity of CO2 to dissolve into the
meat; and
packaging the meat.
13. The method as claimed in Claim 10, comprising:
a) placing goods in an enclosed vessel containing a gas to
enhance the keeping of the goods;
b) allowing the gas to contact and dissolve in water, liquids and
oils present in the goods;
c) restricting the formation of oxymyoglobin in substantially
displacing ambient atmospheric oxygen in air, that may otherwise contact the
surface
of the goods, with the gas;
d) providing a retail package comprising a substantially gas
barrier plastics pouch; and
e) transferring the goods from the vessel into a said pouch
without allowing significant formation of oxymyoglobin on surface of the
goods.
14. The method as claimed in Claim 10, having the following steps:
a) placing goods in an enclosed vessel containing a gas to
enhance the keeping of the goods;
b) allowing the gas to contact and dissolve in water, liquids and
oils present in the goods;

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c) restricting the formation of oxymyoglobin by substantially
displacing ambient atmospheric oxygen in air, that may otherwise contact the
surface
of the goods, with the gas;
d) providing a retail package including two overlapping webs
with a space therebetween, with at least one of the webs being gas permeable;
and
e) transferring the goods from the vessel to a position between
the two overlapping webs and into the space without allowing significant
formation
of oxymyoglobin on surface of the goods.
15. The method as claimed in Claim 14, wherein said two overlapping
webs are sealed so as to provide a hermetically sealed and liquid tight
package.
16. The method as claimed in Claim 14, wherein the goods are fresh
meats and the gas is a substantially oxygen free gas
17. The method as claimed in Claim 10, comprising the steps of placing
meat in a pressure vessel containing carbon dioxide; and
dissolving carbon dioxide in the meat at a pressure above ambient pressure.
18. The method as claimed in Claim 17, further comprising packaging the
meat in a tray and sealing with a permeable web.
19. The method as claimed in Claim 17, wherein the pressure is about
50 psi or greater.
20. The method as claimed in Claim 17, further comprising the step of
controlling the temperature of the pressure vessel between about 25 degrees F
and
about 40 degrees F.

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21. The method as claimed in Claim 18, further comprising the step of
loading the packaged tray in a master container.
22. The method as claimed in Claim 17, further comprising grinding the
meat.
23. The method as claimed in Claim 10, comprising:
cutting meat containing deoxymyoglobin in an atmosphere substantially
deficient of oxygen; and
inhibiting contact between the cut meat surface with oxygen.
24. A method of processing and packaging goods, characterized in that
the goods are brought in contact with a selected gas during processing and
packaging
that will enhance the keeping qualities of the goods.
25. The method as claimed in Claim 24, comprising:
a) placing goods in an enclosed vessel containing a gas to
enhance the keeping of the goods;
b) allowing the gas to contact and dissolve in liquids and oils
present in the goods;
c) restricting the formation of oxymyoglobin by substantially
displacing ambient air, that may otherwise contact the surface of the goods,
with the
gas;
d) providing a retail package including two overlapping webs
with a space therebetween, with at least one of the webs being gas permeable;
and
e) transferring the meats from the vessel to a position between
the two overlapping webs and into the space without allowing significant
formation
of oxymyoglobin on surface of the meats.

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26. The method as claimed in Claim 25, wherein the goods are fresh red
meats and the gas is a substantially oxygen free gas.
27. The method as claimed in Claim 24, comprising:
a) locating and processing the fresh red meat containing de-
oxymyoglogin in a vessel with a gas that is substantially free of oxygen;
b) transferring the fresh red meat, with de-oxymyoglobin, from
the vessel and into a substantially gas barrier package that contains a
substantially
oxygen free gas;
c) sealing the fresh red meat, with de-oxymyoglobin, in the
package; and
d) performing steps a), b) and c) in such a manner so that any
contact of the fresh red meat containing de-oxymyoglobin with atmospheric
oxygen
during the transfer, prior to subsequent exposure of the red meat with de-
oxymyoglobin to ambient atmospheric gas after packaging, will be minimized to
the
extent that any oxymyoglobin that may consequentially become present at the
surface
of the fresh red meat, as a result of brief contact with any atmospheric
oxygen, will
not be subsequently cause generation of metmyoglobin to an extent that is
visibly
recognizable as a brown discoloration by human eye.
28. The method as claimed in Claim 24, including the steps of:
a) locating and processing the fresh meat containing de-
oxymyoglogin in a vessel with a gas that is substantially free of oxygen.
b) transferring the fresh red meat, with de-oxymyoglobin, from
the vessel and into a substantially gas barrier package that contains a
substantially
oxygen free gas.

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c) sealing the fresh red meat, with de-oxymyoglobin, within the
package;
d) performing steps a), b) and c) in such a manner so that any
contact of the fresh - meat containing de-oxymyoglobin with atmospheric oxygen
during the transfer, prior to subsequent exposure of the red meat with de-
oxymyoglobin to ambient atmospheric gas after packaging, will be minimized to
the
extent that any oxymyoglobin that may consequentially become present at the
surface
of the fresh red meat, as a result of brief contact with any atmospheric
oxygen, will
not subsequently cause generation of significant quantities of metmyoglobin to
an
extent that is visibly recognizable as a brown discoloration by human eye.
29. The method as claimed in Claim 24, comprising the following steps:
a) transferring goods into an enclosed first vessel and a gas to
enhance the keeping of the goods, and wherein said first vessel is
substantially sealed
so as to inhibit entry of atmospheric gas therein;
b) controlling gas pressure and temperature in said first vessel
and thereby controlling dissolving of said gas into said goods;
c} mixing of said goods;
d) inhibiting the formation of oxymyoglobin by substantially
displacing ambient atmospheric oxygen in air, that may otherwise contact the
surface
of the goods, with the gas;
e) transferring said goods from said first pressure vessel into a
second pressure vessel; and
f) transferring said goods into a substantially gas barrier package
without allowing significant formation of oxymyoglobin on surface of the
goods, and
hermetically sealing said goods therein.

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30. The method as claimed in Claim 24, comprising the following steps:
a) transferring ground meats into an enclosed first vessel with a
gas to enhance the keeping of the ground meats, and wherein said first vessel
is
substantially sealed so as to inhibit entry of atmospheric gas therein;
b) controlling gas pressure and temperature in said first vessel
and thereby controlling dissolving of said gas into said ground meats;
c) mixing of said ground meats;
d) inhibiting the formation of oxymyoglobin by substantially
displacing ambient atmospheric oxygen in air, that may otherwise contact the
surface
of the ground meats, with the gas;
e) transferring said ground meats from said first vessel into a
second vessel via pumping means in a substantially continuous stream through
an
enclosed conduit and substantially exclude voids in said stream;
f) measuring fat content of said ground meats continuously
during transfer from said first vessel to said second vessel;
g) mixing said ground meats; and
h) transferring said ground meats into a substantially gas barrier
package without allowing significant formation of oxymyoglobin on surface of
the
goods, and hermetically sealing said ground meats therein.
31. The method as claimed in Claim 24, the method having the following
steps:
a) treating goods with agents to reduce the quantity of bacteria
present in said goods and ensuring that said quantity of bacteria does not
exceed the
maximum acceptable level for goods intended for human consumption, as required
by prevailing government regulations;

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b) transferring goods into an enclosed vessel containing a gas to
enhance the keeping of the goods;
c) providing a package including overlapping gas barrier web
material with a space therebetween;
d) providing a gas in said space; gas selected for having
properties to enhance the keeping of the goods;
e) transferring the goods from the vessel to a position between
the overlapping gas barrier web material and into the space;
f) hermetically sealing said overlapping gas barrier web material
to enclose said goods and said gas therein, to provide a finished package; and
g) storing said finished package in a temperature controlled space
ensuring that the quantity of bacteria present in said goods does not exceed
the
maximum acceptable level for goods intended for human consumption, as required
by prevailing government regulations, prior to removing said goods from said
finished package for use.
32. The method as claimed in Claim 24, the method having the following
steps:
a) providing a first quantity of fresh meat portions comprising
proportions of fat, water and protein content;
b) providing a second quantity of fresh meat portions comprising
proportions of fat, water and protein content;
c) treating both first and second quantities of fresh meat with
agents to reduce the quantity of bacteria present in said goods and ensuring
that said
quantity of bacteria does not exceed the maximum acceptable level for goods
intended for human consumption, as required by prevailing regulations;

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d) transferring said first quantity of fresh meat into a first
enclosed vessel containing a gas to enhance the keeping of the goods and
mixing said
goods thereby;
e) transferring said second quantity of fresh meat into a second
enclosed vessel containing a gas to enhance the keeping of the goods and
mixing said
goods thereby;
f) measuring at least the fat content of said first quantity of fresh
meat while transferring into a third enclosed vessel containing a gas to
enhance the
keeping of the fresh meat and mixing therein, wherein method of transfer is
provided
via an enclosed conduit connected directly to said third vessel, through which
said
first quantity of fresh meat is transferred;
g) measuring at least the fat content of said second quantity of
fresh meat while transferring into said third enclosed vessel and mixing
therein with
said first quantity of fresh meat, wherein method of transfer is provided via
an
enclosed conduit connected directly to said third vessel, through which said
second
quantity of fresh meat is transferred;
h) providing a package including overlapping gas barrier web
material with a space therebetween;
i) transferring the combined first and second streams of fresh
meat from said third vessel to a position between the overlapping gas barrier
web
material and into the space; and
j) hermetically sealing said overlapping gas barrier web material
to enclose said fresh meat, and excluding substantially all ambient air
therefrom.
33. The method as claimed in Claim 24, comprising the processing or
packaging of meat in a substantially enclosed series of connecting conduits,
vessels

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and enclosures wherein any free space therein is substantially filled with a
selected
gas.
34. Apparatus to provide finished processed and packaged goods
according to the method of Claim 33.
35. A method as claimed in Claim 33 wherein more than two streams of
fresh meat are processed, measured and packaged.
36. The method as claimed in Claim 24, comprising of an apparatus for
the removal of oxygen in a step in the processing or packaging, followed by
the
introduction of a suitable gas or agent at a suitable pressure and
temperature, and for
a suitable time period to cause the dissolution of the gas or agent into the
beef, such
that upon return of the beef to ambient temperature and pressure, the gas or
agent is
released from the beef, thereby delaying the onset of bacterial growth and the
formation of metmyoglobin on the beef.
37. The method as claimed in Claim 24, comprising of a step in the
processing or packaging of removing oxygen from in and around the beef,
followed
by the introduction of a suitable gas or agent into the beef at a suitable
pressure and
temperature, and for a suitable time period to cause the dissolution of the
gas or agent
into the beef, such that upon return of the beef to ambient temperature and
pressure,
the gas or agent is released from the beef, thereby delaying the onset of
bacterial
growth and the formation of metmyoglobin on the beef.
38. A goods packaging tray including a base with upwardly extending
side walls that terminate at a flange that extends around a perimeter of the
tray to
provide a cup-shaped recess, the tray having at least one extension connected
to the
flange at a hinge, the extension including a cup-shaped flap that can be
folded about

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the hinge and be sealed to at least one of the upwardly extending side walls
to
provide an enclosed space, the tray having apertures at a base of the side
wall of the
tray so as to provide communication between the enclosed space and the tray
that
will allow liquids to pass from the tray cup-shaped recess to the enclosed
space.
39. Packaging for perishable goods, comprising:
a stackable base over which goods are placed, the base having upwardly
extending walls terminating at a peripheral lip extending around a perimeter
of said
base, and wherein each wall comprises an inner layer and an outer layer of
plastics
material, wherein said outer layer is substantially vertical to said base and
said inner
wall extends upwardly and away from said base, thereby providing a space
between
said inner and outer walls;
a web of gas permeable material, having two parallel edges, wherein said web
is first sealed to itself along a path that is close to said parallel edges to
form a
tubular section, positioned with said base enclosed within said tubular
section, and
wherein said tubular section is stretched prior to further sealing to itself
along second
and third substantially parallel paths close to opposite ends of an end of
said tubular
section and perpendicular to said first seal, so as to hermetically seal and
enclose said
base, and allowing said tubular section to shrink after severing from said
web, and
firmly contact portions of the outer surface of said base, walls and
peripheral lip;
space within said tubular section with said goods and said base;
a gas in said space, said gas selected for enhancing preservation of the
packaging goods by contacting the surface of said goods;
said gas contacting said goods by permeating said tubular section stretched
over said goods and held to said packaging so said tubular section is
maintained
stretched to firmly contain said goods within the packaging; and

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said tubular section permitting viewing of a major portion of an upper surface
of said goods.
40. A master container, wherein one or more packages of Claim 39 are
stacked together in a second substantially gas barrier master container
fabricated
from plastics material and having a substantially flat base with upwardly
extending
walls terminating at a lip extending around the perimeter of said base to
provide a
continuous wall, and thereby providing a cavity above said base and within
said
walls, into which said packages are stacked, and thereby fill said cavity with
said first
packages and space therebetween.
41. Master container as claimed in Claim 40, wherein a lid of
substantially gas barrier web material is hermetically sealed to said lip
after
providing a suitable gas or blend of selected gases in said space and
substantially
displacing any residual oxygen.
42. Master container as in Claim 41, wherein an oxygen absorbing agent
is provided into said space prior to hermetically sealing said lid to said
lip.
43. Packaging as claimed in Claim 39, wherein said peripheral lip
configuration is displaced in height from said base, and wherein said goods
are
contacting said base, and a portion of the upper surface of said goods is
above the
upper surface of said lip, and said tubular section extends over the top of
said goods
and is held to a portion of the peripheral lip and a portion of the upper
surface of said
goods.
44. Packaging as claimed in Claim 39, wherein said base has a bottom
displaced in height from a peripheral lip and wherein said goods are
contacting said

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bottom, and a portion of said tubular section held to said packaging at a
position
below a portion of the top of said goods.
45. Packaging as claimed in Claim 39, wherein said tubular section is held
to the bottom of said base.
46. Packaging as claimed in Claim 39, wherein a portion of the top of
goods is below said peripheral lip and a portion of the top of said goods is
above a
portion of said peripheral lip.
47. Packaging as claimed in Claim 39, wherein the top of said goods is
below said peripheral lip and there is provided a tubular section of gas
permeable
plastics material held to said peripheral lip with a space between said
tubular section
and the upper surface of said goods and a gas in said space for enhancing
keeping of
said goods by permeating said tubular section and wherein said package is
removable
from said gas barrier container and whereby oxygen can permeate said tubular
section from atmosphere to bloom said goods to a red color following
discoloring of
said goods from extended packaging in an oxygen depleted gas.
48. Packaging as claimed in Claim 39, wherein packaging materials used
to manufacture said lid and said base have been treated with a bactericide
that
remains effective in killing bacteria, virus, and fungi after use of said base
in
packaging.
49. Packaging including a base that comprises a thermoformed, nestable,
tray with a floor, walls and at least one flap attached by a hinge to a wall,
wherein
said flap comprises a cup shaped flap with at least one depression and a
continuous
substantially flat section at a path close to the perimeter of said flap, such
that when

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folded against the corresponding wall a hermetic seal can be provided between
said
flap flat section and said wall enclosing a space between said walls.
50. Packaging as claimed in Claim 49, wherein capsules of any chosen
agent or substance may be provided in said space between said walls.
51. Packaging as claimed in Claim 49, wherein apertures may be provided
along the outer edge of said tray floor and at the lower section of said inner
wall and
thereby providing a communication between said cavity and said space between
said
walls.
52. Packaging as claimed in Claim 49, wherein a selected gas is provided
in said space and all other spaces in said packaging and maintained at ambient
pressure for a period of time after hermetically sealing said flaps.
53. Packaging as claimed in Claim 49, wherein a selected gas is provided
in said space and maintained at a pressure above ambient pressure for a period
of
time after hermetically sealing said flaps.
54. Packaging as claimed in Claim 49, wherein a chosen agent or
substance comprises a bactericide contained in a capsule that can be ruptured
by
exposure to micro wave, a magnetic field, or Radio Frequency from a remote
source.
55. Packaging as claimed in Claim 49, wherein a web of plastics material
containing an oxygen absorbing agent is laminated to a surface of said tray
prior to
fabrication, wherein said oxygen absorbing agent contained in said web of
plastics
material is only rendered substantially active and capable of absorbing oxygen
after
exposure to a suitable micro wave source, magnetic field or radio frequency
from a
remote source.

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56. Packaging as claimed in Claim 49, wherein a web of plastics material
containing any desirable agent that can perform any desirable function such as
a
bactericide, is laminated to a surface of said tray prior to fabrication,
wherein said
oxygen absorbing agent contained in said web of plastics material is only
rendered
substantially active and capable of absorbing oxygen after exposure to a
suitable
micro wave source, magnetic field or radio frequency from a remote source.
57. Packaging as claimed in Claim 49, wherein said chosen agent or
substance comprises an oxygen absorbing ferric element or gel contained in a
capsule
wherein said capsule can be ruptured by exposure to micro wave, a magnetic
field, or
Radio Frequency from a remote source after package assembly thereby providing
a
means to absorb any residual O2 that may be present in the interstices of
packaging
materials used in the packaging.
58. Packaging as claimed in Claim 49, wherein said first packaging tray is
manufactured from a foamed plastic, wherein said chosen agent or substance
comprises an oxygen absorbing ferric element in granule/powder form applied to
a
portion of the inner surfaces of space between said first package walls, and
wherein
granules are individually and substantially enclosed in a covering layer of
water
barrier material wherein said water barrier material can be ruptured or
modified by
exposure to micro wave, a magnetic field, or Radio Frequency from a remote
source
after package assembly thereby allowing gas contact of said ferric element to
gases
enclosed in said first package and thereby providing a means to absorb any
residual
O2 that may be present in the interstices of packaging materials used in the
packaging.
59. Packaging as claimed in Claim 49, wherein said walls are arranged
such that when more than one packaging trays are stacked together in a single
stack

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with a tray located directly above another, the base of an upper tray contacts
the lip
of the lower tray immediately below it such that there is a minimized distance
or
space between the surface of the underside of said upper tray and the upper
surface of
the portion of the tubular section web material directly below the upper tray.
60. Packaging as claimed in Claim 39, wherein one or more apertures are
provided in the tubular section web at a location adjacent to said outer walls
and in
such a position that will allow communication of gas between the tray cavity
and
external to said package but also restricting communication of any free
liquids that
may be in said cavity.
61. Packaging as claimed in Claim 39, wherein portions of said tubular
section web is printed with inks, and/or heat activated adhesives and/or
pressure
sensitive adhesives whereby when heat and or pressure is applied to urge
portions of
said web against any contactable portion of said tray a bonding will occur
therebetween at selected portions of said web and said tray.
62. Packaging as claimed in Claim 39, wherein said tubular section web is
fabricated from plasticized polyvinyl chloride.
63. Packaging as claimed in Claim 39, wherein said tubular section web is
fabricated from any suitable transparent web of material.
64. Packaging as claimed in Claim 39, wherein said tubular section web is
fabricated from any suitable transparent web of material that has been treated
with
anti-fog agents.
65. A goods packaging tray including a base with upwardly extending
side walls that terminate at a flange that extends around a perimeter of the
tray to

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provide a cup-shaped recess. The tray having at least one extension connected
to the
flange at a hinge. The extension including a cup-shaped flap that can be
folded about
the hinge and be bonded to at least a portion of one of the upwardly extending
side
walls to provide an enclosed space.
66. A package as in Claim 65, having apertures at a base of at least a
portion of one side wall of the tray so as to provide communication between
the
enclosed space and the tray that will allow liquids to pass from the tray cup-
shaped
recess into the enclosed space.
67. A packaging tray for use in the method of Claim 1, comprising;
a thermoformed web of material, wherein the web is formed to have a bottom
and at least four sides, wherein at least two of the sides are reclining, at
least a first
member, integrally formed with the tray, wherein the member is movable between
a
first position and a second position, and wherein at the second position, the
member
is substantially level with the upper horizontal surface of the tray to
provide a
support.
68. A packaging tray for use in the method of Claim 1, comprising:
a thermoformed web of material, wherein the web is formed to have a bottom
and four sides, a perforation in the tray allowing evacuation and flushing of
gases
between the interior of the and and ambient atmosphere.
69. A packaging tray for use in the method of Claim 1, comprising:
a web of thermoformed material, comprising:
a bottom and four sidewalls extending horizontally from the bottom base to
form an opening, wherein the opening is surrounded by a flange on at least two
sides,
and wherein the sidewalk are formed with areas of higher concentration
material.

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70. A package for perishable goods for use in the method of Claim 1,
comprising:
a first web defining a base;
a plurality of first walls extending upwardly and outwardly from the base to
define a depression in the web with an opening, wherein the perimeter of the
opening
defines a lip;
a plurality of second walls extending from the lip downward to define a space
between a wall from the first walls and a wall from the second walls, wherein
at least
one of the second walls includes a ledge substantially level with the web
base; and
a second web of gas-permeable material, wherein the second web is sealed or
stretched on the first web in a modified atmosphere environment.
71. A tray for use in the method of Claim 1, wherein a plastics web used
to produce the tray comprises a sheet material that has been extruded from any
suitable source of polymer, such as polypropylene, but with a quantity of
suitable
bactericide provided therein that remains active and capable of reducing
levels of
bacterial contamination such as bacteria contained in goods in contact with a
surface
of the tray.
72. A packaging tray for use in the method of Claim 1, comprising:
a thermoformed web of material including a bottom and four sides; and
a first and second flap located at opposite sides, wherein the first and
second
flaps are foldable between a first and second position.
73. A package for perishable goods for use in the method of Claim 1,
comprising:
a first web defining a base;

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a plurality of first walls extending upwardly and outwardly from the base to
define a depression in the web with an opening, wherein the perimeter of the
opening
defines a lip;
a plurality of second walls extending from the lip downward to define a space
between a wall from the first walls and a wall from the second walls, wherein
at least
one of the second walls includes a ledge substantially level with the web
base; and
a second web of gas-permeable material, wherein the second web is sealed or
stretched on the first web in a low oxygen environment.
74. Apparatus for producing packaging trays, comprising:
means for thermoforming plastics sheet to form and trim a packaging tray
with a base and upwardly extending side walls that terminate at a flange that
extends
around a perimeter of the tray to provide a cup-shaped recess with at least
one
extension connected to the flange at a hinge including a cup-shaped flap that
can be
folded about the hinge and be sealed to at least one of the upwardly extending
side
walls to provide an enclosed space;
means to seal the flap to the tray wall around a perimeter of the flap; and
means to provide apertures in the side wall of the tray recess so as to
provide
a communication between the enclosed space and the tray recess.
75. Apparatus for producing packaging trays, comprising:
means for thermoforming plastics sheet to form and trim a packaging tray
with a base and upwardly extending side walls that terminate at a flange that
extends
around a perimeter of the tray to provide a cup-shaped recess with at least
one
extension connected to the flange at a hinge including a cup-shaped flap that
can be
folded about the hinge and be sealed to at least one of the upwardly extending
side
walls to provide an enclosed space;

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means to seal the flap to the tray wall around a perimeter of the flap; and
means to provide apertures in the side wall of the tray recess so as to
provide
a communication between the enclosed space and the tray recess.
76. An apparatus for forming trays comprising:
a first chamber, having a porous mold for forming a web; and
a second chamber, suitably arranged to move toward the first chamber; and
a plurality of ports for attaching to a vacuum source and a preferred gas.
77. An apparatus for sealing a master bag, comprising:
a first vacuum chamber;
a second vacuum chamber suitably configured to mate with the first vacuum
chamber enclosing a container with packages therein; and
a web dispenser to pass a web over the opening of the master container; and
a sealer to seal the web to the master container.
78. Apparatus for packaging perishable goods in a gas environment to
enhance the keeping properties of said goods comprising means for stacking
packages in a master container, evacuating said master container without
rupturing
said packages and providing said gas therein applying a lid and hermetically
sealing
to said master container said gas contacting said goods by permeating said web
and
being of a size permitting viewing of a major portion of an upper surface of
said
goods.
79. Apparatus for printing or applying a method of packaging perishable
goods in packaging so said goods will be in a gas environment which will
enhance
the keeping properties of said goods said method comprising providing a base,
placing goods over said base, applying a web of oxygen permeable material over
said

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goods, and locating said packaging in a master container by stacking directly
one
above another without any other packaging materials therebetween with a
desired gas
between packaging which will enhance the keeping properties of said goods by
contacting the surface of said goods and sealing said lid to said master
container with
said gas therebetween, said web of oxygen permeable material then holding said
goods relative to said packaging and being of a size permitting viewing of a
major
portion of an upper surface of said goods and allowing said gas to contact
said goods
by permeating said web.
80. An apparatus for automatically stacking and locating packages in a
master container wherein a portion of the top of goods in each package is
below said
peripheral lip and a portion of the top of said goods is above a portion of
said
peripheral lip and wherein there is no other packaging materials provided
between
the packages and wherein the underside of an upper package does not contact
the
goods contained in a lower package.
81. A goods master container, said master container having two gas
barrier webs and intermediate gas permeable webs, goods between a pair of gas
permeable webs and said gas permeable webs being sealed together by a seal
extending completely around and near the perimeter of the packaging, a gas
sealed in
a gas barrier manner in the master container and contacting said goods, said
gas
selected for enhancing the keeping of said goods, and wherein said pair of gas
barrier
webs comprises a gas permeable webs that said goods are between is of tray
like
configuration with a bottom displaced in height from a peripheral lip, said
seal being
on said peripheral lip and wherein said height is greater than the height of
said goods
so when said goods are resting on said gas barrier web said gas permeable web
is not
touching said goods.

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82. A goods package as claimed in Claim 81, wherein said gas permeable
web has openings therein to allow said gas to pass through said openings.
83. A goods package as claimed in Claim 81, wherein said gas permeable
web is stretched and said package is sealed with it stretched so it remains
taut over
said bottom.
84. A goods package as claimed in Claim 81, wherein said gas is
typically 80% CO2 and more than 19% N2 and less than 0.05% O2.
85. A method for sealing a master bag container, comprising:
providing a first and a second vacuum chamber, wherein one of the chambers
includes a heat bank, the first and second chambers being opposedly configured
to
open and close, locating the master bag container within the first or second
chamber,
when chambers are in open position, wherein the master bag defines an opening;
extending a web across the opening of the bag;
closing the first and second chamber to define an enclosed space;
evacuating the enclosed space;
flushing the enclosed space; and
sealing the web to the bag.
86. Apparatus for packaging goods in a gas environment to enhance the
keeping of said goods, comprising a gas flushing and sealing chamber means for
holding a first web of a gas barrier material with said goods over said first
web, and
characterized by means for feeding an intermediate web of gas permeable
material
over said first web, and means for applying a further web of gas barrier
material over
said first web, and means for applying a further web of gas barrier material
over said
first web, said gas flushing and sealing chamber being closable to bring both
webs

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together prior to any of those webs being sealed together at a seal path near
a
perimeter of the packaging, and means for introducing a gas to enhance the
keeping
of said goods into said gas flushing and sealing chamber and sealing means in
said
gas flushing and sealing chamber for then sealing both webs together in said
gas
flushing and sealing chamber with said gas sealed in the resulting master
container
package.
87. Apparatus for packaging perishable goods as claimed in Claim 86,
characterized that said first web has a bottom displaced in height from a
peripheral
lip and wherein said means for holding said first web comprises a pair of
horizontally
displaced gripper chains plate with an aperture therein so said bottom passes
into said
aperture, and said peripheral lip rests on the upper surface of said plate
around the
perimeter of said aperture and wherein said gas flushing and sealing chamber
is
sealed, evacuated and gas flushed, and said webs are sealed with said gas
sealed in
the resulting package.
88. Apparatus for packaging perishable goods as claimed in Claim 87,
characterized that said first web has a bottom displaced in height from a
peripheral
lip and wherein said means for holding said first web comprises a plate with
an
aperture therein so said bottom passes into said aperture, and said peripheral
lip rests
on the upper surface of said plate around the perimeter of said aperture and
wherein
said gas flushing and sealing chamber is sealed, evacuated and gas flushed,
and said
webs are sealed with said gas sealed in the resulting package.
89. An apparatus for conditioning meat, comprising a meat grinder, with
an entry and exit point, a tube connected to the exit point of the grinder,
wherein the
tube is passed through an enclosure containing cooling medium.

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90. An apparatus for shaping meat, comprising a container, having
sidewalls surrounding a lower base, so as to define an opening, a plug,
suitably
configured to fit in the opening slide within the interior sidewalk, a press
base,
attached to an elevating shaft, the press base configured to mate with the
lower
portion of the container, a plurality of independently driven clamps
positioned above
the plug.
91. An apparatus for shaping meat, comprising a container, having a base
and upwardly extending parallel side-walls, so as to define a cavity with
parallel
sides, a plug, suitably configured to fit into the cavity and slide within the
interior of
side-walls and thereby define an enclosure with plug inserted, said plug
having a
flexible outer perimeter rim such that a substantially gas tight seal is
provided to any
gas outside said container after said plug is inserted and such that gas
contained
within said enclosure can be expelled by depressing said plug closer to said
base.
92. A method for shaping meat, comprising the following steps:
a) selecting and separating a meat portion from an animal carcass
following death of said animal but prior to rigor mortis of said meat portion
occurring;
b) placing said meat portion in a container having a base and
upwardly extending parallel side-walls, so as to define a cavity with parallel
sides
and an opening;
c) inserting a plug suitably configured to fit into said container
opening and slide within the interior of side-walls and thereby displacing any
free gas
from within said container and causing said meat portion to conform to the
internal
shape of said container and plug;

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d) locating said container, meat portion and plug into a
temperature controlled enclosure and progressively lowering the temperature
within
said enclosure so as to lower the temperature of said meat portion and thereby
cause
rigor mortis to occur providing a permanently shaped portion of meat with a
profile
substantially identical to the inner profile of said container with plug; and
e) remove said meat portion from said container and cut to
produce sliced meat with slices having a profile substantially the same as
each other.
93. A method for shaping meat, comprising the steps of:
placing a meat portion in a container with a plug, between a press base and a
clamp;
advancing the clamp toward the press base and the plug;
applying a vacuum source between the clamp and the plug; and
applying pressure to the plug with the clamp to as to substantially remove the
air from the container.
94. The method of Claim 93 wherein the container is immersed in brine.
95. The method of Claim 93, wherein the container is further subjected to
ultra high pressure.
96. The method of Claim 93, wherein a high voltage current is passed
through the container.
97. The method of Claim 93, further comprising immersing the container
in a cooling medium.
98. The method of Claim 93, wherein a plurality of meat portions are
shaped.

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99. An apparatus for shaping meat, comprising a container arranged to
provide a desired internal profile, comprising a longitudinal trough having at
least
two sidewalls connected by a bottom side member, a mating closure which is
received by the trough between the sidewalls; and, a first and second plug
received
by the trough on the first and second end.
100. An apparatus for thermoforming trays, comprising:
a tube for storing spools of web material, the tube being flooded with a
suitable gas.
101. A method for the storing webs, comprising:
locating the web within a pressure chamber, evacuating the vessel by
lowering the pressure, maintaining the vacuum, and
increasing the pressure by introducing a suitable gas.
102. An apparatus for the exchange of ambient gas in foam webs to a
preferred gas, comprising:
a tube having a first and second open ends;
a first cap located on a first one of the open ends to substantially seal the
end;
a second cap located on a second of the open ends, the second cap defining a
port through the cap center; and
a piston enclosed within the tube.
103. The apparatus of Claim 102, wherein the tube is mounted on a rotating
member.
104. An apparatus for the exchange of ambient gas in foam webs to a
preferred gas, comprising:
a tube having a first and second open ends;

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an evacuation port; and
a gas entry port.
105. Apparatus for processing and packaging perishable goods,
comprising:
a) apparatus and means to transfer goods into an enclosed first
vessel with a gas to enhance the keeping of the goods, and wherein said first
vessel is
substantially sealed so as to inhibit entry of atmospheric gas therein;
b) means to control gas pressure and temperature in said first
vessel and thereby control dissolving of said gas into said goods;
c) means for mixing of said goods;
d) means to inhibit the formation of oxymyoglobin by
substantially displacing ambient atmospheric oxygen in air, that may otherwise
contact the surface of the goods, with the gas;
e) means to transfer the goods from said first pressure vessel into
a second pressure vessel; and
f) means to transfer said goods into a substantially gas barrier
package without allowing significant formation of oxymyoglobin on surface of
the
goods, and hermetically sealing said goods therein.
106. Apparatus for processing and packaging perishable goods,
comprising:
a) an enclosed first vessel containing goods and a gas to enhance
the keeping of the goods, and wherein said first vessel is substantially
sealed so as to
inhibit entry of atmospheric gas therein;
b) means to control gas pressure and temperature in said first
vessel and thereby control dissolving of said gas into said goods;

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c) means for mixing of said goods;
d) means to inhibit the formation of oxymyoglobin by
substantially displacing ambient atmospheric oxygen in air, that may otherwise
contact the surface of the goods, with the gas;
e) means to transfer the goods from said first pressure vessel into
a second pressure vessel; and
f) means to transfer said goods into a substantially gas barrier
package without allowing significant formation of oxymyoglobin on surface of
the
goods, and hermetically sealing said goods therein.
107. Apparatus for processing and packaging ground meats, comprising:
a) a means of transferring ground meats into an enclosed first
vessel with a gas to enhance the keeping of the ground meats, and wherein said
first
vessel is substantially sealed so as to inhibit entry of atmospheric gas
therein;
b) means of controlling gas pressure and temperature in said first
vessel and thereby controlling dissolving of said gas into said ground meats;
c) means of mixing said ground meats;
d) means of inhibiting the formation of oxymyoglobin by
substantially displacing ambient atmospheric oxygen in air, that may otherwise
contact the surface of the ground meats, with the gas;
e) means of transferring said ground meats from said first vessel
into a second vessel via pumping means in a substantially continuous stream
through
an enclosed conduit and substantially excluding voids in said stream;
f) means of measuring fat content of said ground meats
continuously during transfer from said first vessel to said second vessel;
g) means to mix said ground meats; and

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h) means of transferring and packaging said ground meats in a
substantially gas barrier package without allowing significant formation of
oxymyoglobin on surface of the goods, and means of hermetically sealing said
ground meats therein.
108. Apparatus for processing and packaging goods, including:
a) means for treating goods with agents to reduce the quantity of
bacteria present in said goods and ensuring that said quantity of bacteria
does not
exceed the maximum acceptable level for goods intended for human consumption,
as
required by prevailing government regulations;
b) means for transferring goods into an enclosed vessel
containing a gas to enhance the keeping of the goods;
c) means to provide a package including overlapping gas barrier
web material with a space therebetween;
d) means to provide a gas in said space at a controlled pressure
and temperature; gas selected for having properties to enhance the keeping of
the
goods;
e) means to transfer the goods from the vessel to a position
between the overlapping gas barrier web material and into the space;
f) packaging means to hermetically sealing said overlapping gas
barrier web material to enclose said goods and said gas therein, to provide a
finished
package; and
g) means to store said finished package in a temperature
controlled space ensuring that the quantity of bacteria present in said goods
does not
exceed the maximum acceptable level for goods intended for human consumption,
as
required by prevailing government regulations prior to removing said goods
from
said finished package for use.

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109. Apparatus for processing, measuring and packaging fresh ground
meats, comprising the following:
a) means to provide a first quantity of fresh meat portions
comprising proportions of fat, water and protein content;
b) means to provide a second quantity of fresh meat portions
comprising proportions of fat, water and protein content;
c) means to treat both first and second quantities of fresh meat
with agents to reduce the quantity of bacteria present in said goods and
ensuring that
said quantity of bacteria does not exceed the maximum acceptable level for
fresh
meat intended for human consumption, as required by prevailing regulations;
d) means to provide gas and transfer said first quantity of fresh
meat into a first enclosed vessel containing gas to enhance the keeping of the
fresh
meat and mix said fresh meat thereby;
e) means to provide gas and transfer said second quantity of
fresh meat into a second enclosed vessel containing gas to enhance the keeping
of the
fresh meat and mix said fresh meat thereby;
f) means to provide gas and transfer and measure at least the fat
content of said first quantity of fresh meat and transfer into a third
enclosed vessel
containing gas and mixing means therein, wherein an enclosed conduit means of
transfer is connected, via transfer and fat measuring means, directly to said
third
vessel from said first vessel;
g) means to provide gas and transfer and measure at least the fat
content of said second quantity of fresh meat and transfer into said third
enclosed
vessel containing gas and mixing means therein, wherein an enclosed conduit
means
of transfer is connected, via transfer and fat measuring means, directly to
said third
vessel from said second vessel;

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h) means to provide packaging including overlapping gas barrier
web material with a space therebetween;
i) means to transfer the combined first and second streams of
fresh meat from said third vessel to a position between the overlapping gas
barrier
web material and into the space; and
j) packaging means to hermetically seal said overlapping gas
barrier web material and enclose said fresh meat, and means to exclude
substantially
all ambient air from said package.
110. A method of automatically producing ground meats having a selected
proportion of fat and lean meat, comprising the following steps:
a) pumping a first, independently controlled, measured stream of
ground meats, with means to adjust the velocity of said stream, through an
enclosed
conduit connected to a fourth vessel with mixing means therein;
b) pumping a second, independently controlled, measured stream
of ground meats, with means to adjust the velocity of said second stream,
through an
enclosed conduit connected to said fourth vessel with mixing means therein;
c) providing gas and controlling said gas pressure and
temperature in said fourth vessel and thereby controlling dissolving of said
gas into
said ground meats;
d) mixing means of said first and second streams of ground
meats;
e) inhibiting the formation of oxymyoglobin by substantially
displacing ambient atmospheric oxygen in air, that may otherwise contact the
surface
of the ground meats, with the gas;
f) transferring said ground meats from said fourth vessel into a
fifth vessel through an enclosed conduit for storage in said fifth vessel or

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alternatively transferring said ground meats from said fourth vessel directly
into an
enclosed fine grinder in a manner so as to substantially exclude voids and in
a
continuous stream; and
g) transferring said ground meats into a substantially gas barrier
package without allowing significant formation of oxymyoglobin on surface of
the
goods, and hermetically sealing said ground meats therein.
111. Apparatus for automatically producing ground meats having a
selected proportion of fat and lean meat, comprising the following:
a) means to provide pumping of a first, independently controlled,
measured stream of ground meats, with means to adjust the velocity of said
stream,
through an enclosed conduit connected to a fourth vessel with mixing means
therein;
b) means to provide pumping of a second, independently
controlled, measured stream of ground meats, with means to adjust the velocity
of
said second stream, through an enclosed conduit connected to said fourth
vessel with
mixing means therein;
c) means to provide gas and means for controlling said gas
pressure and temperature in said fourth vessel and thereby controlling
dissolving of
said gas into said ground meats;
d) means for mixing of said first and second streams of ground
meats;
e) means to inhibit the formation of oxymyoglobin by
substantially displacing ambient atmospheric oxygen in air, that may otherwise
contact the surface of the ground meats, with the gas;
f) means of transferring said ground meats from said fourth
vessel into a fifth vessel through an enclosed conduit for storage in said
fifth vessel
or alternatively transferring said ground meats from said fourth vessel
directly into an

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enclosed fine grinder in a manner so as to substantially exclude voids and in
a
continuous stream; and
g) means of transferring said ground meats into a substantially
gas barrier package and means for packaging therein without allowing
significant
formation of oxymyoglobin on the surface of said ground meats, and
hermetically
sealing said ground meats therein.
112. A method for making bacteria-detecting soaker pads, comprising steps
for:
providing a first web of material;
providing a trough comprising water and an engineered polymerized
molecular film that forms on the surface of the water;
contacting the web and film at a substantially similar velocity so that the
film
is transferred to the web;
drying the web; and
applying the web to a soaker pad.
113. The method of Claim 112, wherein the engineered polymerized
molecular film detects the presence of E-coli bacteria.
114. The method of Claim 112, further comprising a step for applying the
soaker pad onto a perforated second web material and heat sealing the first
and the
second web materials.
115. A product made by the method of Claim 112.
116. An apparatus for making bacteria-detecting soaker pads, comprising:
means for providing a first web of material;

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means for providing a trough comprising water and an engineered
polymerized molecular film that forms on the surface of the water;
means for contacting the web and the film at a substantially similar velocity
so that the film is transferred to the web;
means for drying the web; and
means for applying the web to a soaker pad.
117. The apparatus of Claim 116, further comprising:
means for applying a second web, and;
means to bond the first web to the second web so as to provide a pad between
the first and the second web material.
118. A method for applying iron powder onto web materials, comprising
steps for:
providing a web of material;
applying an adhesive to an imprint roller;
contacting the roller with the web;
applying iron powder to the web, wherein a magnet is used to attract the iron
powder to a desired position; and
drying the adhesive to adhere the iron particles onto the web.
119. The method of Claim 118, further comprising a step for bonding the
web material with iron particles onto a second web material to provide a cover
for
packaged goods.
120. An apparatus for applying iron powder onto web materials,
comprising steps for:
means for providing a web of material;

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means for applying an adhesive to an imprint roller;
means for contacting the roller with the web;
means for applying iron powder to the web, wherein a magnet is used to
attract the iron powder to a desired position; and
means for drying the adhesive to adhere the iron particles to the web.
121. The apparatus of Claim 120, further comprising means for bonding
the web material with iron particles to a second web material to provide a
cover for
packaged goods.
122. A method for applying substances to webs for trays, comprising steps
for:
providing a web of material, said material being suitable for forming into
trays,
spraying an adhesive onto a surface of the web material;
applying a substance onto the web material; and
drying the adhesive to produce a web material with bonded substances
thereto.
123. The method of Claim 121, wherein the substance is an iron powder,
and a magnet is disposed underneath the web to selectively pattern the web
with the
powder.
124. An apparatus for applying substances to webs for trays, comprising:
means for providing a web of material, said material being suitable for
forming into trays;
means for spraying an adhesive onto a surface of the web material;
means for applying a substance onto the web material; and

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means for drying the adhesive to produce a web material with bonded
substances thereto.
125. The apparatus of Claim 124, further comprising magnets disposed
underneath the web to selectively pattern the web with the substance.
126. The apparatus of Claim 124, further comprising:
means for applying a vacuum from an underside of the web, so as to direct
the substance onto a localized portion of the web.
127. The apparatus of Claim 124, further comprising means for applying an
energy source onto the substance to adhere the substance to the web.
128. The apparatus of Claim 127, wherein the energy source is magnetic
radiation or microwave radiation.
129. A method for sealing a perishable goods tray, comprising steps for:
providing a continuous conveyor;
dispensing pre-form trays onto the conveyor;
loading perishable goods onto the pre-forms;
sealing a second web onto the trays;
providing apertures in the trays; and
folding the tray flaps and bonding the flaps to the tray.
130. An apparatus for sealing a perishable good tray, comprising:
a continuous conveyor;
means for dispensing pre-form trays onto the conveyor;
means for loading perishable goods onto the pre-forms;
means for sealing a second web onto the trays;

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means for providing apertures in the trays; and
means for folding the tray flaps and bonding the flaps to the tray.
131. A method for packaging a perishable good, comprising steps for:
providing means for weighing a perishable good and a first web;
encoding onto a second web information concerning the perishable good;
laminating the second web to the third web to form a composite;
sealing the composite to the first web.
132. The method of Claim 131, wherein the information contains the
weight of the perishable good and the date of packaging.
133. The method of Claim 131, wherein the step of encoding information is
applied onto a label, the label being applied to the second web.
134. An apparatus for packaging a perishable good, comprising:
means for weighing a perishable good with a first web;
means for encoding onto a second web information concerning the perishable
good;
means for laminating the second web to the third web to form a composite;
and
means for sealing the composite to the first web.
135. The method of Claim 133, wherein the information contains the
weight of the perishable good and date of packaging.
136. The apparatus of Claim 134, further comprising means for encoding
the information onto a label and means for applying the label to the second
web.
137. A product produced by the method of Claim 131.

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138. A method for producing laminated webs, comprising steps for:
providing a first web of material on a roll;
providing a second web of material on a roll;
applying a tensioning force on the first material by retarding the rate of
unwinding the first material;
bringing the first material and the second material together to expel
substantially all the air between the first and second material; and
laminating the first material to the second material to form a web composite.
139 The method of Claim 138, wherein the first material is made from a
substantially impermeable material.
140. The method of Claim 138, wherein the second material is made from a
permeable gas material.
141. A method for packaging a perishable good, comprising steps for:
providing a continuous conveyor;
placing a first web on the conveyor;
loading a perishable good on the conveyor;
locating the first web with the perishable good in a first vacuum chamber;
providing a composite web made from a second and third material, and;
sealing the composite web onto the first web under conditions of reduced
oxygen.
142. The method of Claim 140, further comprising a step for locating the
first web in a second chamber.
143. An apparatus for packaging a perishable good, comprising:
a continuous conveyor;

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means for holding a first web on the conveyor;
means for loading a perishable good on the first web;
means for locating the first web with perishable good in a first vacuum
chamber;
a composite web made from a second and third material, and;
means for sealing the composite web onto the first web under conditions of
reduced oxygen.
144. The apparatus of Claim 143, wherein the means for sealing is a
vacuum chamber.
145. The apparatus of Claim 143, wherein the means for holding a first
web, inwardly compress the walls of the web.
146. The apparatus of Claim 143, wherein the means for placing the first
web on the conveyor includes a sealing plate, wherein the walls of the first
web are
compressed inwardly.
147. An apparatus for packaging a perishable good, comprising:
a first chamber portion to carry a first web;
a second chamber portion, suitably adapted to mate with the first chamber
portion, thereby forming a vacuum enclosure;
means on the enclosure for evacuating the enclosure;
means on the enclosure for introducing a suitable gas at a suitable pressure;
means for carrying a second and third web, wherein the second web is
disposed between the third and the first webs, and the third web is disposed
above the
second web; and
means for sealing the second web to the first web and the third web to the
second web.

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148. The apparatus of Claim 147, further comprising means for bonding
the second web to the first web without bonding the third web.
149. A packaging tray, comprising:
a first web with a recessed portion, wherein said web includes a flange
portion with a first and second surface, wherein the first surface is bondable
to a
second web, and the second surface is bondable to the second and a third web.
150. A packaging tray, comprising:
a first web having a recessed portion, said web defining an upper peripheral
flange above said recess;
a second web bonded to the first web, and
a third web peelably bonded to the second web.
151. The tray of Claim 150, wherein the first web is made from a
substantially impermeable gas barrier material.
152. The packaging tray of Claim 151, wherein the first web is selected
from the group consisting of amorphous polyethylene terephthalate,
unplasticized
polyvinyl chloride, and polyvinylidene chloride.
153. The packaging tray of Claim 150, wherein the second web is made
from a gas permeable material.
154. The packaging tray of Claim 153, wherein the second web is selected
from the group consisting of plasticized polyvinyl chloride and polyethylene.
155. The packaging tray of Claim 150, wherein the third web is made from
a material that is substantially impermeable to gas.

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156. The packaging tray of Claim 155, wherein the third web is selected
from the group consisting of amorphous polyethylene terephthalate,
unplasticized
polyvinyl chloride and polyvinylidene chloride.
157. A packaging tray comprising:
a web material defining a base portion, upwardly and outwardly extending
sidewalls from the base, the sidewalk defining a recess portion, wherein the
sidewalk terminate at a substantially horizontal flange with relation to the
base.
158. The tray of Claim 157, further comprising an aperture that allows
communication between the recess portion and an exterior tray environment,
wherein
said communication is provided by an aperture located at a juncture portion of
two
sidewalls and the flange.
159. The packaging tray of Claim 157, further comprising a first and
second flap, disposed on opposite edges of the peripheral flange, said flaps
including
ridges and an aperture that provides communication between the recess portion
and
the exterior tray environment.
160. The packaging tray of Claim 159, further comprising protrusions on a
lower exterior surface of the base, wherein said protrusions are suitably
constructed
so as to mate with a top portion folded flap portion.
161. The packaging tray of Claim 159, further comprising a depressible
dimple on a flap portion to seal the communication between the interior recess
and
the exterior.
162. The packaging tray of Claim 157, further comprising a raised central
base portion, reinforcing ribs extending approximately the length of the base
portion

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and reinforcing ribs extending vertically approximately from the flange to the
base
portion of the sidewalk, at least a first and second flap foldably hinged at a
flange,
and an aperture to provide communication between the recess and the exterior
tray
environment.
163. The packaging tray of Claim 157, further comprising a one-way valve.
164. The packaging tray of Claim 157, further comprising a soaker pad
disposed on a lower surface of the base.
165. The packaging tray of Claim 157, further comprising at least one flap
connected to the flange, wherein the flap includes a plurality of buttresses
disposed
along the longitudinal length of the flap, channels interconnecting the
buttresses,
apertures located between a first and second channel, and apertures on tray
sidewalls
to provide communication between the recesses and the buttresses.
166. The packaging tray of Claim 165, further comprising apertures in the
base to absorb liquids in an open cell structure.
167. The packaging tray of Claim 166, further comprising a flap base,
wherein the flap base extends beyond the lower surface of the tray base, when
the
flap base is folded to lay adjacent one of the sidewalk.
168. The packaging tray of Claim 157, further comprising at least one
foldable flap, disposed on an edge of the flange, wherein the flap includes a
flap base,
which is substantially aligned with the tray base, when the flap is folded to
lie
adjacent to one of the sidewalls.
169. The packaging tray of Claim 157, further comprising at least one flap
connected at an edge of a flange, wherein the flap includes a first and second
peak,

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wherein an aperture is provided in a region between the first and the second
peak so
as to provide communication between the recess portion and the exterior tray
environment.
170. The packaging tray of Claim 157, further comprising at least one flap
connected to an edge of the flange, wherein the flap includes vertically
disposed
channels along an outside surface of the flap when the flap is folded over to
lie
adjacent one of the sidewalls.
171. The packaging tray of Claim 170, further comprising apertures located
on a recessed portion of the flap.
172. The packaging tray of Claim 171, further comprising an elevated base
so as to provide a depression on an underside of the packaging tray.
173. Any one of the packaging trays of Claims 149-172, further comprising
substances adhered to the base or in the space formed between the sidewall and
a flap
when in a folded position.
174. Any one of the packaging trays of Claims 149-172, wherein the web
material is made from expanded polystyrene sheet, and the base includes a
plurality
of apertures to absorb liquids.
175. The packaging tray of Claim 157, further comprising at least one flap
foldable to lie adjacent to a sidewall, and a cover made from a substantially
gas
barrier shrink material, wherein apertures are provided in the gas barrier
cover and a
peelable gas burner label is sealed over the apertures.
176. The packaging tray of Claim 157, further comprising at least one flap
connected to an edge of the flange, wherein upon folding of the flap to lie
adjacent to

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one of the sidewalls, a flap base is formed that suitably mates with an upper
portion
of a tray, so as to enable trays to be stacked atop one another.
177. A packaging container for packaging a plurality of packaged trays,
comprising:
a substantially impermeable gas barrier material defining a base and vertical
walls extending from the base to an upper horizontal flange, and;
a peelable lid attached to the flange.
178. The packaging container of Claim 177, further comprising an oxygen
scavenger located in the interior of the packaging container.
179. The packaging container of Claim 177, wherein the sealed portion
between the lid and the flange can be folded so as to accommodate the
container in
substantially similarly sized, but slightly larger packaging carton.
180. The packaging tray of Claim 157, further comprising at least one flap
connected to an edge of the flange, wherein the tray further includes a base
rim that
extends around the perimeter of the base, wherein depressions and perforations
can
be provided at the tray base.
181. The packaging tray of Claim 157, further comprising at least one flap,
foldable about a hinge, and an inner structural undulating member disposed
between
the sidewall and a flange surface so as to create a rigid wall.
182. The packaging tray of Claim 157, further comprising at least one flap
connected to the flange by a hinge, wherein the flap further includes a first
and
second corner flap connected at opposing edges of said flap.

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183. The packaging tray of Claim 157, further comprising at least one flap
connected to an edge of the flange, wherein the flap further includes a second
flap
connected by a hinge on a longitudinal edge of the first flap.
184. The packaging tray of Claim 157, further comprising vertical ribs
approximately from the flange to the base, wherein the ribs are formed on a
sidewall
such that they form a hollow space therein.
185. The packaging tray of Claim 184, wherein the rib is formed by a first
and a second tray half, such that the first tray half includes an inwardly
extending
portion of the rib and the second tray includes an outwardly extending portion
of the
rib, said first and second tray halves being bonded together to form the tray.
186. The packaging tray of Claim 184, wherein the outwardly extending
portion of the rib is formed by a separate member attached to one of a
plurality of
ribs.
187. The packaging tray of any of Claims 157, further comprising ribs,
wherein the ribs include a suitable gas therein.
188. The packaging tray of Claim 157, wherein the tray includes a plurality
of members bonded together to form a double wall structure, including
horizontal
ribs enclosed within a first and second wall.
189. The packaging tray of Claim 157, further comprising a first and
second hinge foldable to produce a semicircular flange about the perimeter of
the
tray, and including a bonded portion adjacent to the semicircular structure
bonded to
a tray wall near the upper portion of the wall.

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190. The packaging tray of Claim 157, further comprising ribs located on
the base portion, the tray sidewalls, and the tray flaps.
191. An apparatus for forming a tray, comprising:
a platen;
a fixture suitably formed to carry a preformed tray with flaps attached to the
tray, said fixture attached to the platen;
a plurality of members, suitably hinged to the fixture to fold said tray
flaps;
and
a suitable chamber to enclose the fixture including one or a plurality of
ports
to provide a suitable gas within the enclosed space or to provide a vacuum.
192. A method for forming a tray, comprising steps for:
providing a preform tray;
locating the preform on a fixture; and
applying a vacuum to secure the preform to the texture.
193. The method of Claim 192, further comprising the step for:
applying a suitable adhesive to a selected surface of one of a plurality of
flaps
of the preform and folding the flaps against the sidewalk of the preform.
194. A product made by the method of Claim 192.
195. The packaging tray of Claim 157, further comprising upwardly
projecting ribs so as to engage a tower portion of a second tray which
provides a
space between the base of the overlying tray and the goods contained in an
underlying tray.

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196. The packaging tray of Claim 157, further comprising a substantially
horizontal flange portion, and lateral ribs formed by a sidewall of the tray
and a flap
portion.
197. The packaging tray of Claim 196, further comprising apertures located
on a portion of the base to allow liquids to enter the cavity formed by the
tray
sidewall and the flap.
198. The packaging tray of Claim 197, further comprising ribs located on a
lower portion of the tray flap and bonded to the tray sidewall.
199. Any one of the packaging trays of Claims 157-198, made from
polyethylene terphthalate.
200. The packaging tray of Claim 157, further comprising a first and
second crest constructed from the flange portion.
201. The packaging tray of Claim 200, further comprising a radiused lower
base portion made to rest on the first and second crest.
202. The packaging tray of Claim 157, further comprising an indentation
constructed on a flap portion.
203. The packaging tray of Claim 157, further comprising a reduced
thickness portion at a foldable hinge to facilitate folding of flap.
204. The packaging tray of Claim 157, made from a single web material
having four flaps.
205. An apparatus for pumping grinds into a profiled conduit, comprising:
a tapered housing;

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a tapered screw rotatably mounted in the housing, such that the external
surfaces of the tapering screw can be profiled to match the internal surface
of the
housing, such that the surfaces are in close but not touching proximity; and
a piston, suitably mounted on the housing at an exit location, such that
piston
is provided with a radius surface that matches the external radius of the
screw, such
that when the piston is closed but not touching proximity to the rotating
screw, the
external surface of piston will be wiped by the outermost edges of screw as it
rotates,
such that the piston can eliminate any voids in the grinds.
206. The apparatus of Claim 205, further comprising a plurality of piston
arrangements disposed radially on an exit of the housing.
207. The apparatus of Claim 205, further comprising a profiled conduit for
shaping beef patties and a cutting means.
208. The apparatus of Claim 205, further comprising temperature control
means at an exit of the housing.
209. The apparatus of Claim 208, wherein the temperature is maintained at
a suitable temperature so as to cause a crust freezing of the external surface
of the
stream of grinds to provide an improved cutting condition for slicing by the
cutting
means.
210. A method for producing beef patties, comprising steps for:
providing a continuous stream of grinds to an entry point of a pumping
apparatus; and
a piston on an exit of the apparatus, so as to provide a retractable reservoir
for
the continuous stream to temporarily halt the motion of the stream of grinds,
to allow

-290-
a cutting means to cut a beef patty while the stream is halted then resume the
stream
by compressing the piston.
211. An apparatus for producing fine ground beef from course ground beef,
in an enclosed system that substantially excludes oxygen, comprising:
temperature control means;
a pump for propelling the beef; and
means for introducing a suitable gas at a suitable pressure into the
apparatus.
212. An apparatus for slicing beef in a substantially oxygen deficient
environment, comprising:
pumping means to move ground beef in an enclosed conduit;
a cutting means located at an exit of the conduit;
a conveyor located adjacent to the cutting means;
plugs containing an iron core; and
electromagnetic rings mounted to a drive mechanism for each of said plugs,
wherein the movable rings control the movement of the beef so that said beef
can be
portioned according to thickness or to weight.
213. The packaging tray of Claim 157, further comprising a first and
second flap, wherein the first flap is opposite of the second flap on a side
of the tray,
and the flaps are foldable such that each of said flaps can be bonded to an
upper
surface of the tray flange.
214. The packaging tray of Claim 213, further comprising a web sealed
along the perimeter of the tray flange, wherein the web includes one or a
plurality of
apertures to enable the exchange of gases between the interior of the tray and
the
outside atmosphere.

-291-
215. The packaging tray of Claim 157, further comprising a tray cover to
mate with the tray flange, wherein the upper surface of the tray cover
provides a
viewing window to view the interior contents, said tray cover lower perimeter
defining a flange to bond to a lower web material, said material being bonded
to the
tray flange.
216. The packaging tray of Claim 215, further comprising a plurality of
recesses formed from the tray cover ridges to provide for the exchange of
gases
between stacked trays.
217. The packaging tray of Claim 215, further comprising a recess around
the exterior base portion to mate with a ridge formed on the upper cover.
218. The packaging trey of Claim 215, further comprising grooves on an
edge of the tray cover, apertures on the sealing web, and a plurality of
slots, to enable
the exchange of gas between the tray recess and the tray exterior environment.
219. The packaging tray of Claim 215, wherein the tray cover is hinged to
the tray at a reduced hinge formed from the tray flange.
220. A master gas barrier container, comprising a plurality of stacked
finished packages which has been hermetically sealed after substantially all
the
oxygen has been evacuated and replaced with a suitable gas which is
substantially
oxygen free.
221. The packaging tray of Claim 157, further comprising:
vertical ridges disposed on a sidewall, said ridges having an upper horizontal
surface extending from said flanged:

-292-
one or a plurality of flaps, said flaps including ridges having a defined
surface
area so that the surface area of the sidewall is adjacent and below the
surface area of
the flap when the flap is folded to lie adjacent to the upper flange surface.
222. The packaging tray of Claim 157, further comprising:
apertures located in the base portion, so as to absorb any liquids in the open
cell structure.
223. The packaging tray of Claim 157, further comprising depressions in
the tray base, such that the inner layer of tray base includes an open cell
structure that
will absorb liquids when the liquids contact said depressions.
224. The packaging tray of Claim 157, further comprising:
a flap hingedly attached to the tray cavity by a sealing web.
225. The packaging tray of Claim 157, further comprising:
at least one flap hinged to a portion of the flange, such that upon folding
the
flap to lie adjacent to the tray sidewall, a space is formed between the
exterior of the
tray sidewall and the flap;
an aperture provided at a lower portion of the tray sidewall to provide
communication between the interior tray cavity and the space;
an aperture provided along a portion of the flap to provide communication
between the space and the exterior environment.
226. The packaging tray of Claim 157, further comprising:
one or a plurality of flaps hingedly attached to a portion of the flange,
wherein the flaps are inwardly foldable;
at least one or a plurality of depressions and perforations formed on the tray
base; and

-293-
wherein the tray is suitable to be placed in a shrink bag for sealing therein.
227. The packaging tray of Claim 157, further comprising depressions:
at least one or a plurality of flaps attached to an outer edge of the flange;
a radiused portion formed on a flap, and a recess portion formed on the
exterior tray sidewall, such that when the flap is folded to lie adjacent to
the tray
sidewalk the radiused portion mates with the recessed portion.
228. The packaging tray of Claim 157, further comprising:
a flap base that corresponds to the profile of a tray flange, such that trays
can
be stacked atop one another without damaging contents of a lower packaged
tray.
229. The packaging tray of Claim 157, further comprising:
a heat sealable lip to maintain the flap in a tray adjacent position.
230. A method of making packaging trays, comprising steps for:
providing a preformed web of material for forming into a packaging tray;
cutting in place, scrap material to form a plurality of flaps; and
bonding the flaps to a corner of the tray cavity and to an adjacent flap.
231. The packaging tray of Claim 157, further comprising:
at least one ridge on a tray sidewall;
at least one recess on a flap, wherein a suitable bonding material is applied
on
the ridge or recess to bond the flap to the tray sidewall, and wherein said
bonding
occurs under the influence of a heat source, such as microwave, radio or
magnetic
field emitting devices.
232. The packaging tray of Claim 231, wherein the bonding adhesive is
applied by suitable ink jet means.

-294-
233. A method for evacuating a master container, comprising steps for:
providing a gas barrier material;
packaging said material with one or a plurality of finished packages;
evacuating and flushing said master container with a suitable gas and at a
suitable pressure and temperature to substantially remove oxygen from within
the
master container and from within the finished packages;
sealing a gas barrier lid on the master container.
234. An apparatus for evacuating a master container, comprising:
a lower vacuum chamber;
an upper vacuum chamber with a movable heat bank, attached to a driver;
a web unwinding assembly arranged to allow controlled unwinding of web
material from a roll; and
at least one or a plurality of conduits for evacuating said chamber and
providing a suitable gas at a suitable temperature and pressure.
235. The apparatus of Claim 234, wherein a series of apparatus are
arranged in a carousel-style assembly.
236. An apparatus for forming master containers, comprising:
a web material supply assembly;
means for thermoforming master containers;
means for punching holes in the lower web located between containers;
means for loading finished packages into the master container;
at least one or a plurality of upper chambers;
at least one or a plurality of lower chambers, wherein said upper and lower
chambers can be closed around a master container to substantially evacuate the

-295-
container of oxygen and provide a suitable gas at a suitable temperature and
pressure
to allow said gas to dissolve into, said packaged goods.
237. The method of Claim 236, wherein the pressure of the gas is greater
than zero to about 200 psi.
238. An apparatus for grinding and conditioning beef, comprising:
a vessel having an entry and an exit point;
a grinding head attached to the vessel entry point, wherein a cutter is
located
at the entry point and compacted meat provides a substantially gas tight seal
at the
entry point to provide for the pressurization of the vessel;
a first screw auger to carry meat to the cutter; and
a second screw auger located at a lower portion of the vessel so as to carry
the
meat forward to the exit point, wherein the vessel is substantially filled
with a
suitable gas at a suitable pressure and temperature so as to cause the
dissolution of
said gas into said ground meat.
239. The apparatus of Claim 238, wherein a suitable profile is formed at
the exit point.
240. The apparatus of Claim 238, wherein the vessel is jacketed vessel
wherein a cooling or heating medium can recirculate about the jacket thus,
heating or
cooling the vessel contents.
241. The apparatus of Claim 238, further comprising:
an injection point at the grinding head to provide a concentrated solution of
carbonic acid.
242. The apparatus of Claim 238, further comprising:

-296-
a conduit located downstream of the vessel wherein a carbonic acid solution
may be sprayed onto portions of meat while passing through the conduit.
243. The apparatus of Claim 238, further comprising:
means for collecting liquid;
means for reducing bacteria in the liquid at a suitable temperature;
means to dissolve carbon dioxide in said liquid; and
means to apply the liquid onto the perishable goods.
244. A method for producing a goods stream having a desired
concentration of a suitable measurable variable, comprising steps for:
feeding a first stream of goods to a first device capable of measuring a
suitable variable;
feeding a second stream of goods to a second device capable of measuring a
suitable variable;
joining the first and second streams after measuring the variable of each
stream to form a third stream; and
feeding the third stream to a blending device to form a fourth stream having a
substantially uniform cross-sectional composition.
245. The method of Claim 244, wherein the streams are provided in
substantially enclosed conduits that minimize contact with oxygen.
246. The method of Claim 244, further comprising a step for measuring the
resulting measurable variable of the fourth stream.
247. The method of Claim 244, wherein the steps of feeding the first,
second, and third streams occurs substantially simultaneously.

-297-
248. The method of Claim 244, further comprising a step for diverting the
fourth stream to one of a plurality of vessels based on the measured variable
measured after the blending step.
249. The method of Claim 244, further comprising the step of returning all
or a portion of the fourth stream to the first or second goods streams.
250. The method of Claim 244, further comprising the step of returning all
or a portion of the fourth stream as a third feed stream to the blending
device.
251. The method of Claim 244, wherein the measured variable of the
fourth stream is controlled by increasing the flow rate of the first or the
second
stream or both substantially simultaneously with feeding the third stream.
252. The method of Claim 244, wherein the measured variable of the
fourth stream is controlled by decreasing the flow rate of the first or the
second
stream or both substantially simultaneously with feeding the third stream.
253. The method of Claim 244, wherein the measurable variable is the
approximate fat, lean tissue, or water content of the goods.
254. The method of Claim 244, further comprising a step for grinding the
goods of the first and the second streams before the step of feeding the first
or the
second streams to the first and second devices.
255. The method of Claim 254, further comprising the step of reducing
bacteria on the goods, with an agent, prior to the grinding step.
256. The method of Claim 255, wherein the agent comprises a halogen.
257. The method of Claim 256, wherein the agent comprises chlorine.

-298-
258. The method of Claim 257, wherein the agent comprises an acid and
sodium chlorite.
259. The method of Claim 258, wherein the acid is an organic acid.
260. The method of Claim 259, wherein the acid is citric acid.
261. The method of Claim 255, wherein the agent comprises ozone.
262. The method of Claim 244, further comprising treating the first and
second streams with radiation selected from the group consisting of E beam, X-
ray
and ultraviolet C.
263. The method of Claim 244, further comprising a step for exposing the
first and the second streams to a selected gas during the grinding step.
264. The method of Claim 263, wherein the gas comprises carbon dioxide
or nitrogen.
265. The method of Claim 244, further comprising a step for exposing the
first and second streams to a selected gas.
266. The method of Claim 254, further comprising a step for exposing the
first and second streams to a selected gas, prior to grinding.
267. The method of Claim 254, further comprising a step for mixing the
goods after the grinding step and before the measuring step.
268. The method of Claim 267, further comprising a step for exposing the
first and second streams to a selected gas during the mixing step.

-299-
269. The method of Claim 268, wherein the gas is carbon dioxide or
nitrogen.
270. The method of Claim 244, further comprising a step for containing the
first and the second streams in an enclosed vessel before the feeding steps to
allow
continuous feeding through an enclosed conduit while substantially minimizing
escape of any gas provided in the vessel.
271. The method of Claim 270, further comprising a step for exposing the
goods to a selected gas during the containing step.
272. The method of Claim 271, wherein the gas comprises carbon dioxide
or nitrogen.
273. The method of Claim 244, further comprising a step for exposing the
goods to a selected gas during the blending step.
274. The method of Claim 273, further comprising a step for removing
water from the gas during the blending step.
275. The method of Claim 273, wherein the gas comprises carbon dioxide
or nitrogen.
276. The method of Claim 244, further comprising a step for grinding the
fourth stream.
277. The method of Claim 276, further comprising a step for exposing the
goods to a selected gas during the grinding step.
278. The method of Claim 277, wherein the gas comprises carbon dioxide
or nitrogen.

-300-
279. The method of Claim 244, wherein the first stream comprises a
plurality of two or more goods streams.
280. The method of Claim 279, further comprising the step of treating the
plurality of streams under ultraviolet radiation.
281. The method of Claim 244, where the second stream comprises a
plurality of two or more goads streams.
282. The method of Claim 281, further comprising the step of treating the
plurality of streams under ultraviolet radiation.
283. The method of Claim 244, wherein the first stream has a lower
percentage of the measurable variable in comparison with a higher percentage
in the
second stream.
284. The method of Claim 283, further comprising a step for substantially
simultaneously blending the third stream to produce the fourth stream to have
a
measured composition that is between the low percent of the first stream and
the high
percent of the second stream.
285. The method of Claim 244, further comprising the step of substantially
simultaneously forming a plurality of blended streams from the first and the
second
goods stream in a plurality of blending devices.
286. The method of Claim 285, further comprising a step for substantially
simultaneously and automatically controlling the measurable variable of the
plurality
of blended streams by increasing or decreasing the flow rates of the first or
the
second stream or both to each of the blending devices.

-301-
287. The method of Claim 244, wherein the fourth stream feeds a
controlled atmosphere packaging system.
288. The method of Claim 244, wherein the feeding of the first and the
second stream is carried out by pumps that suitably compensate for surge of
the
streams.
289. The method of Claim 244, wherein the flowrate of the first and second
streams is controlled to provide a fluid stream of substantially constant
content,
before the blending device.
290. The method of Claim 244, further comprising the step of reducing
bacteria with an agent before the blending step.
291. The method of Claim 290, wherein the agent comprises a halogen:
292. The method of Claim 291, wherein the agent comprises chlorine.
293. The method of Claim 292, wherein the agent comprises an acid and
sodium chlorite.
294. The method of Claim 293, wherein the acid is an organic acid.
295. The method of Claim 294, wherein the acid is citric acid.
296. The method of Claim 290 wherein the agent comprises ozone.
297. A product made by the method of Claim 244.
298. An apparatus, comprising:
dissolve a suitable gas that minimizes the formation of oxymyoglobin on the
goods;

-302-
a transfer tube;
means for measuring the content of a suitable variable of the propelled goods;
means for blending the goods in a selected gas, wherein said goods come
from a plurality of grinding means, for producing a goods stream having the
blended
fat content of the plurality of streams.
299. The apparatus of Claim 298, further comprising means for controlling
the temperature of the goods.
300. An apparatus for pumping blended goods comprising:
means for propelling goods in an enclosed conduit and for compressing goods
to eliminate voids containing a suitable gas that dissolves into the goods,
said gas
being capable of reducing the formation of oxymyoglobin on the goods;
means for reducing the exiting flow rate of the propelled goods by means
which expand the volume of the conduit; and
means for shaping the goods leaving the conduit.
301. An apparatus for grinding goods, comprising:
a vessel including an entry and an exit, wherein the vessel defines a
longitudinal housing;
a member with a continuous spiraling edge portion rotatably mounted within
the housing, said edge portion being substantially flush with walls of said
housing;
at least one reciprocating piston mounted on a housing chamber, said
chamber being located approximately at said vessel exit.
302. An apparatus for grinding goods, comprising:
means for grinding goods;

-303-
means for containing the ground goods in a substantially enclosed
environment;
means for introducing a selected gas into the means for containing the goods;
and
means for propelling the goods in an enclosed conduit and for compressing
goods to eliminate voids containing the selected gas that dissolves into the
goods.
303. The apparatus of Claim 302, further comprising a second means for
grinding the goods exiting the conduit.
304. The apparatus of Claim 302, further comprising means for shaping the
propelled goods leaving the conduit.
305. An apparatus for grinding meat, comprising:
a vessel having an entry and exit point for meat;
a meat grinding head attached to the entry point;
a conduit leading to the entry point, said conduit including an auger for
propelling meat through the grinding head and into the vessel;
a second auger mounted at a lower portion of the vessel for discharging the
contents of the vessel to an exit conduit; and
at least one port on the vessel for introducing a suitable gas that reduces
the
formation of oxymyoglobin on the goods.
306. The apparatus of Claim 305, wherein the exit conduit has a selected
cross-sectional profile.
307. The apparatus of Claim 305, wherein the exit conduit further
comprises a valve.

-304-
308. The apparatus of Claim 305, wherein the exit conduit further
comprises a second grinding head.
309. The apparatus of Claim 308, wherein the second auger comprises a
plurality of apertures to introduce a selected gas.
310. An apparatus for blending goods, comprising:
a plurality of means for grinding and feeding a plurality of goods streams;
means for blending each one of the plurality of streams into a stream of
substantially uniform cross-sectional composition; and
means for introducing a selected gas to contact the goods.
311. An apparatus for blending meat, comprising:
a vessel having an entry pint and an exit point for the meat;
a plurality of augers disposed longitudinally inside the vessel to blend the
meat from one or a plurality of incoming feed streams;
a port on the vessel for introducing a selected gas;
a blower in communication with the interior of the vessel to propel the gas
through a gas entry and gas exit point; and
a heat exchanger in communication with the interior of the vessel to remove
accumulated liquids in the gas.
312. The apparatus of Claim 311, further comprising twin augers meshing
inside a conduit, wherein the external surfaces are in close proximity to an
internal
conduit surface.
313. An apparatus for blending meat, comprising:
a plurality of conduits each having an entry point and an exit point for the
meat;

-305-
a plurality of augers disposed longitudinally inside each conduit to blend the
meat from one or a plurality of incoming feed streams into a plurality of
streams each
of substantially uniform cross-sectional composition;
an enclosure surrounding the plurality of vessels; and
a port on the enclosure for introducing a selected gas.
314. An apparatus for blending goods, comprising:
means for grinding and feeding a goods stream
means for blending the stream into a stream of substantially uniform cross-
sectional compositions;
means for containing the goods in contact with blending means;
means for introducing a selected gas;
means for removing accumulated liquids in the gas; and
means for propelling the gas through the liquid removing means.
315. The apparatus of Claim 314, further comprising:
means for returning the liquid to the means for blending.
316. The apparatus of Claim 315, further comprising:
means for reducing bacteria of the liquids.
317. A system for controlling a measurable variable in the production of
goods, comprising:
means for feeding a first stream of goods in an enclosed conduit to a first
device capable of measuring a suitable variable;
means for feeding a second stream of goods in an enclosed conduit to a
second device capable of measuring a suitable variable;

-306-
means of joining the first and second streams in an enclosed conduit after
measuring the variable of each stream, at a confluence to form a third stream;
and
means for feeding the third stream in an enclosed conduit to a blending device
to form a fourth stream having a substantially uniform cross-sectional
composition
wherein the feeding of the first, second, and third streams occurs
substantially
simultaneously.
318. The system of Claim 317, further comprising means for controlling
the flow rate of the first and second streams to thereby control the fourth
stream's
composition.
319. The system of Claim 318, further comprising means for measuring the
fourth stream's composition.
320. The system of Claim 319, further comprising means for diverting the
fourth stream in an enclosed conduit to one of a plurality of vessels.
321. The system of Claim 317, further comprising means for grinding the
goods of the first and second streams before feeding to the measuring devices.
322. The system of Claim 317, further comprising means for reducing
bacteria in the goods before, after, or during blending the goods.
323. The system of Claim 317, further comprising means for contacting a
suitable gas with the goods, before, during, or after blending the goods, that
reduces
the formation of metmyoglobin on the goods upon exposure to ambient
atmospheres.
324. The system. of Claim 317, further comprising means for packaging the
fourth stream of goods in controlled atmosphere packages.

-307-
325. The system of Claim 317, further comprising means for diverting a
stream of goods.
326. An apparatus for blending goods, comprising:
a vessel defining a first radiused portion and a second radiused portion, the
first radiused portion being larger than the second radiused portion;
a plurality of inlets to the first radiused portion for introducing goods;
a rotating member having a plurality of arm members that are in close
proximity to the walls of the first radiused portion said arm members defining
a
constant volume between each of said arms;
a driver to rotate said rotating member; and
an auger having a continuous spiraling edge in close proximity to the walls of
the second radiused portion to propel the goods out of the vessel.
327. The apparatus of Claim 326, further comprising a plurality of inlets to
the first radiused portion for introducing a suitable gas to the first
portion.
328. An apparatus for processing goods, comprising:
a vessel having an entry and an exit for the goods;
a first port to introduce a first selected gas on a first end of the vessel;
a second port to introduce a second selected gas on a second end of the
vessel; and
a third port located between the first and the second port to remove the first
and second gases;
wherein the vessel entry and exit are plugged with the goods to minimize the
escape of the selected gases.

-308-
329. The apparatus of Claim 328, wherein the first gas is ozone and is
introduced near the vessel's entry.
330. The apparatus of Claim 328, wherein the second gas is carbon dioxide
and is introduced near the vessel's exit.
331. A method for producing one or more separately selected, quantities of
goods each having a desired concentration of a suitable measurable variable,
comprising steps for:
providing a first quantity of goods comprising at least first and second known
variables of unknown relative concentrations but where the first variable
comprises a
greater relative amount when compared to the first variable of a second
quantity of
goods comprising at least first and second known variables of unknown
concentrations;
providing a second quantity of goods comprising at least first and second
known variables of unknown relative concentrations but where the first
variable
comprises a lesser relative amount when compared to the first variable of the
first
quantity of goods;
feeding the first quantity of goods into a first vessel containing ozone gas;
feeding the second quantity of goods into a second vessel containing ozone
gas;
transferring said first quantity of goods, after substantially removing said
ozone gas, from said first vessel in a first stream of goods in an enclosed
conduit to a
first device capable of measuring said first variable;
transferring the second quantity of goods, after substantially removing said
ozone gas, from said second vessel in a second stream of goods in an enclosed
conduit to a second device capable of measuring a suitable variable;

-309-
joining the first and second streams in an enclosed conduit after measuring
the variable of each stream to form a third stream; and
feeding the third stream to a blending device to form a fourth stream having a
substantially uniform cross-sectional composition.
332. The method of Claim 331, wherein the goods are ground meat and the
first component is ft and the second component is lean tissue.

Description

DEMANDE OU BREVET VOLUMINEUX
LA PRESENTE PARTIE DE CETTE DEMANDE OU CE BREVET COMPREND
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CA 02387349 2002-04-03
WO 01/30655 PCT/US00/29038
PRODUCTS, METHODS AND APPARATUS FOR FRESH MEAT
PROCESSING AND PACKAGING
Field of the Invention
The present invention relates to products, methods, apparatus, and the
products made therefrom used for processing and packaging perishable foods and
particularly to processed perishable foods that are packaged in plastic food
trays that
are overlaid with one or more layers of sealable plastic materials. The
present
invention also relates to apparatus for processing and pre-treating perishable
foods
and associated packaging with gases.
Background of the Invention
For the entire history of fresh red meat processing for human consumption,
where slaughtered, eviscerated, and chilled carcasses are produced in the
normal
process, improvements in terms of reducing labor and or reducing costs of the
process, have been sought. Few major improvements have been achieved in the
recent past and it is a purpose of this present invention to expose
opportunities and to
provide methods, apparatus and products of improving the efficiency and
competitiveness of the red meat industry. Such opportunities are epitomized
by, for
example, the condition that all carcasses contain a great deal of bone and
other
materials that are not used for human consumption and yet the entire carcass
must be
chilled prior to further processing, in order to chill those parts that are
used for
human consumption. Furthermore, the shape of all animals used for human
consumption are of irregular and inconvenient profile. Conversely, packaging
trays
that have been cost effectively and efficiently manufactured, are invariably
rectangular and/or square in profile. By adopting procedures disclosed herein
it will

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-2-
be seen that costs of chilling are reduced since, for example, the skeleton
can be
removed before chilling thereby saving costs of such chilling process. Fresh
red
meat tissue is typically quite soft and easy to cut immediately after the
animal has
been slaughtered and prior to the natural, "hardening" effects of rigor mortis
has
occurred. It can therefore be easier and quicker to cut primal portions from
animal
carcasses, during the normal animal "disassembly" process prior to rigor
mortis and
chilling. Those fresh red meat primal items, that are intended for human
consumption, can then be shaped by placing into molds of a specifically
designed
and desired profile prior to rigor mortis and then chilled during the natural
rigor
mortis process. This device will provide a method to change and adjust the
shape of
fresh red meat primal items so that, for example, fresh red meat primal items
can be
readily and automatically processed during the slicing and cutting process as
required
prior to packaging. Furthermore, profiles of primal meat portions can be
arranged so
as to be more convenient when slices of fresh red meat primal items are loaded
into
improved packaging, such that more can be loaded into improved packaging while
still maintaining a space efficient, appealing and attractive appearance for
the
consumer at the point of retail display andlor foodservice outlet.
Typical modified atmosphere packages for fresh foods, such as red meats and
other perishable foods, having a limited shelf life, typically include a
thermoformed
tray or other package composed of EPS/tie/PE (barrier foam trays) plastics
material
or other suitable substantially gas impermeable material, i.e. tray, overlaid
with a
single transparent web of plastics material that can be heat sealed to the
tray. A
typical substantially gas impermeable heat sealable composite web includes a
biaxially oriented polyester (PET) layer/tie layer/gas barrier layer (such as
PVDC) an
adhesive layer/heat sealing layer (such as polyethylene), which in turn is
finally
adhered by a heat sealer to the tray. The polyethylene layer is a heat
sealable layer
that is tied to a gas barrier layer such as polyvinylidene chloride which is
in turn
adhered to polyester. Because of the diverse types of materials that are
employed in
the foregoing package, it is difficult to reprocess and recycle the post-
consumer
package. Moreover, the cost associated with post-consumer recycling of
multiple
layer plastics material renders the process impractical and substantially not
economically feasible.
Commonly used modified atmosphere packages for fresh foods such as red
meats and other perishable foods having a limited shelf life typically
comprise a tray
thermoformed from a sheet of EPS (expanded polystyrene) laminated to a web of

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-3-
substantially gas impermeable web material or other suitable substantially gas
impermeable material. A lid, such as a single or composite transparent web of
plastics material that can be bonded to the flanges of the tray. Both tray and
lid
materials are typically substantially gas impermeable heat sealable composite
structures and cannot be readily recycled. Lid material typically comprises a
laminated structure including several layers such as bi-axially oriented
polyester
bonded to a gas barrier layer (such as PVDC) which is sandwiched between an
adhesive or heat sealing layer (such as polyethylene). Because of the diverse
types of
materials that are employed in the foregoing package, it is difficult to
reprocess and
recycle the "post-consumer" package. Moreover, the cost associated with
post-consumer recycling of multiple layer plastics material, such as the
aforementioned, renders the process impractical and substantially not
economically
feasible.
A further limitation of packaging perishable goods such as fresh red meats in
hermetically sealed gas barrier packages results from the need to enclose a
relatively
large volume of gas, and particularly carbon dioxide, within the package.
Clearly,
consumers have no interest in purchasing these gases that accompany the red
meat.
Minimizing the size and bulky appearance of such packaging is desirable,
therefore it
is a goal to reduce the overall size and volume of the packaging to a minimum
size.
Additionally, a major proportion of red meat production occurs at locations
that are
located at a substantial distance from the point of retail sale of red meats
to
consumers. Most US beef is produced in the central plains around Kansas,
Nebraska
and Iowa and the major markets are situated on the coastal regions such as New
York
or California. Costs of shipping these fresh red meat items from the point of
production and packaging can be reduced if the packages are reduced in volume.
However, reduction in the volume of gases provided within a package can have a
deleterious effect on shelf life of the perishable goods and red meat
contained therein.
Typical methods used for production of ground meats and patties, that are
substantially composed of fat, muscle tissue, protein and water, have remained
unchanged for many decades and are inefficient when compared with other food
production methods that are commonly applied in other industries. These
inefficiencies that result in large part from poor controls and questionable
safety
standards, often cause significant and unnecessary wastage of meat in addition
to
occasional loss of human life.

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A limitation of producing perishable goods such as fresh beef patties at the
point of source animal slaughter results from shelf life limitations inherent
with
current packaging systems. A major proportion of beef patties production
occurs at
locations that are situated at a substantial distance from the point of sale
of these
products. Beef patties are often produced at locations remote from the point
of
slaughter due to short shelf life.
The packaging industry has therefore felt the need for simplified individual
packaging structures that will provide finished package performance including
label
requirements for a variety of applications. Additionally, if the packaging can
be
handled economically both in the pre-consumer handling and in post-consumer
recycling, significant economic advantages are available.
With conventional packaging of meats and other perishable type goods, the
shelf life is limited due to bacterial growth within the package. The growth
can be
inhibited when the package contains carbon dioxide gas, however, carbon
dioxide
will dissolve in liquids such as water contained within the goods in the
package.
After time, carbon dioxide can become substantially dissolved in the water and
shelf
life may be limited by this. After time, discoloration due to formation of,
for
example, metmyoglobin on the outer surface of the red meat also reduces
consumer
appeal of the packaged goods. It is also known to provide other gases within
the
package to enhance the keeping of the packaged goods. In the case of red meat
blends of C02 and Nz, in varying proportions and up to 100% of each single gas
have
been used. When carbon dioxide dissolves into liquids and water, this can
cause the
package to collapse inwardly. Collapsing causes the appearance of the package
to be
unacceptable to consumers and can also cause the package to rupture.
In order to extend shelf and storage life of the packaged goods several
inventions have been disclosed and examples of known packaging for this
purpose
are given in the following US Patents:
5,779,832 Kocher Method and Apparatus for making a peelable film
5,629,060 Garwood Packaging with Peelable Lid
5,560,182 Garwood Packaging Method
5,534,282 Garwood Packing Perishable Goods

CA 02387349 2002-04-03
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-S-
5,514,392 Garwood Packaging for Perishable Goods
5,323,590 Garwood Method of producing food packaging with gas between
tensioned film and lid
5,226,531 Garwood Food Packaging with gas between tensioned film and Lid
5,155,974 Garwood Food Packaging with gas between tensioned film and Lid
5,115,624 Garwood Thermoplastic skin packing means
5,129,512 Garwood Packaging
The subject matter of the above patents is hereby incorporated by reference.
Prior art as described in USP 5,779,832 to Kocher, discloses a method of
making a multilayer peelable film. Kocher discloses a method of co-extruding
two
webs of material simultaneously in the form of a multilayer film that can be
delaminated into a third web and a second web and then after treating the
second web
to improve gas permeability therethrough, re-laminating the third and second
webs
together. These two re-laminated webs can be sealed to a first web of gas
barrier
material and thereby produce a package. The first web may have a depression
formed therein into which goods such as red meat can be placed before heat
sealing
the third and second webs to the first web. Typically, goods will not
completely fill
the depression and space will remain in the depression in addition to the
goods. A
blend of gases or a single gas such as C02 can be provided in the space with
the
goods and thereby can contact the goods. After storage and prior to retail
display at
an intended point of sale to consumers, the third web can be peeled from the
package
allowing atmospheric oxygen to permeate the second web of gas permeable
material
and to contact the goods. The atmospheric oxygen can then allow generation of
a
bright red colored substance such as oxymyoglobin thereby providing an
appearance
attractive to the consumers.
It has been found that when applying the second and third webs extruded in
the manner as disclosed in Kocher to packaging as that disclosed in the
inventor's
own U.S. Patent No. 5,534,282, a dull appearance of the second web can result
with
reduced clarity when compared with other webs of material that are produced in
a
single web such as plasticized PVC (pPVC). Furthermore, after removal of the
third
web, from the re-laminated co-extrusion, by peeling, as described in U.S.
Patent

CA 02387349 2002-04-03
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-6-
No. 5,534,282, distortions and ripples can appear in the second web. This
occurs,
partly, as a result of inadequate lateral tension provided in the second web
when
limited by the inherent limitations of co-extruding the second and third webs
simultaneously. This can, therefore, severely detract from the visual
appearance of
the package in the eyes of consumers.
A further limitation of packaging perishable goods such as fresh red meats in
hermetically sealed gas barrier packages results from the need to enclose a
relatively
large volume of gases, and particularly carbon dioxide, within the package.
Clearly,
consumers have no interest in purchasing gases with red meat and minimizing
the
size and bulky appearance of the package is desirable. Additionally, a major
proportion of red meat production occurs at locations that are situated at a
substantial
distance from the point of sale for red meats. Costs of shipping the goods
from point
of production and packaging can be reduced if the packages are reduced in
size.
However, reduction in the volume of gasses contained within a package can have
a
deleterious effect on the shelf life of perishable goods and red meats
contained
therein.
Conventional modified atmosphere "case ready" retail packaged fresh red
meats and other perishable type goods experience limited shelf life because of
bacterial growth, such as aerobic and anaerobic bacteria, on the packaged
goods;
rancidity "off flavors" caused, in part, by oxidizing fats; and discoloration
to visible
meat surfaces. The growth can be inhibited when goods are treated by exposure
to
certain agents prior to packaging and then providing certain gasses and/or
other
agents with the goods within the finished and sealed package. Such a gas,
blend of
gasses agent or agents may include one or a combination of the following:
oxygen,
carbon dioxide, ozone, hydrogen, nitrogen, argon, krypton, neon, helium,
xenon,
hydrogen peroxide, potassium permanganate, chlorine dioxide, fluorine,
bromine,
iodine and/or any other suitable substances. However, some gasses such as
carbon
dioxide gas, for example, can quickly dissolve in substances such as oils and
water
contained in the goods. After time, carbon dioxide can become substantially
dissolved in water which may limit shelf life. Furthermore, when oxygen is
present
and more particularly when a quantity of approximately 5,000 to 30,000 parts
per
million of oxygen is present in a gas within a package, discoloration due to
formation
of metmyoglobin on the visible surface of red meat, reduces consumer appeal of
the
packaged goods. When carbon dioxide dissolves (into another substance) the
combined volume of the residual substances is substantially reduced which can
cause

CA 02387349 2002-04-03
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the package to collapse inwardly. Collapsing causes the appearance of the
package
to be unacceptable to consumers and can also cause the package to rupture and
render
it unfit for use. In compensating for such a deleterious event, several
existing
packaging systems require large volumes of gas to be packaged with the goods.
However, when large volumes of gas are provided, the resultant "bulky"
condition
does not provide for cost efficient shipping and distribution from the
location of
packaging to the point of retail sale of the packaged goods.
Conventional packages for red meat are produced in one or more sizes.
When packaging red meats or other perishable goods, the package must conform
to
the goods. Therefore, if a red meat portion is too large for one size of a
package, the
next larger size must be used. Oftentimes, this will lead to an overly large
sized
package introducing inefficiency into the process because of the wasted space.
In
order to maximize efficient use of the internal space available in a typical
road, rail or
sea, refrigerated shipping container or trailer, it is important to increase
the density
and unit weight per unit volume of the packaged perishable goods. The
maximized
efficient use of the space in the shipping containers can be achieved by
adjusting the
shape of the inconveniently shaped animal fresh red meat primal portions such
that
slices of the fresh red meat primal portions will fit and substantially fill
the available
space within trays of the improved packaging.
High oxygen case ready packages are inefficient, in large part, due to the
inherent need to include a quantity/volume of gas that is equal to, or greater
than the
volume of the package meat contents. For example, a high oxygen package
comprising a barrier foam tray and clear barrier film lid, hermetically sealed
to
flanges of the barrier foam tray and with a 21b quantity of meat sealed
therein will
require approximately 1 liter of gas to be enclosed and sealed within the
package to
ensure that an approximate 10 day shelf life extension can be provided. Said
gas
(referred to as modified atmosphere) will typically comprise 80% Oxygen and 20
Carbon Dioxide but other combinations that may include relatively small
quantities
(say <10%) of residual atmospheric nitrogen are also typical. The relatively
high
level of C02 (when compared to ambient atmosphere) is provided to inhibit
bacterial
growth, and with good storage temperature control a shelf life for sound,
fresh meat
can be extended to over 10 days from packaging. The bacterial controlling
effect is a
consequence, in part, of a characteristic of bacteria entering a "lag phase"
when the
environment in which it is placed, significantly changes... eventually the
bacteria will
equilibrate and adapt to the atmosphere that is present and commence normal

CA 02387349 2002-04-03
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_g_
reproduction and extended infection. The shelf life extension will vary
according to
several factors including, for example, the following: storage temperature ie:
the less
variation from a minimum temperature of approximately 29.Sdegrees F is
optimum,
(while ensuring that freezing of the meat, which occurs at about 26 - 27
degrees F,
does not occur); the condition and age of the meat at packaging, the
conditions at the
point of packaging such as hygiene, temperature etc., muscle type and age of
animal
from which the meat was harvested. Nevertheless, a shelf life extension of 10
days is
readily reproducible when conditions are maintained as required. After a
relatively
short period of time, the C02 provided within the package will dissolve into
the
water and oils contained in the meat and the oxygen is present to ensure that
a
consumer appealing/acceptable "bloom: or "redness" is maintained. The "bloom"
is
caused by the natural color of oxymyoglobin and oxyhemoglobin that is present
in
freshly cut meat but when oxygen is present, after approximately 9 to 10 days
discoloration such as browning due to increased levels of surface
metmyoglobin, will
occur, rendering the product unsaleable or requiring a reduction in price to
sell to a
consumer. Furthermore, the excessive volume of the finished packages, results
in
excessive packaging material and shipping costs and display case space at
retail
outlets and also excessive costs incurred for disposal of additional cardboard
etc. at
the supermarket outlets. Therefore by reducing volume of the retail package,
costs for
packaging, shipping and display are substantially reduced, which is a purpose
of the
inventions.
Effective packaging materials for existing, extended shelf life, retail
packaged, case ready perishable goods are often relatively expensive and the
associated packaging processes are typically labor intensive. The use of EPS
and FP
can provide desirable low cost packaging materials but the inherent cell
structure of
these materials can retain residual oxygen (from air) within the cell
structure, even
during and after exposure to very low levels of air pressure (vacuum). When
EPS
and FP materials are used in low residual oxygen modified atmosphere
packaging,
such as described in US Patent Application Serial No. 09/039,150, residual
oxygen
can diffuse and exchange from the cell structure, and become present as a free
gas
within the master container thereby elevating the level of oxygen present
therein to a
potentially undesirable level. As described in the subject matter of US Patent
Applications in the name of the present inventor, apparatus for minimizing the
level
of residual oxygen retained in the cell structure and master containers are
disclosed.
However, such a process of gas exchange is problematic and difficult to
reliably

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-9-
maintain. Therefore, packaging fabricated from solid plastics sheet, may be
more
efficiently employed in this application.
Conventional "master container" or "master package" modified atmosphere
packaging (MAP) systems include loading perishable goods into trays and then a
plurality of loaded trays are subsequently placed into a larger "master
container"
which may be manufactured from a suitable gas barrier material. The "master
container" is typically evacuated of air and then filled with a gas blend that
may
include a mixture of any desirable gasses which may include, for example, 40%
carbon dioxide and 60% nitrogen for a low oxygen MAP system. The master
container is then sealed with loaded trays to provide an airtight, sealed
master
container, containing loaded trays and a gas blend with a residual quantity of
atmospheric oxygen. Most desirably, for low oxygen MAP systems, the residual
quantity of atmospheric oxygen will not exceed an amount of 100 to 300 PPM
(parts
per million) with the balance of the gas blend including nitrogen and carbon
dioxide
and/or other inert or .oxygen free gasses. Low cost packaging materials
include
foamed polystyrene (EPS trays), however, the choice of material for tray
manufacture must exclude materials (unless treated in a manner that will
substantially remove atmospheric oxygen from the cell structure), such as
expanded
(foamed) polystyrene (EPS), that have a capacity to "retain" air, even after
exposure
to a high vacuum as may occur in packaging processes. Therefore, in order to
maintain the residual quantity of atmospheric oxygen at not more than 100 PPM,
untreated expanded (foamed) polystyrene (EPS) or FP trays cannot be easily and
efficiently used. By way of explanation, EPS trays are typically thermoformed
from
extruded EPS sheet. A typical method of producing EPS sheet is to "foam" the
melted (liquid) polystyrene by injection of a foaming agent, such as nitrogen,
carbon
dioxide or pentane, into liquid polystyrene thereby causing it to foam (become
frothy, with bubbles and/or tiny gas filled cells within the foam) and then
extrude the
foam through a slot in a flat or annular die. The extruded EPS can then cool
and
solidify into a sheet that can be slit and wound onto a roll prior to further
processing.
Immediately after extrusion of the EPS sheet, cells retained within the foam
are filled
with nitrogen or other gas (foaming agent) used in the foaming process.
However,
such a foaming agent gas, if not retained by other means in the cell
structure, can
quickly exchange with the ambient air during storage and the cells can become
filled
with air. When placed within a vacuum chamber and exposed to a high level of
vacuum, as is normal in a "master container " packaging process for low oxygen

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-10-
MAP systems, cells can retain a quantity of air, even during and subsequent to
evacuation (unless the exposure to vacuum is significantly extended to the
extent
required). The retained quantity of air in the cells, can subsequently
exchange with
gas within the sealed "master container" which can, thereby, elevate the
residual
oxygen content of the "free" gas contained within the "master container" above
a
desirable level.
A fundamental need that resulted in the development of thermoformed EPS
trays initially arose in the modern supermarket. Fresh meats and poultry were
formerly processed and retail packaged at the supermarket immediately prior to
retail
display and sale. EPS foam trays were developed to meet these supermarket
requirements, and have provided a functional and low cost retail package, when
"over wrapped" with a low cost web of plastic material such as plasticized
PVC.
However, with case ready MAP systems, such EPS trays are now required to be
shipped in trucks and other means of transport from the point of packaging,
which
may be located many hundreds of miles from the point of sale. Abuse and damage
can occur to the packaging during this shipping. In an effort to protect
against
damage, rigid and heavy weight cartons with sheets, cushions and/or columns,
made
from suitable materials such as chipboard are manufactured and assembled with
EPS
trays and goods contained therein. Such protective packaging is expensive,
bulky
and results in excessive shipping costs. Furthermore, excessive packaging, as
required for the sole purpose of protection during shipping, must be discarded
at the
supermarket thereby creating excessive waste disposal problems with the
attendant
costs to the environment.
Summar~r of the Invention
Methods and apparatus of the present invention are directed at saturating
fresh meat with C02 prior to packaging. In this situation, adequate C02 can be
dissolved in the tissue of the meat and to such a level that the meat can
become a
source of COZ after packaging. This can be achieved by lowering the
temperature of
the meat to a minimum (typically about 29.5 degrees F) and exposing it to
relatively
high pressure (ambient to 200 psi or more) C02 gas. C02 gas dissolves more
readily
at lower temperatures and therefore a part of the method is to expose the meat
to high
pressure C02 at the lowest temperature above freezing and then retail package
the
meat in a tray, then over wrapped with a highly gas permeable web of material
such
as pPVC. If an extended shelf life of say not more than 10 days is adequate,
then a
3 S barrier pouch master container may not be needed, the C02 gas "entrained"
in the

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meat tissue prior to packaging will gradually be released immediately after
removal
from a higher pressure to ambient and as the temperature elevates during
delivery to
the point of sale and this can be sufficient to inhibit bacterial growth and
atmospheric
oxygen in unlimited quantities is available to maintain the requisite "bloom".
In this
way, shipping, packaging and display costs can be reduced substantially, while
providing an extended shelf life which may be sufficient for some industry
packers
and supermarkets.
Thus, the present invention discloses a method of processing and packaging
goods, the method having a step for placing goods in an enclosed vessel
containing a
gas to enhance the keeping of the goods, a step allowing the gas to contact
and
dissolve in liquids and oils present in the goods, a step restricting the
formation of
oxymyoglobin by substantially displacing ambient air, that may otherwise
contact the
surface of the goods, with the gas, a step providing a retail package
including two
overlapping webs with a space therebetween with at least one of the webs being
gas
permeable, a step transferring the meats from the vessel to a position between
the two
overlapping webs and into the space without allowing significant formation of
oxymyoglobin on surface of the meats.
In a preferred embodiment, the method is suitable to use on goods including
fresh red meats wherein the gas is a substantially oxygen free gas.
A further embodiment is a method of packaging goods, the method having a
step providing four or more overlapping web sections, the two outer, first and
second, web sections being gas barrier webs, the inner web sections having
folded,
third web material with at least one cup-shaped depression therein that
restricts
nesting of the webs together, and a fourth gas permeable web material with
space
between the third and fourth web sections, a step providing goods between the
folded
third web material and the fourth web material, a step for sealing the folded
third web
material and the fourth web material so as to substantially retain the goods
in the cup-
shaped depression but allowing gas to pass into and out of the space, a step
for
sealing the overlapping webs after sealing the third and fourth web material
but prior
to sealing the first and second webs together at a seal path near the
perimeter of the
packaging which will provide a hermetically sealed package, a step for gas
flushing
the chamber means with a gas to enhance the keeping of the goods, a step for
sealing
the first and second webs together by a sealing means which defines a seal
path near
what will be an outer perimeter of the packaging and which encloses the third
and

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fourth web material within a hermetically and substantially gas impermeable
package
with the goods and the gas sealed therein and allowing the gas to contact the
goods.
A further embodiment includes one or more packaging tray(s), each
fabricated from a single web of thermoformed plastics material web. Said
packaging
tray having upwardly disposed side walls, defining depressions) with space
therein
into which goods are placed, a second web of gas permeable material
overlapping
said first web which may have been stretched over said packaging tray with
goods
therein and hermetically sealed to fully enclose said packaging tray and goods
therein, a third web of gas impermeable material overlapping and hermetically
sealed
so as to fully enclose one or more of said first and second webs with space
therein, a
suitable gas in said space, said gas or blend of gases selected for enhancing
preservation of the packaging goods by contacting the surface of said goods, a
chamber means to enclose said first, second and third webs, prior to sealing
said third
web, which can be isolated from external atmosphere by valve means, providing
a
suitable pressure to said gas in said chamber, hermetically sealing said third
web.
A further embodiment is a goods packaging tray having a base with upwardly
extending side walls that terminate at a flange that extends around a
perimeter of the
tray to provide a cup-shaped recess. The tray having at least one extension
connected
to the flange at a hinge. The extension having a cup-shaped flap that can be
folded
about the hinge and be sealed to at least one of the upwardly extending side
walls to
provide an enclosed space. The tray having apertures at a base of the side
wall of the
tray so as to provide communication between the enclosed space and the tray
that
will allow liquids to pass from the tray cup-shaped recess to the enclosed
space.
A further embodiment is an apparatus for producing packaging trays having
means for thermoforming plastics sheet to form and trim a packaging tray with
a base
and upwardly extending side walls that terminate at a flange that extends
around a
perimeter of the tray to provide a cup-shaped recess with at least one
extension
connected to the flange at a hinge having a cup-shaped flap that can be folded
about
the hinge and be sealed to at least one of the upwardly extending side walls
to
provide an enclosed space. The apparatus further includes a sealer to seal the
flap to
the tray wall around a perimeter of the flap and a device to optionally
provide
apertures in the side wall of the tray recess so as to provide a communication
between the enclosed space and the tray recess.
A further embodiment includes a method and apparatus for grinding boneless
beef directly into an enclosed chamber that has been filled with a suitable
gas such as

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C02 and which substantially excludes oxygen from contacting with the ground
beef.
Adjusting temperature of the ground beef to a suitable temperature.
Processing and mixing ground beef (meat), in a vessel or series of vessels
substantially excluding oxygen, so as to blend and adjust the relative
quantities of fat
and muscle in the finished product to a desired ratio. Maintaining the ground
beef at
a suitable temperature.
Extruding ground beef in a stream of grinds by pumping through an enclosed
conduit with an exit end and a selected cross sectional area and profile that
is
substantially similar to typical beef patty, at a velocity that is adjustable
while
maintaining pumping at a substantially constant rate. Pressurizing a stream of
ground beef in a conduit at a selected pressure and compressing any voids such
that
C02 gas contained therein dissolves into the stream of ground beef.
Maintaining
ground beef at a suitable temperature.
Intermittently adjusting the velocity of stream of grinds so as to
intermittently
slow or stop its flow as it emerges from the exit end of the enclosing conduit
and
allow slicing with knife means to provide single beef patties in stacks of a
chosen
quantity. Intermittent slowing or stopping of flow may exceed 500 cycles per
minute.
Interfacing with a packaging system and packaging fresh meat patties without
exposure to air while maintained at a suitable temperature.
The present invention provides an efficient method and apparatus for
processing fresh red meat products at the point of animal slaughter for
subsequent
case ready packaging and delivery to the consumer via a typical supermarket or
retail
sale outlet. The consumer may be located thousands of miles away from the
point of
slaughter which often results in distribution and delivery that can require a
period of
time exceeding 20 days.
The present invention provides a most efficient method and apparatus for
packaging fresh red meat products at the point of animal slaughter for
subsequent
delivery to the consumer via a typical supermarket or retail sale outlet.
Consumers,
located thousands of miles away from the point of slaughter and packaging
often
results in distribution and delivery that can require a period of time
exceeding 15
days.
The present invention maximizes efficient use of the internal space available
in a typical road, rail or sea, refrigerated shipping container or trailer, it
is important
to increase the density and unit weight per unit volume of said packaged
perishable

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goods. Effective packaging materials for existing case ready packaging systems
are
often expensive and the associated packaging processes are typically labor
intensive.
The present invention provides low cost packaging trays by utilizing various
packaging materials such as polypropylene or PET.
The present invention provides improved packaging for perishable goods, an
improved appearance of the packaging and a means to increase the level of
carbon
dioxide dissolved into the liquid and water contained on or with the
perishable goods,
thereby reducing the total volume of the packages, increasing density for more
efficient shipping and subsequent display at the point of sale. The goods
includes
fresh red meat and a further purpose of this invention is to provide a means
of
enhancing the keeping qualities of the goods.
The present invention provides several alternative methods of stretching the
second web such that after removal of the third web, the second web will be in
a
substantially "ripple free", clear, smooth, and at least partially tensioned
condition.
Additionally, a further description of a method to pre-stretch the second web,
before
sealing the first web, second web and third webs, within a single chamber
sealing
means is disclosed. A further description of methods to package goods in a
single
chamber sealing and packaging machine when the first and second webs are
applied
separately without having been re-laminated after treatment of the second
permeable
web.
Therefore in accordance with a first broad aspect of the present invention
there may be provided improved packaging for perishable goods including: a
tray or
first web over which the goods are placed, the goods including oils, fats,
protein,
liquids and water. The tray having upwardly disposed side walls, defining a
depression with space therein, the side walls having been urged inwardly to a
controlled and predetermined extent and are tensioned, thereby retaining an
outwardly urging force; a second web of gas permeable material overlapping the
first
web which may have been pre-stretched; a third web of gas impermeable material
overlapping the first and second webs; a gas in the space, the gas or blend of
gasses
(preferably carbon dioxide and nitrogen) selected for enhancing preservation
of the
packaging goods by contacting the surface of the goods; a chamber means to
enclose
the first, second and third webs, prior to sealing, which can be isolated from
external
atmosphere by valves, providing pressure to the gas in the chamber, the
pressure
being at a level above ambient atmospheric pressure, thereby providing
accelerating
dissolving of the gasses and carbon dioxide into the liquids and water; and
sealing

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the first, second and third webs together while retaining the side walls of
the first
web tray in tension with the second and third webs.
In this way, the shelf life of the packaged goods can be extended and when
the third web is removed, the tension between the side walls and the second
web can
cause the second web to be stretched and be substantially flattened with fewer
ripples
in its surface. Thus the packaging will be pleasing to an intending purchaser.
The invention provides a labor efficient, low cost processing and packaging
system for perishable goods that can minimize the presence of undesirable
levels of
both anaerobic and aerobic bacteria, fungi, virus and residual oxygen, for an
extended period of storage time by enhancing the keeping qualities of the
perishable
goods. The processing and packaging system is disclosed herein, with further
disclosures providing details of several package configurations produced from
various packaging materials including polypropylene, amorphous polyester,
expanded polystyrene (EPS) and foamed polyester (FP).
Additionally, the present invention provides efficient methods and apparatus
for delivering fresh red meat products from the point of animal slaughter and
retail
packaging to the consumer via a typical supermarket or retail sale outlet. The
consumer may be located thousands of miles away from the point of slaughter
which
often results in distribution and delivery that can require a period of time
exceeding 14 to 25 days.
The present invention provides methods and apparatus for reducing the
processing costs, provide a method to reduce the labor content of the process
and
separate the carcass into at least two groups of components that can be either
used for
human consumption or not for human consumption prior to chilling the carcass.
The present invention provides improved and accurate "portion control." For
example, a New York Strip primal that includes a strip of muscle with a fat
covering
on one side, can be substantially shaped into a uniform strip prior to
slicing.
Additionally, such primal items as tenderloin that have a tapered profile can
be
combined and pressed together to form a single tenderloin of uniform cross-
section
and then sliced to produce uniform slices of equal size and weight. In yet a
further
embodiment, the present invention provides for the cutting of meat containing
deoxymyoglobin in an atmosphere that excludes oxygen and substantially
inhibiting
and preventing contact of the freshly cut surface with oxygen in the ambient
atmosphere.

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The present invention provides a labor efficient, low cost processing and
packaging system for perishable goods that can minimize the presence of
undesirable
levels of bacteria, rancidity, discoloration and enhance the keeping qualities
of the
perishable goods.
Trays and packaging apparatus are disclosed in the present invention that can
incorporate either a low oxygen modified atmosphere or alternatively a high
oxygen
modified atmosphere. A high oxygen modified atmosphere may include a blend of
gasses including 20% carbon dioxide, 70% oxygen and 10% nitrogen. Part of this
blend of gas may include some residual ambient atmospheric gases.
The tray construction and packaging disclosed in this invention describe ways
to substantially eliminate excessive packaging by incorporating
multifunctional
features in a single tray. The multifunctional features include devices to
allow
stacking of a plurality of trays in a vertical stack, incorporation of an in-
built
protective cushion around the perimeter of the tray and a purge absorbing
feature.
Additionally, the present invention provides a most efficient means of
delivering fresh red meat products from the point of animal slaughter and
retail
packaging to the consumer via a typical supermarket or retail sale outlet. The
consumer may be located many hundreds of miles away from the point of
slaughter
which often results in distribution and delivery time that can exceed 14 to 25
days.
The present invention increases the volume of carbon dioxide gas within a
package without increasing the size and volume of the package. This can be
achieved by carbonation and increasing the quantity of dissolved carbon
dioxide in
the free liquids, oils and water contained in the package with red meat prior
to
hermetically sealing the package.
In order to maximize exploitation of the benefits of improved packaging as
described herein for use with packaging of perishable goods such as cuts of
fresh red
meat, as detailed herein, a method and apparatus of changing and/or adjusting
the
shape and profile of the red meat primal, before slicing the primal, such that
slices of
the primal will have a permanently adjusted shape facilitating more efficient
use of
the improved packaging, is highly desirable. The description contained herein
provides a method and apparatus of achieving an adjustment and or shape of
large
fresh red meat primal portions and combinations of smaller pieces pressed
together.
Brief Description of the Drawin;~s
The foregoing aspects and many of the attendant advantages of this invention
will become more readily appreciated as the same becomes better understood by

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reference to the following detailed description, when taken in conjunction
with the
accompanying drawings, wherein:
FIGURE 1 is a perspective view of one package made in accordance with the
present invention;
FIGURE 2 is a perspective view of a corner section of the package of
FIGURE 1 with the heat sealable layers up turned;
FIGURE 3 is a cross-sectional view of the package of FIGURE 1 taken along
section line 3-3;
FIGURE 4 is a schematic view of an assembly line for manufacturing a
package such as shown in FIGURE 1;
FIGURE 5 is a schematic view of a master bag method of packaging
individual packages for storage and transport in accordance with the present
invention;
FIGURE 6 is an alternate embodiment of a tray having a vent hole in
accordance with the present invention;
FIGURES 7, 8, and 9 show another embodiment of a stackable tray built in
accordance with the present invention;
FIGURES 10-15 show another embodiment of a stackable tray constructed in
accordance with the present invention;
FIGURE 16 shows another embodiment of a master package and method for
storing and transporting individual packages containing edible materials in
accordance with the present invention;
FIGURES 17 and 18 show an alternate valve arrangement to that shown in
FIGURES 14 and 15;
FIGURES 19-21 show another alternate valve arrangement;
FIGURES 22-26 show the incorporation of a material for indicating the
presence of E. coli bacteria into a tray, constructed in accordance with the
present
invention;
FIGURES 27-30 show a production line and method in accordance with the
present invention for producing a material for indicating the presence. of E.
coli
bacteria.
FIGURE 31 shows a perspective view of a tray with flaps constructed
according to the present invention;
FIGURE 32 shows a perspective view of the tray of FIGURE 31;

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FIGURE 33 shows a cross-sectional view of the tray of FIGURE 32 taken
along line 33;
FIGURE 34 shows a finished package constructed according to the present
invention;
FIGURE 35 shows a master container constructed according to the present
invention;
FIGURE 36 shows the master container of FIGURE 35 with finished
packages enclosed therein and sealed with a lid and enclosed in a cardboard
box;
FIGURE 37 shows a cross-sectional view of a tray constructed according to
the present invention;
FIGURE 38 shows a perspective view of a finished package constructed
according to the present invention;
FIGURE 39 shows a cross-sectional view of a tray portion including a flap in
the up position;
FIGURE 40 shows a bottom plan view of the flap of FIGURE 39;
FIGURE 41 shows a cross-sectional view of the flap of FIGURE 39 in the
down position;
FIGURE 42 shows a schematic view of a tray sealing apparatus constructed
according to the present invention;
FIGURE 43 shows a web material constructed according to the present
invention;
FIGURE 44 shows a web material constructed according to the present
invention;
FIGURE 45 shows a cross-sectional view of a finished package constructed
according to the present invention;
FIGURE 46 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 47 shows a perspective view of a finished package constructed
according to the present invention;
FIGURE 48 shows a tray portion including a flap in a down position,
constructed according to the present invention;
FIGURE 49 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 50 shows a perspective view of a tray with flaps constructed
according to the present invention;

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FIGURE 51 shows a bottom perspective view of the tray of FIGURE 50;
FIGURE 52 shows a bottom plan view of the tray of FIGURE 50;
FIGURE 53 shows a side plan view of the tray of FIGURE 50;
FIGURE 54 shows a cross-sectional view of a tray constructed according to
the present invention;
FIGURE 55 shows a perspective view of a tray constructed according to the
present invention;
FIGURE 56 shows a cross-sectional view of a tray portion of FIGURE 55
taken along line 56;
FIGURE 57 shows a cross-sectional view of a tray portion of FIGURE 55
taken along line 57;
FIGURE 58 shows a cross-sectional view of a tray portion of FIGURE 55
taken along line 58;
FIGURE 59 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 60 shows a perspective view of a tray constructed according to the
present invention;
FIGURE 61 shows a cross-sectional view of a tray portion of FIGURE 60
taken along line 61;
FIGURE 62 shows a perspective view of stacked trays constructed according
to the present invention;
FIGURE 63 shows a cross-sectional view of the stacked trays of FIGURE 62;
FIGURE 64 shows a perspective view of a finished package constructed
according to the present invention;
FIGURE 65 shows a perspective view of a tray with flaps constructed
according to the present invention;
FIGURE 66 shows a schematic view of a tray portion including a flap
constructed according to the present invention;
FIGURE 67 shows a cross-sectional view of a tray portion of FIGURE 65
taken along line 67;
FIGURE 68 shows a cross-sectional view of a tray portion of FIGURE 65
taken along line 68;
FIGURE 69 shows a detailed view of FIGURE 68;
FIGURE 70 shows a cross-sectional view of a tray portion including a flap
constructed according to the present invention;

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79
FIGURE 71 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 72 shows a cross-sectional view of a detailed tray portion of
FIGURE 70;
FIGURE 73 shows a cross-sectional view of a finished package with a
pealable label constructed to the present invention;
FIGURE 74 shows a perspective view of the package with label of
FIGURE 73;
FIGURE 75 shows a cross-sectional view of a finished package with over
wrap web material constructed according to the present invention;
FIGURE 76 shows a perspective view of the finished package of
FIGURE 75;
FIGURE 77 shows a cross-sectional view of the finished package of
FIGURE 76 with the over wrap in its loose state;
FIGURE 78 shows a cross-sectional view of the finished package of
FIGURE 76 with the over wrap in a stretched state;
FIGURE 79 shows a cross-sectional view of a master container containing
finished packages, the master container being enclosed within a cardboard box,
constructed according to the present invention;
FIGURE 80 shows a portion of the master container of FIGURE 79;
FIGURE 81 shows a portion of the master container of FIGURE 79;
FIGURE 82 shows a perspective view of a tray with flaps constructed
according to the present invention;
FIGURE 83 shows a cross-sectional view of the tray of FIGURE 82 taken
along line 83;
FIGURE 84 shows a pair of tray pre-forms with ribs that are arranged to
provide enclosed pressure vessels after sealing;
FIGURE 85 shows a side elevation of a packaging tray that has been
manufactured from a pair of pre-forms shown in FIGURE 84;
FIGURE 86 shows a cross-sectional view of a tray portion of FIGURE 85
taken along line 86;
FIGURE 87 shows a cross-sectional view of the tray portion of FIGURE 86
taken along line 87;
FIGURE 88 shows a three dimensional view of a complete packaging tray
comprising a base 6540 with four upwardly extending side walls terminating at
a
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continuous flange 6542 that follows a path at a perimeter of the packaging
tray and
surround a cavity 6544;
FIGURE 89 shows a cross sectional view through the packaging tray shown
in FIGURE 88;
S FIGURE 90 shows a plan view of a thermoformed pre-form that can be
fabricated by folding and bonding to form a packaging tray as shown in FIGURE
88;
FIGURE 91 shows a cross-sectional view of a tray portion of FIGURE 89;
FIGURE 92 shows a plan view of a thermoformed pre-form that can be
fabricated by folding and bonding flaps 6700, 6702, 6706, 6714, 6710, and 6712
to
form a packaging tray with ca~,rity 6704 as shown in FIGURES 95 and 96;
FIGURE 93 shows two thermoformed and fabricated packaging trays 20 and
21, that are nested and stacked together to provide a stack of trays;
FIGURE 94 shows a cross section through an apparatus that is arranged to
seal flaps (such as 6700, 6702, 6706, 6714, 6710, and 6712 shown in FIGURE 92)
to
the walls of a packaging tray (such as shown in FIGURE 92) to produce trays
such as
6828 and 6830 shown in FIGURE 95;
FIGURE 95 shows a side elevation of two packaging trays that are stacked
after flaps, such as 6700, 6702, 6706, 6714, 6710, and 6712 shown in FIGURE 92
have been sealed to walls of the tray;
FIGURE 96 shows an end view of two packaging trays that are stacked after
flaps, such as 6700, 6702, 6706, 6714, 6710, and 6712 shown in FIGURE 92 have
been sealed to the corresponding walls of the tray;
FIGURE 97 shows a three dimensional view of a packaging tray 6900 with
ribs 6916, 6914, 6910 and 6908 formed into the profile of flaps and walls of
the
2S packaging tray;
FIGURE 98 shows a cross-sectional view of tray 6900 in FTGURE 6 taken
along line 98;
FIGURE 99 shows a perspective view of a tray according to the present
invention;
FIGURE 100 shows a cross-sectional view of a tray portion of FIGURE 99
taken along line 100;
FIGURE 101 shows a cross~sectional view through a segment of a preferred
packaging tray embodiment;
FIGURE 102 shows a cross-sectional view of a tray portion of FIGURE 101
taken along line 102;
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FIGURE 103 shows details of the components used to manufacture a
composite tray;
FIGURE 104 shows a plan view of a web material to construct a tray
according to the present invention;
FIGURE 105 shows a cross section through an apparatus with housing 7534,
and a tapering screw 7508 mounted therein; a piston 7514, with corresponding
cylinder 7512, is mounted to housing 7534 and a restricting conduit 7526 is
attached
to the exit end of housing 7534, grinds 7506 can be transferred into said
housing 7534 and screw 7508 may be used for pumping said grinds into a
profiled
conduit thereby providing an extruded stream of grinds for subsequent slicing
and
thereby production of patties;
FIGURE 106 shows a cross section through an apparatus intended for use in
slicing extruded streams of ground meats to produce patties, a temperature
controlled
conduit 7560 is mounted adjaccnt to a revolving blade 7542, such that stacks
of
sliced patties 7544 and 7546 can be produced and transported to a packaging
station
via conveyor belting 7550 that is driven intermittently by drive roller 7552
in
direction shown by arrow 754ti;
FIGURE 107 shows a cross-sectional view of an apparatus portion of
FIGURE 105 taken along ~.ine 107;
FIGURE 108 shows a side elevation of an apparatus assembled to produce
fine ground boneless beef 7630, from coarse ground boneless beef 7602, after
fine
grinding into vessel 7618 from grinder 7608, ground beef 7630 is pumped, in
the
direction shown by arrow 7622, via servo driven positive displacement pump
7628,
through conduit 7620 which can be connected directly to conduit 7502, shown in
FIGURE 105. Conduit connections 7638 and 7634 are provided to allow injection
of
gas such as C02 there through and conduit connection 7614 is provided to allow
gases to be withdrawn from vessel 7618;
FIGURE 109 shows a side elevation, cross sectional view of an apparatus that
is arranged to automatically measure and slice portions of meat primals that
have
been molded to a predetermined profile corresponding with a temperature
controlled
conduit 7702 of similar profile, pre-conditioned and tempered primal cuts of
boneless
meat 7738 are located in an entry end of conduit 7702 followed by a plug such
as
7704, electromagnetic driving fixtures 7712 are arranged to intermittently
drive and
by magnetic bonding to each plug, carry plugs such as 7704, in a forward
direction
and a distance equal to the selected thickness of a single slice of beef,
blade 7732 is
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CA 02387349 2002-04-03
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controlled to intermittently slice during a single revolution shaft 7734,
conveyor 7726 is
mounted in an enclosure 7722, and adjacent to the exit end of conduit 7702, so
as to
conveniently carry slices to a further processing or packing station;
FIGURE 110 shows a cross-sectional view of an apparatus portion of
FIGURE 109 taken along line 110;
FIGURE l11 shows a cross-sectional view of an apparatus portion of
FIGURE I09 taken along line 11 I ;
FIGURE I12 shows a cross-sectional view of a finished package constructed
according to the present invention;
FIGURE 113 shows a perspective view of a finished package constructed
according to the present invention;
FIGURE 114 shows a perspective view of a tray with flaps constructed
according to the present invention;
FIGURE 115 shows a cross-sectional view of a tray portion including flaps of
FIGURE 114;
FIGURE 116 shows a cross-sectional view of a tray constructed according to
the present invention;
FIGURE 117 shows a perspective view of a tray with a flap constructed
according to the present invention;
FIGURE 118 shows a cross-sectional view of packages stacked atop one
another, constructed according to the present invention;
FIGURE 119 shows a top plan view of a tray constructed according to the
present invention;
FIGURE 120 shows a cross-sectional view of a tray portion of FIGURE 119;
FIGURE 12I shows a cross-sectional view of a tray portion of FIGURE 119;
FIGURE 122 shows a cross-sectional view of a plurality of stacked trays with
flaps, constructed according to the present invention;
FIGURE 123 shows a cross-sectional view of a tray with a flap constructed
according to the present invention;
FIGURE 124 shows a cross-sectional view of a finished package constructed
according to the present invention;
FIGURE 125 shows a cross-sectional view of a master container containing
finished packages constructed according to the present invention;
FIGURE 126 shows a perspective view of a txay portion constructed
according to the present invention;
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FIGURE 127 shows a cross-sectional view of a tray portion of FIGURE 126;
FIGURE 128 shows a cross-sectional view of stacked trays in a master
container constructed according to the present invention;
FIGURE 129 shows a cross-sectional view of a finished package with a flap
constructed according to the present invention;
FIGURE 130 shows a cross-sectional view of a tray with flap constructed
according to the present invention;
FIGURE 131 shows a top plan view of a tray portion with flap constructed
according to the present invention;
FIGURE 132 shows a side plan view of a tray portion of FIGURE 131;
FIGURE 133 shows a side plan view of stacked trays according to the present
invention;
FIGURE 134 shows a top plan view of a tray portion with flaps constructed
according to the present invention;
FIGURE 135 shows a perspective view of a tray portion with the flaps folded
down according to the present invention;
FIGURE 136 shows a cross-sectional view of a tray portion of FIGURE 135
taken along line 136;
FIGURE 137 shows a cross-sectional view of a tray with flaps constructed
according to the present invention;
FIGURE 138 shows a cross-sectional view of a tray with flaps containing
iron particles constructed according to the present invention;
FIGURE 139 shows a cross-sectional view of a tray portion of FIGURE .138;
FIGURE 140 shows a schematic view of an apparatus for applying iron
particles according to the present invention;
FIGURE 141 shows a cross-sectional view of an apparatus portion of
FIGURE 140;
FIGURE 142 shows a cross-sectional detailed view of an apparatus portion of
FIGURE 141;
FIGURE 143 shows a schematic view of an apparatus for applying iron
particles according to the present invention;
FIGURE 144 shows a top plan view of a web material containing iron
particles according to the present invention;
FIGURE 145 shows a cross-sectional view of the web of FIGURE 144 taken
along line 145;
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FIGURE 146 shows a schematic view of an apparatus for packaging and
forming holes in web materials according to the present invention;
FIGURE 147 shows a side plan view of a tray formed by the apparatus of
FIGURE 146;
FIGURE 148 shows a schematic view of a master container sealing apparatus
according to the present invention;
FIGURE 149 shows a perspective view of an apparatus portion of
FIGURE 148;
FIGURE 150 shows a cross-sectional view of an apparatus portion of
FIGURE 149 taken along line 150;
FIGURE 15I shows a schematic view of a packaging, labeling, and weighing
apparatus according to the present invention;
FIGURE 152 shows a top plan view of the apparatus of FIGURE 151;
FIGURE 153 shows a top plan view of a register formed according to the
presentinvention;
FIGURE 154 shows a cross-sectional view of a vacuum chamber constructed
according to the present invention;
FIGURE 155 shows a cross-sectional view of an apparatus portion according
to the present invention;
FIGURE 156 shows a cross-sectional view of a vacuum chamber constructed
according to the present invention;
FIGURE 157 shows a cross-sectional view of a tray with flaps according to
the present invention;
FIGURE 158 shows a cross-sectional view of a tray portion with flap of
FIGURE 157;
FIGURE 159 shows a cross-sectional view of a sealing plate constructed
according to the present invention;
FIGURE 160 shows a top plan view of a sealing plate according to the
present invention;
FIGURE 161 shows a top plan view of a sealing plate according to the
present invention;
FIGURE 162 shows a cross-sectional view of the sealing plate of
FIGURE 161 taken along line 162;
FIGURE 163 shows a cross-sectional view of a finished package constructed
according to the present invention;
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FIGURE 164 shows a cross-sectional view of a tray located in a sealing plate
according to the present invention;
FIGURE 165 shows a top plan view of a sealing plate according to the
present invention;
FIGURE 166 shows a schematic view of tray walls being bonded when
located in the sealing plate according to the present invention;
FIGURE 167 shows a cross-sectional view of a vacuum chamber constructed
according to the present invention;
FIGURE 168 shows a schematic view of an apparatus for loading and sealing
trays according to the present invention;
FIGURE 169 shows a schematic view of an apparatus for forming a
laminated web according to the present invention;
FIGURE 170 shows a schematic view for an apparatus for packaging trays
using a laminated web according to the present invention;
FIGURE 171 shows a cross-sectional view of a web material according to the
presentinvention;
FIGURE 172 shows a schematic view of a packaging and sealing apparatus
constructed according to the present invention;
FIGURE 173 shows a cross-sectional view of a tray with a laminated web;
FIGURE 174 shows a cross-sectional view of a tray with a single web;
FIGURE 175 shows a schematic view of an apparatus for forming master
containers according to the present invention;
FIGURE 176 shows a cross-sectional view of the apparatus of FIGURE 175
taken along line 176;
FIGURE 177 shows a cross-sectional view of an apparatus portion of
FIGURE 175 taken along line 177;
FIGURE 178 shows a cross-sectional view of an apparatus portion of
FIGURE 176;
FIGURE 179 shows a finished package enclosed within a master container;
FIGURE 180 shows an apparatus for grinding and processing meat
constructed according to the present invention;
FIGURE 181 shows an apparatus for grinding and processing meat
constructed according to the present invention;
FIGURE 182 shows a cross-sectional view of an apparatus portion of
FIGURE 181;
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FIGURE 183 shows a cross-sectional view of an apparatus portion of
FIGURE 181;
FIGURE 184 shows a front plan view of a manifold constructed according to
the present invention;
FIGURE 185 shows a side plan view of the manifold of FIGURE 184;
FIGURE 186 shows a cross-sectional view of an apparatus for grinding and
processing meat according to the present invention;
FIGURE 187 shows a cross-sectional view of an apparatus for processing
meat constructed according to the present invention;
FIGURE 188 shows a side plan view of an apparatus portion of FIGURE 187;
FIGURE 189 shows a cross-sectional view of an apparatus portion of
FIGURE 188 taken along line 189;
FIGURE 190 shows a cross-sectional view of an apparatus portion of
FIGURE 187 taken along line 190;
FIGURE 191 shows a top plan view of a tube structure according to the
present invention;
FIGURE 192 shows a cross-sectional view of an apparatus portion having
three meat processing tubes, constructed according to the present invention;
FIGURE 193 shows a cross-sectional view of an apparatus for grinding and
processing meat;
FIGURE 194 shows a cross-sectional view of an apparatus portion of
FIGURE 187;
FIGURE 195 shows a cross-sectional view of a measuring device constructed
according to the present invention;
FIGURE 196 shows a top plan view of a packaging and slicing apparatus
having a tunnel, constructed according to the present invention;
FIGURE 197 shows a cross-sectional view of the apparatus of FIGURE 196
taken along line 197;
FIGURE 198 shows a schematic view of a meat processing apparatus
constructed according to the present invention;
FIGURE 199 shows a schematic view of a meat processing and packaging
apparatus constructed according to the present invention;
FIGURE 200 shows a schematic view of a meat processing and packaging
apparatus constructed according to the present invention;
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CA 02387349 2002-04-03
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FIGURE 201 shows a schematic view of a meat processing and packaging
apparatus constructed according to the present invention;
FIGURE 202 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 203 shows a perspective view of an over wrapping web material
constructed according to the present invention;
FIGURE 204 shows a perspective view of an over wrapped package
constructed according to the present invention;
FIGURE 205 shows a schematic view of an apparatus portion constructed
according to the present invention;
FIGURE 206 shows a top plan view of an apparatus portion constructed
according to the present invention;
FIGURE 207 shows a cross-sectional view of a meat blending apparatus
constructed according to the present invention;
FIGURE 208 shows a cross-sectional view of the meat blending apparatus of
FIGURE 207 taken along line 208;
FIGURE 209 shows a schematic view of a meat processing and conditioning
apparatus constructed according to the present invention;
FIGURE 210 shows a cross-sectional view of a meat forming and shaping
apparatus constructed according to the present invention;
FIGURE 211 shows a side plan view of an apparatus portion of FIGURE 210;
FIGURE 212 shows a perspective view of a meat forming and shaping
apparatus constructed according to the present invention;
FIGURE 213 shows a schematic view of a master container sealing apparatus
constructed according to the present invention;
FIGURE 214 shows a cross-sectional view of the apparatus of FIGURE 212;
FIGURE 215 shows a cross-sectional view of a meat forming and shaping
apparatus constructed according to the present invention;
FIGURE 216 shows a side plan view of an apparatus portion of FIGURE 215;
FIGURE 2I7 shows a cross-sectional view of a forming and shaping
apparatus for several primals, constructed according to the present invention;
FIGURE 218 shows a cross-sectional view of an apparatus portion of
FIGURE 216;
FIGURE 219 shows a cross-sectional view of an apparatus portion of
FIGURE 218;
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FIGURE 220 shows a cross-sectional view of an apparatus portion for
forming and shaping meat primals constructed according to the present
invention;
FIGURE 221 shows a cross-sectional view of an apparatus portion for
shaping and forming meat primals constructed according to the present
invention;
FIGURE 222 shows a schematic view of an equipment layout constructed
according to the present invention;
FIGURE 223 shows a cross-sectional view of a master container vacuum
chamber constructed according to the present invention;
FIGURE 224 shows a schematic view of an equipment layout constructed
according to the present invention;
FIGURE 225 shows a cross-sectional view of a tube apparatus of
FIGURE 224 taken along line 225;
FIGURE 226 shows a perspective view of a spool for storing web material
constructed according to the present invention;
FIGURE 227 shows a schematic view of a thermoforming oven of
FIGURE 224 taken along line 227;
FIGURE 228 shows a schematic view of equipment layout constructed
according to the present invention;
FIGURE 229 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 230 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 231 shows a detailed view of web material constructed according to
the present invention;
FIGURE 232 shows a detailed view of web material constructed according to
the present invention;
FIGURE 233 shows a detailed view of web material constructed according to
the present invention;
FIGURE 234 shows a detailed view of web material constructed according to
the present invention;
FIGURE 235 shows a detailed view of web material constructed according to
the present invention;
FIGURE 236 shows a detailed view of web material constructed according to
the present invention;
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FIGURE 237 shows a detailed view of web material constructed according to
the present invention;
FIGURE 238 shows a perspective view of a tray treatment apparatus
constructed according to the present invention;
FIGURE 239 shows a perspective view of a tray treatment apparatus
constructed according to the present invention;
FIGURE 240 shows a cross-sectional view of a tray forming apparatus
constructed according to the present invention;
FIGURE 241 shows a cross-sectional view of a tray forming apparatus
constructed according to the present invention;
FIGURE 242 shows a cross-sectional view of web material constructed
according to the present invention;
FIGURE 243 shows a cross-sectional view of web material constructed
according to the present invention;
FIGURE 244 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 245 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 246 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 247 shows a cross-sectional view of formed web material
constructed according to the present invention;
FIGURE 248 shows a cross-sectional view of formed web material
constructed according to the present invention;
FIGURE 249 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 250 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 251 shows a perspective view of a tray portion with ribs constructed
according to the present invention;
FIGURE 252 shows a cross-sectional view of formed web material
constructed according to the present invention;
FIGURE 253 shows a cross-sectional view of formed web material
constructed according to the present invention;
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FIGURE 254 shows a cross-sectional view of a web forming apparatus
constructed according to the present invention;
FIGURE 255 shows a cross-sectional view of a web forming apparatus
constructed according to the present invention;
FIGURE 256 shows a cross-sectional view of a web material constructed
according to the present invention;
FIGURE 257 shows a cross-sectional view of a web aperture forming
apparatus constructed according to the present invention;
FIGURE 258 shows a cross-sectional view of a web forming apparatus
constructed according to the present invention;
FIGURE 259 shows a top plan view of an apparatus portion of FIGURE 258;
FIGURE 260 shows a cross-sectional view of a formed web material
constructed according to the present invention;
FIGURE 261 shows a cross-sectional view of a pressure chamber for
removing oxygen from the cell structure of EPS foam constructed according to
the
present invention;
FIGURE 262 shows a cross-sectional view of an apparatus for removing
oxygen within the cell structure of EPS foam constructed according to the
present
invention;
FIGURE 263 shows a perspective view of an apparatus portion of
FIGURE 261;
FIGURE 264 shows a front plan view of the apparatus of FIGURE 262;
FIGURE 265 shows a schematic view of an apparatus with vacuum tubes
constructed according to the present invention;
FIGURE 266 shows a schematic view of equipment layout constructed
according to the present invention;
FIGURE 267 shows a schematic view of equipment layout constructed
according to the present invention;
FIGURE 268 shows a tray with flaps having crests and indentations
constructed according to the present invention;
FIGURE 269 shows a perspective view of the tray of FIGURE 268 with the
flaps opened upward;
FIGURE 270 shows a side plan view of stacked trays of FIGURE 268
showing a space between the crest and a flap indentation;
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FIGURE 271 shows a perspective view of a tray with flaps constructed
according to the present invention;
FIGURE 272 shows a perspective view of the tray of FIGURE 271 with the
flaps folded downward;
FIGURE 273 shows a cross-sectional view of a tray portion with substances
located within a flap space constructed according to the present invention;
FIGURE 274 shows a cross-sectional view of a tray with flaps having flap
spaces.
FIGURE 275 shows a schematic detail portion of the tray flap of FIGURE 92.
Detailed Descriution of the Preferred Embodiment
As used herein, the following terms take the following mean, unless
otherwise indicated.
The term "case ready" refers to retail packaged fresh meats (that were
typically formerly prepared at the supermarket) that has been packaged ready
for
retail sale from the meat case at a place of production remote from the
supermarket.
The term "high oxygen modified atmosphere" refers to a blend of gases that
includes some or all of the naturally occurring atmospheric gases but in
proportions
that are different to air and including a high level of oxygen which may be
greater
than 40%. Such an example would be a gas comprising 80% oxygen and 20%
carbon dioxide, however in virtually all applications a residual quantity of
nitrogen
remains in the sealed "high oxygen modified atmosphere" package.
The term "low oxygen'' or "no oxygen" modified atmosphere" refers to a
blend of gases that includes some or all of the naturally occurring
atmospheric gases
(except oxygen) but in proportions that are different to air and including a
low (or
zero level of oxygen) which may be less than 300-500 parts per million.
The term "MAP" refers to modified atmosphere packaging.
The term "CAP" refers to controlled atmosphere packaging.
The term "Epsilon GMS-40" or "GMS-40" refers to an apparatus that can be
used to measure the fat and/or lean content of pumpable ground meats. The GMS-
40
is manufactured and supplied by Epsilon Industries, of Austin, Texas.
Additional
information is available on web site: www.epsilon-gms.com.
The term "AVS-ET system" refers to a system that can be used to identify the
composition of boneless meats. The system can identify quantities of fat,
muscle/lean tissue, contaminants, bone, metal inclusions and other matter that
is
transferred, in a continuous stream, through a conduit and into and then away
from
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the AVS-ET system. The system operates preferably when the continuous stream
is
exclusive of any voids such as pockets of air. The system is manufactured and
supplied by Holmes Newman Associates, 4221 Fallsbrae Road, of Fallbrook,
CA 92028.
The term "statiflo blending devices" refers to a continuous, static and
enclosed material blending device that can introduce gases such as C02 to the
blended material. STATIFLO is a registered trademark of Statiflo
International, The
Crown Center, Bond Street, Macclesfield, Cheshire SK116QS, LTK. Information is
available on web site: salesC statiflo.co.uk.
The term "blending devices" refers to a continuous, static and enclosed
material blending device that can be used to continuously blend such
perishable
goods as ground meats that comprise substantially two components of fat and
lean
meat and may also be used to introduce gases such as C02 to the blended
materials.
The term "shelf life" refers to the period of time between the date of retail
packaging of perishable goods (that are slowly deteriorating) of acceptable
quality
and a subsequent point in time or date, prior to the perishable goods having
deteriorated to an unaccepta>,le condition.
The term "PP" refers to polypropylene.
The term "EPS" refers to expanded polystyrene.
The term "pPVC" refers to plasticized polyvinylchloride.
The term "PET," polyester or "APET" refers to amorphous polyethylene
terephthal ate.
The term "heat activated adhesives (or coating)" refers to adhesives that
become active and capable of bonding substances together when heated to a
suitable
temperature that otherwise, at ambient temperature, will not bond.
The term "OTR" refers to oxygen transmission rate.
The term "perishable goods" or "goods" refers to any perishable foods such as
sliced beef or other fresh meats, ground meats, poultry pieces etc.
The term "liquids and oils" refers to water, liquids, blood, purge, liquid
animal fats and oils and the like.
The term "master container" generally refers to a substantially gas barrier
container that can be filled with finished packages, evacuated of
substantially all
atmospheric air and filled with any suitable gas. However, said "master
container"
may also be gas permeable if so desired.
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CA 02387349 2002-04-03
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The terms "suitable substance", "suitable gas" or "suitable gases" refer to
any
gas or blend of gasses, provided at any pressure (suitable pressure). A
suitable gas
may include a blend of carbon dioxide and nitrogen and oxygen with residual
atmospheric gases in any relative proportions. Examples are provided, but are
not
restricted to any of the following:
1. A blend of gases including argon, carbon dioxide, nitrogen and a
quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts
per
million).
2. Air that has been filtered to remove substantially all oxygen
therefrom.
3. Carbon dioxide and nitrogen in any relative proportions.
4. Carbon dioxide and oxygen where oxygen does not exceed 5% and is
not less than 5 PPM.
5. Carbon dioxide and a quantity of oxygen that does not exceed S% and
is not less than 5 PPM (parts per million).
6. Nitrogen and a quantity of oxygen that does not exceed 5% and is not
less than 5 PPM (parts per million).
7. A blend of inert gasses and a quantity of oxygen that does not
exceed 5% and is not less than 5 PPM (parts per million).
8. A blend of pentane and nitrogen in any relative proportions and a
quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts
per
million).
9. A blend of propane and nitrogen in any relative proportions and a
quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts
per
million).
10. A blend of butane and nitrogen in any relative proportions and a
quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts
per
million).
11. A blend of a CFC and nitrogen in any relative proportions and a
quantity of oxygen that does not exceed S% and is not less than S PPM (parts
per
million).
12. A blend of an HCFC and nitrogen in any relative proportions and a
quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts
per
million).
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13. A blend of methane and nitrogen in any relative proportions and a
quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts
per
million).
14. A blend of hydrogen sulfide and nitrogen in any relative proportions
and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM
(parts
per million).
15. A blend of carbon monoxide and nitrogen in any relative proportions
and a quantity of oxygen that does not exceed 5% and is not less than 5 PPM
(parts
per million).
16. A blend of sulfur dioxide and nitrogen in any relative proportions and
a quantity of oxygen that does not exceed 5% and is not less than 5 PPM (parts
per
million).
17. A gas including 100% carbon dioxide
18. A substance or agent including one or more of the following:
isoascorbic acid, ascorbic acid, citric acid, erythorbic acid, lactic acid,
succinic acid
or mixtures of salts thereof. Glycerol monolaurate, potassium sarbate, sodium
sorbate, sodium iodoacetate, potassium acetate, iodoacetomide, potassium
iodoacetate, sodium acetate or mixtures or acidic solutions thereof.
The term "suitable gas pressure" or "water pressure" refers to any pressure
that is suitable for the application and may be controlled within any of the
following
pressure ranges, or any other suitable pressure:
Suitable gas pressure:
gas at a pressure of 1 PSI to 14 PSI.
gas at a pressure of up to 13 PSI.
gas at a pressure of 13 PSI to 50 PSI.
gas at a pressure of 50 PSI to 80 PSI.
gas at a pressure of 80 PSI to 120 PSI.
gas at a pressure of 120 PSI to 200 PSI.
gas at a pressure of 200 PSI to 500 PSI.
gas at a pressure above 500 PSI.
Suitable water pressure:
water at a pressure of 1 PSI to 14 PSI.
water at a pressure of up to 13 PSI.
water at a pressure of 13 PSI to 50 PSI.
water at a pressure of 50 PSI to 80 PSI.
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water at a pressure of 80 PSI to 120 PSI.
water at a pressure of 120 PSI to 200 PSI.
water at a pressure of 200 PSI to 500 PSI.
water at a pressure above 500 PSI.
The term "suitable gas temperature" or "suitable water temperature" refers to
any temperature that is suitable for the application and may be controlled
within any
suitable temperature ranges for any suitable period of time, or at any other
suitable
temperature. Suitable temperature also includes a temperature range which may
be a
pasteurizing temperature range such as maintaining a product such as a beef
primal
within a temperature range of not less than 138.5 degrees F to 140 degrees F
and for
a suitable period of time.
Bond or Bonding refers to sealing or welding of two or more surfaces
together by any suitable means such as with any suitable adhesive, RF welding,
ultrasonic welding heat sealing, or any other suitable means.
Hermetic seal refers to a seal or bonding of two or more surfaces of any
suitable material together by any suitable means to provide an enclosed space
and
wherein said enclosed space is rendered fully enclosed in such a manner that
will
substantially inhibit the passage or communication of any substance such as
gas, air
or liquids from within said enclosed space to and with the exterior of said
enclosed
space.
Pre-Form refers to a thermoformed or suitably fabricated packaging
component that has been arranged with one or more hinged flaps that can be
folded
and bonded to produce a useful packaging tray or container for goods.
"Fat" content is a component of meat and may mean the measured fat content
of a quantity of boneless meat harvested from any species of slaughtered
animal such
as beef.
"Meat" can mean any meat harvested from any species of slaughtered animal
wherein the meat comprises several components but generally including water,
fat,
oils, and protein in relative quantities that are not precisely known at the
time of
harvesting and must be measwed to determine the precise ratio of each
component.
Trays with Peelable Lids
In accordance with the present invention, trays having peelable lids are
disclosed herein. Perishable goods packaged in trays with peelable lids have
extended shelf life. A peelable lid provides a method of delaying the exposure
of
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fresh meat contained within a package to ambient air at a predetermined
period,
preferably at the point of sale.
Refernng first to FIGURES 1, 2, and 3, a preferred package 100 made in
accordance with the present invention includes a tray 102 into which meat 104
(FIGURE 3) or other perishable food product is placed. A first layer 106 and
second
layer 108 of heat sealable material are then placed over the tray 102 and heat
sealed
to the upper horizontal flange 110 that extends outwardly from the upper
periphery of
the tray 102. By draftsman's license used in accordance with the present
invention,
the layers 106 and 108 are shown separated. In actuality, they are in intimate
contact
throughout their entire length and width. The layers 106 and 108 are also
shown to
be heat sealed to each other by cross hatching shown in the drawings at
locations 112
between the two layers and between the bottom layer 106 and the tray flange
110. In
actuality again, there is no substantial thickness at the heat sealed
locations, but in
fact, the materials are in intimate contact with each other andlor the flange
110 of the
tray 102. Thereby substantially expelling/removing air or gas from
therebetween.
Depending upon the particular design and use of the tray, the first layer 106
can be composed of a substantially gas impermeable barrier layer or a
substantially
gas permeable layer. Similarly, the outer layer 108 can either be
substantially gas
impermeable or permeable. Substantially gas permeable materials include
plasticized
polyvinyl chloride (pPVC) and polyethylene (PE). Preferably, these are more
typically used in thicknesses from 0.0004 inches to 0.001 inches. Preferably,
suitable
barrier layers (substantially gas impermeable) are composed of amorphous
polyethylene terephthalate (Al'ET) unplasticized polyvinyl chloride (uPVC) and
a
composite material such as a biaxially oriented polyester/tie/polyvinylidene
chloride/tie/polyethylene. Other suitable materials known to those of ordinary
skill
can also be employed in accordance with the present invention. The trays are
preferably made of polyester (APET, amorphous polyethylene terephthalate often
referred to as polyester), polyvinyl chloride or other suitable food grade
polymers.
As used herein, a web is a sheet of material that may have one or a plurality
of layers
or zones of differing compositions. Also, when the terms "substantially gas
permeable" or "substantially gas impermeable" are used, they are intended to
reflect
the fact that no practical heat sealable material is totally gas permeable or
impermeable. Materials disclosed herein as substantially gas impermeable will
serve
as a barrier layer to the transfer of significant amounts of gas over time.
Likewise
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substantially gas permeable materials will not function as a burner but will
allow
ready diffusion of gas therethrough.
Method for Producing_Peelable Lids
A method is disclosed fox producing the peelable lids disclosed above which
include a label.
Referring now to FIGURE 4, a side elevation of a package sealing
arrangement for assembling a package of the type disclosed in FIGURE 1 is
shown.
Trays 102 are loaded with perishable edible material 104 and placed in
conventional
carrier plates on a conveyor {not shown) and conveyed toward a heat sealing
station 114. A roll 116 of heat sealable material is supplied above the
conveyor. The
sheet of material that will become the inner web 106 from the roll 116 travels
downwardly and wraps around a roller 118 and then traverses horizontally in a
left-
to-right direction along with the trays 102 being conveyed by a conveyor (not
shown). A label dispenser 118 positions a label 120 on the upper surface of
the inner
web 106 of heat sealable material. The outer web 108 of sheet material is then
drawn
from roll 122 downwardly around another roller 124 and traverses horizontally
from
left-to-right, where the label 120 is captured between the inner and outer
webs 106
and 108. The two webs and the label are then run through a pair of nip rolls
126 to
cause the two webs and the label to come into intimate contact and also
substantially
removing air from between the webs. The webs of heat sealable material 106 and
108 are then positioned at the heat sealing station 114. Corresponding tray
102 is
positioned in the lower portion 162 of the heat sealing chamber. The lower
portion
of the heat sealing chamber 162 is then raised upwardly toward the upper
portion 160
of the heat sealing chamber wherein the webs 106 and 108 are sealed to each
other
and to the upper surface of the flange/lip portion of the tray 102 around the
periphery
at the flange. At the same time, a knife incorporated into the mechanism trims
the
excess material neatly around the outer edge of the tray flange 110. The scrap
material 128 is then passed around a roller 130 and onto a scrap retrieval
roll 132.
The tray 102 is then moved onto another conveyor where the finished packages
134
are moved from left to right to a transportation and/or storage station.
Apparatus for Forming Peelabl ~ Lids
Referring to FIGURES 42-44, a schematic side elevation view through a
section of a package is shown. A schematic view is provided so as to clearly
disclose
an example of a preferred peelable seal mechanism that will facilitate peeling
of the
third web from the package while the second web remains substantially intact
and
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sealed to the first web. The example is provided to show preferred plastics
materials
that will seal as required when used according to the present invention. Other
selected materials may also be used in similar manner without departing from
the
general ambit of this invention. First 1002, second 1004, and third 1006 webs
are
shown where, in this instance, first web 1002 preferably includes a
thermoformed
tray produced from a multilayer co-extruded material including first, outer
layer 1088
of Eastman 9921 about 0.008" thick and a second inner layer 1086, about 0.004"
thick, including a blend of about 50% PETG 6763 and about 50% Eastman 5116 (or
Eastman PM14458 or equivalent shown in FIGURE 42). Second web 1004
preferably includes a web of pPVC with a thickness of about 0.0008". Referring
to
FIGURE 43, third web 1006 preferably includes a two layer co-extruded web with
a
first outer layer 1082 of Eastman PET 9921 about 0.003" in thickness and a
second
inner layer 1084 about 0.003" thick including a blend of about 16% Eastman
PETG 6763 and about 84% Eastman PET 9921. Referring now to FIGURE 42,
preferably, a water cooled clamp 1104 is shown in position above the flanges
of first,
second and third webs and two separate heat seal bars 1106 and 1008 are
arranged
adjacent thereto and all are separated by space and are each independently
activated
and controlled and moved. Preferably, heat seal bar 1106 can have a set
temperature
of about 385 degrees F and heat seal bar 1 I08 can have a set temperature of
about 370 degrees F. Third web second inner layer 1084 will heat seal to
second web
when the temperature at the interface of second and third webs reaches
about 385 degrees F and abcve. Preferably, second web will heat seal to second
inner layer 1086 of first web 1002 when the temperature of the interface
between the
first and second webs is about 370 degrees F and above.
Preferably, the water cooled clamp 1104 is mounted to an independently
activated pneumatic driver, providing downward pressure such that the water
cooled
clamp can clamp against first., second and third webs so as to hold them
firmly
against the rubber seal 1110 located beneath the first web flange portions
1072 and
1074. Preferably, heat seal bars 1106 and 1108 are independently attached to
pneumatic drivers for applying pressure thereto so as to facilitate a method
to seal
third, second and first webs together under independently selected pressure.
Preferably, heat seal bar 1106 heat seals the third, second and first webs
together
at 1112 and 1114 and heat seal bar 1108 heat seals the second web 1004 to the
first
web 1002 at 1116 but does not heat seal the interface between the third 1006
and
second 1004 webs. When the package is assembled and sealed in the foregoing
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CA 02387349 2002-04-03
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manner, the third web 1006 can be peeled from the package without rupturing
the
second web 1004. Preferably, second web 1004 may be perforated so that after
seals 1112, 1114 and 1116 have been provided, the second 1004 and third 1006
webs
can be separated to provide a space 1118 therebetween.
Seals at 1112, 1114, and 1116 have been shown as heat seals, however,
effective sealing can be achieved with use of ultra sonic devices or
alternatively latex
rubber adhesives when applied at the interfaces of the webs at 1112, 1114, and
1116,
or with any other suitable method of sealing. Such sealing can provide
improved
economics while still providing an effective peeling mechanism as required and
described above. w
Stackable Trays, Trays with Valves
Conventional thermoformed trays are shaped in a mold which have sides that
generally are inclined to facilitate separation between the mold and the tray.
Thus,
making them cumbersome to stack when filled, because the smaller area at the
bottom cannot be suitably supported by the larger opening at the top. Trays
constructed according to the present invention include members, in the form of
flaps
that provide a suitable resting area for the lower portion of the tray when
stacked atop
one another.
Embodiment 1
Refernng now to FIGURES 7-9, a preferred embodiment of a stackable
tray 202 constructed in accordance with the present invention is illustrated.
Referring first to FIGURES 7 and 8, a tray 202 has a recessed bottom 204 so as
to
form peripheral legs 206 on which the tray rests. The longitudinal edges of
the tray
each include a flange 208. The outer flange 208 is coupled to an inner flange
210 of
the tray by a hinge member 212. The inner flange is integral with and extends
outwardly from the upper edge of the tray 202. A recessed platform 214 is
formed
across the corner of the tray at diagonal corners of the tray. The bottom of
the
platform 214 is lowered slightly relative to the level of inner flange 210.
The
platform 214 in the edge of the tray carries a small depression 216, the
bottom of
which is perforated. During evacuation and flushing, gases can rapidly enter
through
the perforation in the 3epression 216, travel through the recess formed by
platform 214 into the interior of the tray and vice versa. Adjacent to the
recessed
platform 214, the flange 208 includes an outwardly extended flap 218. In the
unfolded position shown iti FIGURE 7, the flap carries a concave dimple 220
(viewed from the top). The dimple is located relative to the hinge 212 such
that
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when the flange 208 is folded over on top of the flange 210, the dimple 220
resides
directly above and central to the depression 216. When desired, the dimple can
be
depressed from the upper side so as to reverse its concavity. When the
concavity is
reversed, it extends downwardly into depression 216 to close off the
perforation in
the cavity and thus seal the container.
Referring now to FIGURE 8, a first and second web 222 and 224,
respectively, of heat sealable material overlay the upper portion of the tray
202 and
are heat sealed to the upper surface of the flange 210. First web 222 may be
incorporated by deleting web 224. A label 226 or other indicia bearing
material can
be sandwiched between the heat sealable layers 222 and 224. The method for
incorporating a label between a first and second web has been described above.
The label 226 sandwiched between heat sealable webs 222 and 224 is
optional and can cover the entire surface of the tray 202. Alternatively, the
Label can
cover only a portion of the product contained in the tray. The label can carry
graphics that, for example, show the contents in a fully prepared and cooked
condition to suggest to the consumer how the product will look when cooked,
yet
allowing the consumer to see at least a portion of the fresh product in the
tray. For
example, if the tray contained fresh beef patties, the label could cover half
of the
exposed upper surface. The label may be arranged with a straight cut or
opening
running the full length of the package. Alternatively, the label could be
positioned
on one side of a diagonal through the package, while the portion of the
package on
the opposite side of the diagonal would be open for viewing the fresh,
packaged
product.
Refernng again to FIGURE 7, the remainder of the longitudinal extent of the
flanges 208 include lateral reinforcing ribs 228 that extend upwardly from the
flanges 208 when folded over the top of flange 210. The reinforcing ribs 228
have a
recess 230 that receives the legs 206 of an identical container stacked on top
of a first
container as shown in FIGURE 9. The recesses inhibit lateral movement of one
tray
relative to another. Thus, these containers are stackable for use for example
in the
master bag evacuation technique which will be described below in conjunction
with
FIGURE 5.
Embodiment 2
Referring now to FIGURES 10-13, another embodiment of a stackable
tray 300 constructed in accordance with the present invention is illustrated.
The tray
in plan form is generally rectangularly shaped. The tray includes first and
second
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sidewalls 302 and first and second end walls 304. Walls 302 and 304 are
generally
upright and slope inwardly from their upper portion toward the tray bottom 306
to
facilitate separation from a mold. The bottom 306 has a raised central portion
308
that slopes downwardly towaxd the bottom of each end wall 304. The upper end
of
the sidewalls 302 and end walls 304 terminate in an outwardly extending
horizontal
flange 310 that extends cornpletely around the tray 300. The raised center
portion 308 creates a cavity 312 in the bottom of the tray. When the trays are
filled
and stacked, the contents extend above the flange 310. The cavity 312 will
accommodate the raised contents without compression in a stacked arrangement.
Referring to FIGURES 10-13, a horizontal platform 314 is formed in
diagonally opposed corners of the tray. The platform 314 is positioned at an
elevation slightly below that of flange 310. A wall segment 316 extends
downwardly
from the inner edge 318 of the platform 314 and has edges that join the
sidewalls 302
and end walls 304. The platform 314 and the wall 316 form a recess on the
outside
of the tray. An aperture 320 is formed in the center portion of platform 314
and
allows gas communication between the inside of the tray and the outside of the
tray
via the recess when a web is sealed over the tray to flange 310.
Referring now to FIGURES 14 and 15, the tray 300 also has movable
flanges 322 that are hinged via a hinge 324 to the outer edges of the portions
310 of
horizontal flanges 310 that extend outwardly from the end walls 304. The
flange 322
when open carries a hemispherical shaped dimple 326. The center of the dimple
326
is on a line perpendicular to the hinge 324 which line also runs through the
center of
aperture 320. The centers of the aperture 320 and the dimple 326 are
equidistantly
spaced from the hinges. Thus, as shown in FIGURE 14, when the movable
flange 322 is folded over the flange 310, the dimple 326 resides over the
aperture 320. Referring to FIGURE 14, when a web 328 of material is heat-
sealed
over the top of the tray 300, the interior of the tray 300 remains open to the
atmosphere through the space between platform 314 and web 328 through
aperture 320. As will be better understood below, it is many times desirable
to close
the aperture 320. This is done by pressing downwardly on the exterior of the
dimple 326 forcing it to reverse itself as shown in FIGURE 15 and extend
downwardly and fill the aperture 320, thus closing it and sealing the inside
of the
tray 300 from the external atmosphere.
Embodiment 3
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Refernng now to FIGURES 17 and 18, another embodiment of a stackable
tray with tray valve constructed according to the present invention is shown.
In this
embodiment, a web 400 of substantially gas permeable material is heat sealed
at 402
to the top of the peripheral flange 404 of a tray 406. A frustoconical tube
408
S extends upwardly from ledge 410 and terminates in an opening 412 that is
slightly
above the level of the outer flange 404. After heat sealing web 400 to the
flange 404,
the web 400 overlying the opening 412 contacts the upper edge of the
frustoconical
member thus forming an effective valve to close the interior of the containers
406
from the atmosphere. During evacuation of the master pack, the portion of the
web 400 over the frustoconical member 408 will elastically extend away from
the
aperture until the gas inside the package is completely withdrawn, allowing
full
evacuation of the individual container. This occurs because the air/gas
pressure
inside the package is greater than the air gas pressure outside the package
406 during
evacuation. When gas flushing occurs, which immediately follows evacuation,
the
web at the opening 412 will again be elastically extended and lifted off the
rim of the
frustoconical member 408. This again occurs because a partial vacuum remains
in
the recess of the dome 414 overlying the frustoconical member. Moreover,
during
gas flushing, at least the initial pressure in the container is less than that
on the
outside thus allowing gas pressure on the outside to distend the web 400 away
from
the opening 412. After equilibration, the tension of the web 400 over the rirn
of the
frustoconical member 408 remains so as to effectively close it and prevent
ingress of
undesirable material into and/or egress of juice or matter from the container
406.
Embodiment 4
Referring now to FIGURES 19-22, another alternative arrangement for a
valve structure similar in operation to that shown in FIGURES 17 and 18
includes a
tube 700 that extends upwardly from the upper surface of ledge 702. The tube
is
connected to the ledge 702 by a concentric bellows structure 704 that allows
the
tube 700 to move upwardly and downwardly relative to the ledge. In practice,
the
upper lip of the tube (which forms an opening into the tray from the outside)
is in
contact with the web. The dimple 710 resides over the upper edge of the tube
700.
During evacuation and gas flushing, the web 708 will distend away from the lip
700
of the tube in the same manner as described in conjunction with FIGURES 17 and
18
as shown in FIGURE 20. however, the tube may be more permanently closed by
depression and reversal of the dimple 710. Full reversal of the dimple 710
would
push the tubes 700 downwaudly against the resistance of the bellows structure
704
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thus, forming a very tight closure between the upper lip 700 of the tube and
the
bottom surface of the reversed dimple 710.
Embodiment 5
Referring now to FIGURE 6, another embodiment of a tray with valve
constructed in accordance with the present invention is shown. In this
embodiment,
the tray 146 has an upper peripheral flange 148 that extends outwardly from
the
entire upper periphery of the tray 146. The tray sides extend downwardly to
the
horizontally disposed bottom. A downwardly extending recess 150 is cut in the
tray
corners. The edges of the recess 152 communicate with the interior of the
tray. At
the inner portion of the recess, the recess and the wall of the tray terminate
in an
opening 154 having its upper edge at the same level as the upper surface of
the
flange 148. The opening 154 functions in a similar manner as the apertures in
the
tray 202 shown in FIGURE 7. However, in this embodiment, if the tray is
tipped,
undesirable juices can flow into the recess 150 and hack out through the edges
of the
recess 152. In this manner the undesirable juices/liquids will not easily exit
the
package through the opening 1~4.
Trays constructed in accordance with the present invention provide a
closeable ventilation mechanism. In addition, trays constructed according to
the
present invention provide for ledges which allow the trays to be stacked in a
convenient fashion in master bag or master containers as shown in FIGURE 5.
Further, valves according to the present invention may be one way only valves.
Master Containers, Master Baas
Packaged trays constructed according to the present invention can be stacked
in master containers, evacuated and flushed with desirable gases, and the
master
container can be sealed to enhance the shelf life of the packaged goods.
A description of the master container method of packaging perishable good
according to the present invention will now be described with reference to
FIGURES 5, 10-13, and 16.
One of the aforementioned trays make suitable packages for use with the
master container method provided the tray includes foldable flaps and channels
providing communication from the interior of the package to the exterior
surrounding
environment, for example the tray of FIGURE 10. Referring now to FIGURE 11,
the
package can be used to store and transport red meat 330, for example, ground
beef.
In accordance with the present invention, the ground beef 330 may be ground in
a
conventional grinder. The grinder may be modified so that preconditioned
carbon
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dioxide at a predetermined temperature is injected into the grinder head for
two
purposes. The first is to cool the grinder head; the second is to allow the
carbon
dioxide to mix with the ground beef 330 and become dissolved in the liquid
therein.
The dissolved carbon dioxide will aid in preservation of the ground beef
during the
storage period. A web 328 of substantially gas permeable material is then
placed
over the tray 300 and heat sealed to the flange 310 in a conventional manner
as
shown in FIGURE 12. The web is taut over the top of the red meat to prevent
its
movement about the tray during handling. A label 332 may be applied to the
upper
surface of the web 328 if desired. Alternatively, a dual web can be employed
as
shown in FIGURE 1 and a label sandwiched therebetween: Thereafter, the flaps
or
movable flanges 322 are folded over the top of the flange portions 310 so that
the
dimples 326 reside over the apertures 320. However, any of the aforementioned
trays with valves can be used. The flaps 322 are then further heat sealed
along their
outer edges to the flanges 310 at a second heat sealing station to form a
completed
package as shown in FIGL))~ 13.
Referring now to FIGURE 16, a preferred embodiment of a master container
constructed according to the present invention is shown. The master container
334
can be thermoformed from substantially gas barner materials such as
unplasticized
PVC or alternatively a coextruded material including amorphous polyethylene
terephthalate and polyethylene glycol. The material can be formed with the
polyethylene glycol layer on the inside of the tray allowing exposure to the
web of
PVC material for heat sealing. The master container 334 includes flange 336
located
around the periphery of the ~:pper portion of the container 334. The master
container
containing finished packages 300 with perishable goods therein are evacuated
and
flushed with a gas of suitable composition. The master container can be sealed
by a
web of material to the flange 336.
As shown in FIGURE 16, a plurality of trays 300 may then be positioned in a
master tray 334. For example, in a 3 high by 4 wide array. In accordance with
the
method of the present invention, the master tray 334 can then be evacuated and
flushed with substantially oxygen free gases. At the same time, the individual
packages 300 are evacuated through the apertures 320 and flushed with inert
gases
that enter the individual pacl~:uges through apertures 320 as well. A package
formed
in accordance with the present invention allows the use of relatively large
aperture 320, which in turn enables very rapid evacuation and gas flushing of
the
individual packages. With the disclosed system it is estimated that only a few
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CA 02387349 2002-04-03
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seconds will be needed to completely evacuate and gas flush the master tray
334 and
individual trays 300. After the containers are evacuated and flushed, a master
web 338 is heat sealed to the top of the master tray 334. To form a completed
master
tray 334, if desired, an oxygen absorber may be inserted in the master tray
334 so
that it is assured that the residual oxygen content in the package will stay
below
about 0.05%. This low level of oxygen is required to prevent irreversible
oxidation
of the deoxymyoglobin in the red meat and forming of metmyoglobin.
Once the package reaches its destination, it can be stored for several days in
a
sealed condition. When it is time to display the meat, the master web 338 is
removed
i0 from the master tray 334 and the individual packages can be weighed and
labeled.
At that time, oxygen reenters the individual packages 300 through the aperture
320 as
well as through the substantially gas permeable web 328. The oxygen converts
the
deoxymyoglobin in the red meat to oxymyoglobin, giving the meat a very fresh
red
appearance. Before placing the package in the display case, the dimple 326,
one
embodiment of which is shown in FIGURES 14-15, is depressed so as to close the
aperture 320 which prevents the entry of undesirable elements such as insects
into the
package, and also substantially seals the package so that juices from the red
meat
cannot escape from the container if it is tipped on end.
Refernng now to FIGURE 5, a preferred alternate master bag container
constructed according to the present invention is illustrated. Trays
constructed
according to the present invention can be stacked conveniently atop one
another
because the trays have been provided with flaps which fold inwardly to provide
a
ledge for a tray resting atop another tray can rest. Once trays are placed
inside a
master container as shown in FIGURE 5, the gas inside the master bag and trays
can
be evacuated through opening 140, because trays constructed according to the
present
invention include valves which allow the interior of sealed trays 136 to also
be
evacuated, and then flushed with a gas of desirable composition. The gas is
preferably inert and substantially oxygen-free so as to reduce oxidation of
the edible
products in the packages 136 during storage. The number of cycles which are
necessary to lower the level of the undesirable gas will vary. Once the master
bag
reaches an intermediate processing station prior to delivery to the location
of point of
display, it can be opened and flushed with high oxygen atmosphere
containing 80% 02 + C02. The packages can be weighed and labeled. Then the
dimples may be depressed to close the perforations in depressions at this
station or
alternatively left open. In some alternates of the present invention, the
trays are
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CA 02387349 2002-04-03
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provided with one-way valves which eliminates the need for dimples. Other
alternates of trays may have no valves, because these packages will have been
packaged in a low oxygen atmosphere. After this step, the trays can then be
replaced
into a master bag at which time the interior can be partially or completely
evacuated
and flushed with a high oxygen content gas such as 80% 02 + C02. The master
bag
can then be heat sealed again. In this way, extra days of shelf life can be
obtained
because the CO2 will tend to inhibit bacterial growth.
This method of packaging can be advantageously used for other types of
higher value products such as tomatoes, grapes, peaches and the like.
Referring again to FIGURE 5, an alternative to -evacuating - the -bag 138,
includes an oxygen absorber such as an iron compound that can be placed in a
container 142 in the master bag 138. Thus, instead of or additionally to
evacuating
and flushing with an inert or substantially oxygen free gas, the oxygen-
absorbing
compound quickly absorbs all remaining oxygen in the bag leaving only nitrogen
and
other inert gases that will not adversely affect the condition or value of the
food or
red meat products in the containers.
In practice it is possible that all features described above will be
incorporated
into individual retail package structures. With the valve arrangement, free
passage of
air and/or gas through the aperture is essentially restricted. In addition,
small
microperforations in the overlying web may be employed to allow more rapid
gas/air
exchange than would otherwise occur through a normal substantially gas
permeable
material such as plasticized polyvinyl chloride. Such microperforations would
facilitate more rapid reoxygenation of the deoxymyoglobin and generation of a
desirable bright red meat color.
Soaker Pads
Soaker pads provide absorptive materials to absorb liquids exuded by the
packaged goods. Soaker pads constructed according to the present invention
include
bacteria sensing materials.
Referring now to FIGURE 22, a tray constructed according to the present
invention is shown. Tray 800 is configured similarly to that of the tray shown
in
FIGURE 10, and carries a soaker pad 802 that lies on the bottom of the tray. A
plan
side view of soaker pad 802 is shown in FIGURE 24 and a cross-sectional view
25 is
shown in FIGURE 23. The ground beef 804 or other edible material is positioned
on
the soaker pad and first and second webs 806 and 808 of heat sealable material
are
placed over the tray and sealed to the horizontal flanges 810 that extend
outwardly
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from the upper edges of the tray. The label 812 is included of a special
polymeric
material that has the capability of indicating the presence of E. coli
bacteria. This
material may be laminated into a three-layer web including polypropylenelE.
coli
sensor material/polypropylene or polyethylenelsensor material/polyethylene.
The
polymeric material employed is of the type disclosed in the paper entitled "A
Litmus
Test for Molecular Recognition Using Artificial Membrane," Charych, D. et al.
Chemistry and Biology, Vol. 3, No. 2, February 1996, 3:113-120, expressly
incorporated herein by reference. The lower web 806 may be microperforated in
the
region of the label 812 so that juices from the ground beef 804 can penetrate
the web
and contact the label 812. The label 812 will change color in the presence of
E. cola
bacteria. The upper surface of the label can also be treated so that it may be
printed
with instructions relating to the E. coli test and/or information relating to
the ground
beef 804 or other edible product. A detail of the webs 806 and 808 carrying
the
litmus test label 812 is shown in FIGURE 25.
Alternatively, as shown in FIGURES 24 and 25 (a cross-section of
FIGURE 24 along section line 25) shows that the container for the soaker pad
802
can be made of the laminated three-layer web described above containing as the
middle layer the litmus test sensor material. In this embodiment, the
absorbent
material 814 in the soaker pad 802 is encased in an upper web 816 of the tri-
layer test
material and a lower web 818 of the same test material. It is heat sealed
around the
entire periphery 820 and placed in the bottom of the tray 800 (FIGURE 22).
Both
webs 816 and 818 are microperforated so that juices from the red meat 804 can
penetrate to the absorbent layer 814. The presence of E. coli will be shown by
a
change in color of the test material in the web 816 and 818.
FIGURE 26 illustrates a tray 800 similar to that shown in FIGURE 22.
However, this tray carnes a plurality of ground beef patties 822 that are
interleaved
with layers 824 of the test material. In this manner, the presence of E. coli
bacteria
can be ascertained at a variety of locations in the package.
Apparatus and Methods for the Manufacture of Soaker Pads
Referring to FIGURES 27-30, a side elevation (FIGURE 27) and a plan view
(FIGURE 28) of an apparatus for manufacture of soaker pads with the engineered
polymerized molecular film of the type that detects E. coli and indicates its
presence
by a change of color [EPMF] attached to an inner surface of a side of the
soaker pad
is illustrated. A roll of coextruded transparent, perforated, plastics
materia1900,
including a rolled length of web 902, is mounted on an unwind stand 904 and
the end
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of the web is "threaded" around a series of drive and idler rollers, 906, 908,
910, 912,
and 914 such that when drive rollers 908 and 914 are driven, the web 902 is
pulled
over the drive roller 908 so that the inside surface of the web 902 contacts
the
surface 922 of the water 918 flowing through the trough 920. The trough 920 is
connected to a conventional Langmuir-Blodgett water trough in such a manner as
to
cause water 918 to flow, from the Langmuir-Blodgett water trough,
horizontally,
underneath and parallel to web 902 and at a similar rate of flow to the speed
of the
forward movement of the web 902 as controlled by the rate of revolutions of
drive
roller 908. The Langmuir-Blodgett water trough is provided to generate
sufficient
quantities of EPMF as required by the process. The EPNiF floats on the surface
922 -
of the water 918 and is carried with the flow of water at a similar speed.
When the
web 902 contacts surface 922, the EPMF is transferred from the water surface
to the
web 902 and travels adjacent to a drying section 924 that evaporates any
surplus
water.
The web 902 is transferred from a vertical disposition across drying
section 924 to horizontal by way of movement over the idler roller 910. Soaker
(absorbent) pads 942 are positioned onto the surface of the web 902 and a
further
perforated web 930 is unwound from roll 932 mounted on unwind stand 934. The
two webs, with absorbent pads therebetween, are transferred, between two drive
rollers, 914 and into a heat sealing station 936. The heat sealing station
seals the two
webs 902 and 930 together by applying pressure through two sets of temperature
controlled heat sealing bars 9362, 936b shown in FIGURE 30. The pressure
applied
is sufficient to distort the EPMF layer 960 and allow direct contact of the
web 902
and 930 surface layer material (SURLYN is a registered trademark of Dupont),
which is an ionomer resin and the SURLYN readily bonds together. Webs 902 and
930 are composites which include an outer and inner layer, 962, 964, 966 and
968,
respectively. The longitudinal slitting station 938 slits and separates the
sealed
soaker pads into continuous strips and the lateral cutting station 940 cuts
across the
webs thereby separating the complete soaker pads.
Trays_ with flaps. Trays with Channels
Trays with flaps and trays with channels which are constructed according to
the present invention provide sturdier stackable trays which are able to be
evacuated
of air and flushed with inert gasses and additionally provide channels and
spaces to
retain any liquids exuded from the processed goods.
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Embodiment 1
Refernng now to FIGURE 31, a preferred packaging tray 3000 with flaps, is
shown in a three dimensional drawing. The tray and flaps 3002 can be
thermoformed
from suitable materials such as polystyrene, polyester and polypropylene in a
solid or
S foamed sheet. The tray 3000 is most preferably thermoformed from an expanded
polystyrene sheet of suitable thickness. Tray 3000 includes a base with
perforations 3004. Four upwardly extending sides terminate at a common
flange 3006. Flaps 3002, 3050, 3052 and 3054 are attached to flange 3006 at
the
external edge of flange by way of hinges at a hinge lines as shown. Flap 3002
is
provided with a profile that mirror images flap 3052, and flap 3050 is
provided with
a profile that mirror images flap 3054. Flaps are attached to the outer edge
of flange
rim at hinges as shown, such that flaps 3002, 3050, 3052 and 3054 will fold
downwardly and intimately contact outer surfaces of the tray walls. The cross-
sectional profile of flaps 3002, 3050, 3052, 3054 are similar, flap 3002 and
flap 3052
being of substantially similar dimensions, and flap 3050 and flap 3054 being
of
substantially similar dimensions. Flaps are formed with a rim 3008 that
follows a
continuous path around the perimeter of the flaps. Flaps include a profile
which
includes a flap base 3010, a flap flange wall 3012 and external flap vertical
walls 3022. Buttresses 3016 are formed into flap profile and connect flap
flange
wall 3012 to flap base 3010. Horizontally disposed ridges 3018 and 3020
provide
horizontal channels that connect buttresses 3016 with continuous communication
to
openings at each end of flaps in flap vertical walls 3022. Apertures 3014 are
provided between the ridges. Apertures 3014 thereby provide communication
through flaps at locations between the buttresses. Apertures 3026 are provided
in
upwardly extending walls of tray at points adjacent to buttresses such that
when flaps
are folded into a vertically disposed position relative to tray, apertures
3026 provide
direct communication through tray walls to buttress recesses 3024.
Referring now to FIGURE 32, a three dimensional sketch of the tray 3000
with flaps folded downwardly, is shown. Flaps are folded to a downwardly
position,
such that flap flange wall 3012 is in contact with the underside of flange
3006. In
this position, flaps are located in close proximity and in contact with
upwardly
extending tray sides. Flap base 3010 is substantially horizontally disposed
relative to
tray and provides an extension to base of tray such that when tray with flaps
folded
as shown in FIGURE 32 is placed directly above a similar tray, flap base is
adjacent
to and resting on flange 3006. It should be noted that while packaging shown
in
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FIGURE 31 includes a tray with four flaps, any number of flaps from one to
four
may be provided according to preference and any specific requirements of a
particular application.
Referring now to FIGURE 33, tray base 3028 is shown with perforations
therein. Perforations 3004 may extend directly through tray base or partially
therethrough from either side. Perforations can provide absorption of liquids
that
may accumulate adjacent thereto, by the open cell structure of the tray base
material,
such as when the tray has been thermoformed from expanded polystyrene sheet
which is, at least in part, of open cell structure. A space 3030 is shown
which can be
provided if desired. Space 3030 can be provided after tray with flaps is
inserted into
a pre-formed shrink bag that is then exposed to elevated temperature that can
cause
the shrink bag to shrink around the tray with flaps. Alternatively, tray with
flaps
profile can be arranged such that space 3030 is substantially minimized when
the tray
base is in direct and intimate contact with the shrink bag. Shrink bags may be
printed
as required with information of interest to any person interested in
purchasing the
finished package. Such shrink bags are manufactured for example by Robbie
Manufacturing Inc., and are well known by the name PromoBag TM. Shrink bags
can be printed and fabricated from a clear, biaxially-oriented, heat
shrinkable, anti-
fog, polyolefin film material manufactured by E.I. Dupont De Nemours and known
as Clysar AFG anti-fog shrink film. Clysar is a registered trade mark of
Dupont,
details of which can be obtained from Dupont or on the Internet at
www.clysar.com.
Refernng now to FIGURE 34, a finished package is shown. The finished
package may contain perishable goods such as fresh red meats or fresh ground
meats.
Apertures 3032 can be provided at optimized locations and/or as shown, in the
outer
cover shrink material 3034 of the finished package 3036. Apertures 3032, which
may be provided in the bag or web of shrink material before or after package
assembly, thereby providing direct communication from external atmosphere
through
space 3038, apertures 3032, buttress recess 3024 and apertures 3026, and into
the
tray cavity 3040. A plurality of finished packages can be located inside a
barrier
master container as shown in FIGURE 35 or any other master container/bag
previously described above. Such barrier master container may be thermoformed
from a substantially gas barrier plastics material, such as a co-extruded
multi-layer
sheet of nylon//PVDCI/polyethylene. After inserting finished packages into the
barner master container, the master container can be located inside a vacuum
chamber and substantially all atmospheric gases can thereby be evacuated from
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within the barrier master container, and within the finished packages. A gas
or blend
of suitable gases such as carbon dioxide, nitrogen, oxygen and any other
suitable
gases, can be provided into the barner master container and the finished
packages
prior to hermetically sealing a substantially gas barrier lid to flanges of
the barrier
master container. A plurality of barner master containers can then be
positioned into
a suitably sized shipping case as shown in FIGURE 35, prior to shipping to
another
location.
Referring to FIGURES 35-36, in yet another preferred embodiment, the
master container 3226, with one or more finished packages, 3224, contained
therein
and including a "loaded master container", may be located inside a pressure
vessel
that is also arranged to operate as a vacuum chamber with gas flushing. After
location of the "loaded master container" inside a pressure vessel, the
pressure vessel
is closed and sealed from atmospheric air and substantially all air is
evacuated to a
desired and predetermined level. Following evacuation, the pressure vessel can
be
filled with a desired gas such as carbon dioxide to a predetermined,
controlled and
maintained pressure, above atmospheric pressure, such as 12 psi or up to 250
psi or
higher, and held at a predetermined pressure for a period of time that will
allow
sufficient carbon dioxide gas to dissolve in the perishable goods contained in
the
finished packages in the master container. Carbon dioxide gas can be held at
the
pressure, for a period of time, as required to prolong the subsequent storage
life of
the perishable goods. Folluwing the period of time, the gas pressure may be
lowered
to a pressure equal to that of the prevailing atmospheric pressure and a gas
barrier lid
then hermetically sealed to the flanges of the master container prior to
opening the
pressure vessel and removing the master container. The aforementioned process
may
include the steps of:
i) Locating a master container, 3226 with finished packages such as
those shown as 3224 contained therein, into a suitable pressure vessel.
ii) Closing and sealing the pressure vessel so as to isolate it from
atmospheric air.
iii) Evacuating substantially all air from within the pressure vessel.
iv) Providing a gas such as carbon dioxide in the pressure vessel at a
pressure above atmospheric pressure.
v) Holding the pressurized carbon dioxide provided in the pressure
vessel for a period of time sufficient to enhance the keeping qualities of the
perishable goods contained i~~ the finished packages 3224 , for an extended
period.
x,_f
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vi) Lowering the gas pressure within the pressure vessel, to a level equal
to the prevailing atmospheric pressure.
vii) Hermetically heat sealing a gas barrier lid to the flanges of the master
container so as to substantially exclude oxygen gas from inside the master
container.
viii) Removing the master container from the pressure vessel
automatically.
ix) Locating another master container in the pressure vessel by
automatically and repeating steps l). to viii). in an automatic fashion.
x) Placing and sealing the master container into a finished shipping case
as shown in FIGURE 36 which may be constructed of cardboard material with a
crush test rating of 44. lbs. per inch.
xi) Shipping the finished container to another location.
xii) Removing the finished packages from the finished shipping case and
allowing atmospheric air to penetrate through the apertures in the finished
package.
xiii) Repeating any or all of the above steps as required to maximize the
keeping qualities of the perishable goods.
Refernng again to FIGURE 33, it can be seen that by manufacturing
packaging in this manner, any liquids that may accumulate within the tray
cavity 3040, such as blood, will be substantially restricted from escaping
through
apertures 3032 shown in FIGURE 34. This restriction is provided due to the
arrangement of flaps and apertures therein, and the location of the apertures.
Furthermore, perforations 3004 provide for retention of the liquids within the
package.
Embodiment 2
An alternate embodiment of a tray with flaps constructed according to the
present invention is shown in FIGURES 37-41. The tray of FIGURE 37 includes
four flaps as the tray of FIGURE 31, with modifications as described herein.
FIGURE 37 shows the cross-sectional detail of a tray. The tray walls are
perforated
in sections shown as incision section 3526 and incision section 3528, shown in
FIGURE 39. Perforations may be in the form of small holes or incisions that
extend
fully through the tray walls, but may be only provided within the limits of
regions
shown as incision sections 3526 and 3528.
Referring now to FIGURE 37, a cross-sectional view of finished
package 3514 is shown. Finished package 3514 includes a packaging tray 3556
with
perishable goods located in tray cavity with an outer cover 3516. The outer
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cover 3516 includes an envelope of material that completely covers and
encloses the
packaging tray and the perishable goods and is heat sealed to provide a sealed
package. The outer cover 3516 may be manufactured from a shrink material such
as
Clysar, manufactured by DuPont, and can be printed such that all surfaces are
rendered opaque leaving a transparent window 3522 on the upper surface only,
as
shown in FIGURE 38 of the finished package. Clysar outer cover shrink material
is
then heat shrunk such that the outer cover shrinks, holding the flaps against
the tray
walls. Apertures 3518 are provided on the four vertical faces of the finished
package
when the base 3520 of tray is horizontally disposed.
i0 Referring now to FIGURE 39, a detailed section of a packaging tray 3556
with base 3520, tray wall 3524 and flange rim 3512 attached to flap 3508 at a
hinge 3532, is shown. The relative position of flap 3508 and the section of
tray is in
the "open position". Flap 3508 is attached at hinge 3532 to flange rim 3512,
however
flap 3508 is not folded downwardly.
Referring now to the flap portion 3508 of FIGURE 39, a cross-section is
shown including a first and second raised peaks 3534 and 3536, respectively,
and a
flat area shown as face 3538 and face 3540; also shown are a ridge 3542; and
gussets 3544, with connecting sections therebetween. Packaging tray includes a
base 3520, flange rim 3512 with tray wall connecting base of tray to the
flange rim.
Tray wall includes recess 3546, a first incision section 3526, recess 3548 and
a
second incision section 3528. FIGURE 40 shows a view of flap from the
direction of
arrow 3608. Flap 3508 includes a perimeter 3530 including hinge 3532, face
3538
and end flanges 3550 that are connected together to provide the continuous
flat
perimeter. Referring now to FIGURE 40, depressions 3552 may be provided in the
flap section between peak 3534 and ridge 3542 but do not perforate the section
to
provide direct communication therethrough. Apertures 3554 are also provided in
face 3540.
Refernng now to FIGURE 41, an enlarged view of a tray portion of
FIGURE 37 is shown. Flap and the tray wall are in intimate adjacent contact
and
ridge 3542 and recess 3546 are engaged. Faces 3538 and 3540 as shown in
FIGURE 41, are in direct and intimate contact with the tray wall. Face 3540 is
located in recess 3548, thereby closing apertures 3554 when in this position.
Spaces 3560 and 3558 are directly adjacent to first and second incision
sections 3526
and 3528. Shrink film 3516 holds flap firmly and tightly against the tray wall
providing sealed contents within the finished package. The package may be
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colorized to prevent translucency. An adhesive such as a cold seal latex is
provided
between the continuous perimeter 3530 of the flap as shown in FIGURE 40. The
tray wall is inwardly flexible such that when a vacuum is provided within the
tray
cavity, the recess 3548 and face 3540 will separate to provide direct
communication
from within the tray cavity via perforations or incisions at first and second
incision
sections 3526 and 3528 through apertures 3554, and through apertures 3518 in
outer
cover shrink film 3516.
A plurality of finished packages 3514 of this embodiment can, as well, be
stacked and placed inside a gas barrier master container inside a vacuum
chamber.
Substantially all the air may be evacuated from within the gas barrier
container and .
from inside the finished packages. Air is evacuated from within the packaging
tray
cavity through perforations andlor incisions in the tray wall at first and
second
incisions 3526 and 3528 into space 3560 and 3558, created when the fjap is
placed
adjacent the tray wall, the air flows through apertures 3554 and apertures
3518. A
suitable gas or gas blend such as nitrogen and carbon dioxide can then be
provided
into the vacuum chamber. The desired gas can be provided in a reverse flow
direction into the finished packages by way of direct communication through
apertures 3518, apertures 3554 into spaces 3560 and 3558, through perforations
at
incision sections 3526 and 3528 and thereby fill all free space within the
finished
packages and the gas barrier master container. A gas barrier lid can then be
hermetically heat sealed to the opening of the gas barrier master container
and the
finished packages in the hermetically sealed master container can then be
stored at a
controlled temperature for a desired period of time prior to opening the
master
container and removal of the finished packages for retail sale.
In this way air and gasses can be removed from the finished and sealed
packages by evacuation and then replaced by gas flushing with a desired gas,
while
liquids such as blood cannot readily escape.
Embodiment 3
Referring now to FIGURE 271, another preferred packaging tray with flaps
constructed according to the present invention is shown in a three dimensional
sketch. The packaging tray of this embodiment as with the packaging trays of
previous embodiments is similar in operation, but with an alternate
configuration of
the channels through which evacuation and flushing is accomplished. The tray
with
flaps can be thermoformed from suitable plastics materials such as
polystyrene,
polyester and polypropylene in a solid or foamed sheet. The present packaging
tray
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is preferably thermoformed from expanded polystyrene (EPS) sheet. T'he EPS
sheet
may include an "open cell" structure with a surfactant added prior to
extrusion of the
sheet such that the finished tray will have a capacity to absorb water and
other liquids
such as "purge" or blood. The EPS sheet may be extruded with a "skin" on what
will
become the in-side of the finished tray. The "skin" can be arranged so as not
to
absorb the liquids. The non absorbent "skin" may be provided on both surfaces
of
the extruded sheet.
The EPS sheet may b~ a multi-layer extruded sheet including three layers.
The three layers may include two outer layers of closed cell EPS foam with an
inner
layer of open celled EPS foam. The outer layers may be close celled and
resistant to
liquids such as blood and/or purge. The inner layer of open celled >r'YS roam
can be
extruded with a suitable surfactant contained therein that will enhance the
liquid
absorbing qualities of the open celled EPS foam.
The tray with flaps, shown in FIGURES 271-272, is most preferably
I5 thermoformed from expanded polystyrene sheet of suitable thickness, of
preferably
from about 0.01" to about 0.15", and most preferably about 0.090" and
including at
least two layers including a "skin" that will not absorb the liquids and an
adjacent
layer of open cell structure that will absorb the liquids. FIGURE 271 shows
detail of
the packaging tray with flaps extended and including a tray with tray cavity
and four
flaps shown as flap 7002, flap 7004, flap 7006, and flap 7018. Flap 7002 is
provided
with a profile that mirror images flap 7006, and flap 7004 is provided with a
profile
that mirror images flap 7018. Flaps 7002, 7004, 7006 and 7018 are attached to
the
outer edge of flange rim 7010 at hinges 7012 as shown, such that flaps 7002,
7004,
7006 and 7018 will fold downwardly and intimately contact outer surfaces of
the tray
walls. FIGURE 272 shows the packaging tray with flaps folded downwardly. The
cross-sectional profile of flaps 7002, 7004, 7006 and 7018 are similar. Flap
7002 and
flap 7006 being of substantially similar dimensions, and flap 7004 and flap
7018
being of substantially similar dimensions, but can be longer or shorter than
flaps 7002 and 7006. Referring yet again to FIGURE 271, the packaging tray
includes a base with four upwardly extending tray walls terminating at a
continuous
flange rim 7010. The tray walls can be perforated with openings directly
therethrough with the perforations arranged in sections shown as a first
incision
section 7014 and a second incision section 7016. The perforations may be in
the
form of small holes or incisions that extend fully through the tray walls, but
are
preferably provided within the limits of regions shown as first and second
incision
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sections 7014 and 7016, respectively. Apertures provided in sections 7014 and
7016
preferably extend into spaces between flaps and tray walls. Apertures 7020
provide a
passage for evacuating and flushing the tray in a master container, as
previously
described.
Embodiment 4
In another embodiment shown in FIGURES 45-49, a gap 4126 is provided
between the flap at openings 4128 and the tray wall. The flap 4106 is in a
folded
down position and a gap 4126 is arranged between openings 4128 and the tray
side
wall. Spaces 4130 and 4132 are directly adjacent to incision sections 4118 and
4116.
The shrink film holds the flap firrrily and tightly against the tray wall. An
adhesive
such as a cold seal latex, or any other suitable adhesive may be provided
between the
flaps and the tray walls so as to cause sealing and bonding where contact
between the
flaps and the tray walls occurs. FIGURE 46 provides details of a cross-section
through a section of the tray wall and the flap that are in direct contact. A
"skin" 4134 is shown on the outer surfaces of the section directly adjacent to
EPS
foam that is bonded together by adhesive layer 4146 causing a secure bonding
and
sealing of the tray wall and the flap together. The sealing and bonding can be
arranged so as to provide a completely sealed and "liquid tight" condition
such that
any liquids contained in the spaces 4130 and 4132 will be retained within the
spaces.
As shown in FIGURE 49, an adhesive layer 4142 can be provided between base
4138
and outer cover 4120 so as to bond the outer cover 4120 to the base 4138.
Referring now to diagram FIGURE 47, an elevation of finished
package 4118, is shown. Toe finished package 4118 includes a packaging tray as
shown in FIGURE 45 with perishable goods located in tray cavity with an outer
cover 4120. The outer cover 4120 includes an envelope of material that
completely
covers and encloses the packaging tray and the perishable goods and is heat
sealed to
provide a sealed package. The outer cover 4120 may be manufactured from a
shrink
material such as Ciysar, manufactured by DuPont, or alternatively a stretch
wrapping
material such as Mapac -M, a plasticized polyvinyl chloride web material
manufactured by AEP Industries, Inc. The outer cover 4120 can be printed such
that
all surfaces are rendered opaque leaving a transparent window 4122 on the
upper
surface as shown in FIGURE 47. Clysar outer cover shrink material is then heat
shrunk such that the outer cover shrinks, holding flaps against the tray
walls.
Alternatively, if the Mapac -M, pPVC material is used, heat shrinking may not
be
required and the Mapac -M material is stretched over the tray with flaps such
that
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flaps contact the tray walls. Apertures 4124 are preferably provided on the
four
vertical faces of the finished package. The apertures are conveniently located
in such
a location so as to minimize the probability of any liquids, such as blood or
"purge",
escaping therethrough.
The EPS material, which may contain a suitable surfactant, used in
production of the packaging tray may be manufactured so as to have a capacity
to
absorb liquids such as blood. Incisions and/or perforations provided in
sections of
the packaging tray can enhance the capacity of the EPS material to absorb the
liquids
such as blood.
Referring now to FIGURE 48, an enlarged view of a cross section of the tray
of FIGURE 45 is shown. The flap and the tray wall are in intimate contact and
a
gap 4126 is arranged between openings 4128 and the tray side wall. Spaces 4130
and 4132 are directly adjacent to incision sections 4118 and 4116. A suitable
adhesive can be applied between the flap and the tray at all direct points of
contact
therebetween causing a secure bonding and sealing of the tray wall and the
flap
together. The sealing and bonding can be arranged so as to provide a
substantially
sealed and "liquid tight" condition such that any liquids contained in spaces
4130 and
4132 will be retained. The shrink film, outer cover 4120 holds the flap firmly
and
tightly against the tray wall. Referring now to FIGURE 49, a cross-section of
the
tray base portion and outer cover 4120 are shown to be in adjacent
disposition. An
adhesive layer 4142 can be provided so as to completely bond the outer cover
4120
to the base of tray 4138.
Furthermore, when the outside-surface of foam is arranged to have a capacity
to absorb liquids, such liquids can be retained and substantially prevented
from
escaping from within the finished package. Additionally, a suitable adhesive
can be
provided between the tray flange rim 4144 and the outer cover 4120 where the
continuous flange rim 4144 is in contact with the outer cover 4120 so as to
cause
bonding in a substantially liquid tight fashion therebetween. The openings at
sections 4116 and 4118 in the tray wall, openings 4128 in the flaps and
apertures 4124 in the outer cover 4120 provide a passage and direct
communication
from the tray cavity to the outside of the finished package such that when the
finished
package is exposed to a vacuum, air and gasses can be removed from within the
package and replaced with a desired gas or mixture of gasses through the
passage.
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Embodiment 5
FIGURES 50-54 show yet another embodiment of a tray with flaps
constructed according to the present invention. The tray 8208 of this
embodiment is
similar in operation to the trays described above. Refernng to FIGURE 50, a
tray is
S shown whereby flaps 8202 and 8206 can be arranged so as to have no openings
therein, and flaps 8200 and 8204 can be arranged to have openings 8210
therein.
Tray 8208 as shown in FIGURES SO-54 can be over wrapped with a web of pPVC to
produce a finished package. The web of pPVC can be printed on the inner
surface
with a heat activated coating that can provide a method of bonding the web of
pPVC
~ to faces 8212 on flaps 8202 and 8206 and face 8214 on flaps 8200 and 8204.
The
heat activated coating can be applied to the web of pPVC by typical offset
printing
process and applied in those areas of pPVC that will come into contact with
the
faces 8206 and 8214 after over wrapping the tray 8208 with the web of pPVC in
such
a manner that when heat is applied to the pPVC in contact with the faces 8212
and
8214 the web of pPVC will become bonded to the faces 8212 and 8214. The web of
pPVC will thereby cover recess 8216 and recess 8218 in flaps 8200 and 8204 but
will
not fully enclose and isolate the recesses leaving openings at openings 8220.
The
web of pPVC can also thereby cover recess 8222 and recess 8224 in flaps 8206
and
8202 but will not fully enclose and isolate the recesses leaving openings at
openings 8226. In this way a path of direct communication from internal space
of
the tray to external atmosphere is provided through apertures 8228 into space
8230
shown in FIGURE 274 through apertures 8210 in flaps 8206 and 8202 only into
recessed 8222 and recesses 8224 and through openings 8226 into space between
the
pPVC outer cover and tray through space 8230 and therefrom through openings
8220
into recesses 8216 and 8218 and finally through apertures that are provided in
the
outer cover pPVC adjacent to the recesses 8218 in flaps 8200 and 8204 to
external
atmosphere.
The tray 8208 may be thermoformed from any suitable material such as
expanded polystyrene EPS materials as shown in FIGURES 242-246 and
FIGURES 71-72. The EPS materials may include several layers of co-extruded
material that are arranged so as to allow any liquids that may enter space
8230 of
FIGURE 274 through apertures 8228 to be absorbed into the open cell structure
of
EPS materials through surface perforations 8250 that can be provided into the
surface
of the EPS materials that are adjacent to space 8230 only. Liquids can thereby
be
concealed within the layers 4502 or 4508 as shown in FIGURES 229-230.
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The pPVC outer cover can be bonded to the underside of the tray 8208 by any
suitable method, such as heat sealing or adhesive bonding, so as to follow
contours of
recess 8232 shown in FIGURE 51. The pPVC outer cover can also be bonded, by
any suitable method, such as heat sealing or adhesive bonding, to flange rim
8234
along the full length and perimeter thereof so as to inhibit liquids from
passing
between the flange rim 8234 and the pPVC over wrapping web of material after
the
bonding.
In this way liquids that may accumulate in internal space of tray are
restricted
from escaping from within the finished package, while providing a path to
allow
extraction and injection of suitable gasses into and out of the internal space
of tray.
In another preferred embodiment the flaps may be extended as shown in
FIGURE 54, flap 5056 to provide additional cushioning around the perimeter.
The
additional cushioning can provide protection of the package and the package
contents
during shipping from the point of production of the finished packages and a
point of
sale to consumers such as a supermarket. FIGURE 273 shows a tray flap with a
space wherein substances 8250 may be added, such as wax-coated iron particles.
FIGURE 274 shows a cross section of a tray with flaps, wherein the flaps form
a
plurality of spaces between the tray wall and the flap (outer wall).
Embodiment 6
Refernng now to FIGURE 55, yet another preferred packaging tray 5200 with
flaps, is shown. The flaps are shown folded into a desired position and bonded
to the
tray base and/or walls. The packaging tray with flaps can be thermoformed from
suitable plastic materials such as polystyrene, polyester and polypropylene in
a solid
or foamed sheet. The present packaging tray is preferably thermoformed from
expanded polystyrene (EPS) sheet. The EPS sheet may include a single or multi-
layer construction as shown in FIGURE 59. Any suitable sheet of EPS material
may
be used but most preferably the sheet includes 3 layers 5204, 5206, and 5208.
The
layer 5204 preferably includes a layer of solid plastic material such as
polystyrene
sheet with any suitable thickness, preferably about .001" and is laminated to
layer 5206. Layers 5206 and 5208 preferably include "closed" or "open cell"
structures either with or without a surfactant added prior to extrusion of the
sheet
such that the finished tray may have a capacity to absorb water and other
liquids such
as "purge" or blood. The EPS sheet may be extruded with a "skin" covering on a
surface that will become the in-side of the finished tray. The "skin" can be
arranged
so as not to absorb the liquids. The non-absorbent "skin" may be provided on
both
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surfaces of the extruded sheet. The layer 5204 may contain a white or other
suitable
pigment, such as white titanium dioxide in such a quantity so as to prevent
visibility
of any discoloration that may be caused by blood or purge absorbed by layers
5206
or 5208. In this way the layer 5204, which will be visible, will not show
substantial
discoloration as a result of blood or purge that has been absorbed by any of
the other
layers.
Tray 5200 with flaps is most preferably thermoformed from sheet material of
suitable thickness, preferably about 0.01" to about 0.15" but preferably about
.090"
and includes a tray with tray cavity and four flaps. Two flaps are shown as
flap 5210
and flap 5212. Flap 5210 is an end flap and flap 5212 is a side flap. The
construction of tray 5200 with folded and bonded flaps, allows for production
of
suitably rigid finished trays even though the thickness of the sheet material
from
which the tray is formed, is substantially thinner than would otherwise be
required in
conventionally formed packaging trays that do not have "flaps".
Flap 5210 can be provided with a profile that is a mirror image of 5214 (not
shown), and flap 5212 can be provided with a profile that is a minor image of
flap 5216. Flaps 5210, 5212, 5214 and 5216 are attached to the outer edge of
flange 5218 at hinges as shown by the hinge lines, such that flaps 5210, 5212,
5214
and 5216 can be folded downwardly and intimately contact outer surfaces of the
tray
walls at locations as required. One or more flaps may be provided and folded
to
provide an enclosed space 5222 and/or cavity 5220 shown in FIGURE 58. The
cross-sectional profile of flaps 5210 and 5214 axe similar. The cross-
sectional profile
of flaps 5212, and 5216 can be similar.
Referring again to FIGURE 55, the packaging tray includes a base with four
upwardly extending tray walls terminating at a continuous flange 5218. Tray
walls
can be perforated with openings 5224 directly therethrough with the
perforations
arranged so as to communicate between the tray cavity and space 5222. The
apertures 5224 can be located so as to allow any purge that may be present in
the tray
cavity 5226 to pass therethrough and into space 5222. The perforations 5224,
may
include small holes, slots or incisions that extend fully through the tray
walls. The
flaps can be bonded to the tray walls so as to retain any liquids that enter
therebetween and into space 5222. Any suitable liquid absorbing medium may be
attached to one or more of the flaps so that when the flaps are folded and
bonded the
liquid absorbing material will be enclosed within space 5222. The liquid
absorbing
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material could therefore absorb any liquids that may enter the space 5222
during use
of the tray.
Referring again to FIGURE 55, recesses 5228 and 5230 are shown in
flap 5212. Slots 5232 are shown in flap 5212 and are located in recess 5228.
Perforations 5234 are provided in flap 5212 and are located in recess 5228.
Recesses 5238 and 5240 are shown in flap 5210. A suitable adhesive is provided
at
the interface between flaps and tray walls so as to provide a bonding of flaps
to tray
walls. Bonding of flaps and tray walls is provided in such a manner so as to
ensure
complete bonding of flaps to the tray wall along strips that follow a path
close to
what will become a perimeter of the flaps. FIGURE 58 shows a cross-section
through flap 5212 and tray wall showing enclosed space 5222. Space 5222 is
enclosed between the flap and the tray wall in a substantially liquid tight
manner.
Iron powder deposits 5244 can be applied to locations on the tray walls and
flaps
adjacent to space 5222 and also to the underside surface of the tray base. The
iron
powder deposits 5244 may include iron powder particles that have been fully
coated
with a special coating material, such as wax. The coating can be arranged to
prevent
direct contact of the iron particles with ambient air or any gas that may be
present,
until such direct contact with the air or gas is required. The coating may
have
physical andlor chemical properties that can be activated by exposure to
microwaves,
radio waves or a magnetic field. For example, when using wax as a coating,
microwaves will cause the iron particles to heat up, thereby melting the wax
and
exposing the iron particles. The coating may also contain an adhesive that is
heat
activated and otherwise does not bond with other matter until activated and/or
heated
by exposure to any suitable microwaves, radio waves, magnetic field or any
suitable
electrically or sonically induced waves or field. The coated iron particles
5244 can
be deposited on the surfaces by apparatus shown in FIGURE 140 herein. The
coated
particles can be coated with a substantially gas barrier substance that is
altered when
exposed to suitable microwaves or an electrically induced magnetic field.
Exposure
to the waves, field or microwave can cause the coating gas barner substance to
physically or chemically alter and become gas permeable, in such a manner that
will
cause the iron particles to immediately or subsequently react with any gases
such as
oxygen that may be present. The quantity of iron particles 5244 provided and
attached to the tray and flap selected surfaces can be measured and controlled
in an
amount having an equal or greater capacity that may be required to absorb
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substantially all oxygen gas that may be present andlor become present by
permeating into the finished package.
Refernng now to FIGURE 64, a plurality of finished packages that may be
conveniently stacked as shown in FIGURE 62 may be placed in a gas barrier
master
container which can then be evacuated of substantially all air. Ambient air
that may
be present within the finished package tray cavities and spaces such as 5222
shown in FIGURE 58 will be evacuated through apertures 5306 and replaced with
a
suitable gas. The air can be replaced or displaced with any suitable gas prior
to
hermetically sealing the master container to provide a single container with
finished
packages enclosed and sealed therein. At a convenient time after sealing the
sealed
master containers may be exposed to a suitable level of microwaves or magnetic
field
or other suitable source of energy that will selectively alter the gas barrier
coating on
the iron particles so as to render it permeable and further activate iron
particles to
oxidize with any residual oxygen that may remain within the master container.
The
substance "IPD" 5244 may include any suitable substance that can be applied in
any
convenient manner to the trays 5200 so as to remain inactivated until exposed
to the
microwave and/or magnetic field in such a manner as to render the IPD
activated.
When the IPD is selectively activated by any suitable source of energy that is
applied
before or after the trays are loaded with goods, the IPD can react with and
thereby
absorb any residual oxygen gas remaining within the finished packages, in such
a
manner so as to inhibit the formation of metmyoglobin that may otherwise be
formed
as a result of available oxygen that has been released during reduction of any
oxymyoglobin that may be present in the finished package after sealing the
master
container.
The IPD can be applied in any suitable manner to selected surfaces of the tray
and/or flaps so as to not directly contact but to be in close proximity to
goods that is
subsequently loaded into the cavities of trays. Ground or sliced red meats may
have
been exposed to ambient oxygen, after grinding or slicing and prior to
packaging, for
such a period of time that d~oxymyoglobin present in freshly cut red meats has
reacted with ambient atmospheric oxygen to form oxymyoglobin. Fresh meat with
oxymyoglobin may be then packaged in a substantially oxygen free gas package
such
as a barner master container tlmt has been evacuated and filled with any
suitable gas
that may contain less than 500 PPM oxygen. After packaging, the oxymyoglobin
will reduce to deoxymyoghbin thereby releasing oxygen gas into the spaces in
the
master container. The released oxygen can then react with the deoxymyoglobin
to
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form metmyoglobin. The metmyoglobin is brown in color and is undesirable and
consumers are unlikely to purchase meat that is brown in color. The IPD
substance
can be provided within the finished packages in such a manner so as to
substantially
absorb, and thereby render inactive, the oxygen that has been released by
reduction
of the oxymyoglobin to deoxymyoglobin, after hermetically sealing the finished
packages. In this way the formation of undesirable metmyoglobin can be
inhibited
and/or minimized. In order to enhance the absorption of oxygen gas by the
substance
IPD, any suitable method to cause circulation and movement of any gas inside
the
finished package can be incorporated. Such methods may include shaking or
suitable
movement of the finished and sealed master containers in such a manner so as
to
cause gas to circulate through apertures 5306 from the spaces in the tray
cavities and
more particularly near and over the exposed surfaces of the goods.
In another alternate embodiment, the present invention provides capsules of
suitable size but most preferably having a diameter or widest/longestldeepest
dimension of less than 0.25", wherein capsules have a generally rounded,
spherical or
oval profile with a continuous capsule wall of any suitable thickness but most
preferably approximately 00.060" thickness, with a cavity enclosed within the
continuous capsule wall and wherein each enclosed capsule cavity contains a
suitable
quantity of any selected agent, substance or material, such as, for example, a
bactericide, a water absorbing gel, a C02 generating agent. The capsule wall
may be
manufactured from a material such as wax or a flexible waxy plastics material
that is
affected by micro waves, RF (radio frequency) or a magnetic field that is
generated
from a controlled source and with such an intensity that it can cause the
capsule walls
to rupture or soften or dissolve and to such an extent that the contents of
the capsule
cavities will be expelled or allowed to escape from within the enclosed
capsule
cavity. A suitable quantity of capsules or combination of capsules containing
separate quantities of several agents, with any selected agents) contained
therein
may be enclosed, for example, within the cavity(ies) of any suitable packaging
tray
prior to use in a packaging application. At any time during or after assembly
of such
a tray with capsules contained therein, it may be exposed to the appropriate
source
and intensity of micro wanes, RF (radio frequency) and/or a magnetic field and
in
such a way so as to cause the release of any agents contained within the
cavity of the
capsules. In this way, for example, a bactericide may be held until required
for use
within the package walls or base and after assembly of the package such as a
tray
containing fresh red meat, at which time the bactericide can be released and
thereby
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made available to substantially kill bacteria, fungi, virus or any undesirable
life form
that may be dangerous to human or animal life.
Referring now to FIGURE 64, a finished package 5300 is shown with a
seal 5324, that extends continuously around a horizontally disposed perimeter
of the
finished package. Seal 5324 is provided so as to bond an over wrap 5326, which
is
positioned above the seal 5324, to an over wrap 5328 which is located below
the
seal 5324. The seal 5324 can be provided by any suitable method such as by
heating
and is arranged to be a complete and continuous and gas tight seal along the
full
length of the seal 5324. The over wraps 5326 and 5328 may be either both clear
and
transparent or alternatively printed but most preferably the 5328 over wrap
will be
printed as desired. 5326 and 5328 may be produced from a substantially gas
barner
material such that when sealed along seaI5324 a hermetically sealed finished
package is produced. Alternatively gas permeable plastic materials may be used
to
produce the over wraps. The profile of over wrap 5326 and 5328 may be provided
by a thermoforming method prior to assembly of the finished package whereby a
loaded tray 5300 is located into a thermoformed over wrap 5328 prior to
sealing a
thermoformed over wrap 5326 thereto at seal 5324. Alternatively, both over
wraps 5326 and 5328 may be produced from a web of "stretched" material such as
pPVC. The web of pPVC may be held taut above a depression where the depression
is similar in profile to the lower section of tray 5300 but slightly larger so
as to allow
a neat location of tray 5300 therein. A vacuum can be applied in the
depression so as
to stretch the pPVC web therein and thereby provide a lower over wrap 5328.
Tray 5300 can be located into the stretched pPVC depression and heat sealed at
5324
to an over wrap 5326 that can be formed in a similar manner by stretching into
an
inverted depression, of suitable size, that is located directly above and
aligned
therewith so as to allow such sealing at seal 5324. Apertures 5306 may be
provided
in the over wrap 5328 or alternatively, over wrap 5328 may be maintained
without
apertures so as to provide a complete finished and substantially gas barner
package.
In another preferred embodiment, iron powder that has been completely
coated with a substance, such as a special type of wax, can be included in one
or
more layers of a tray thermoformed from a one, two, three or more layer sheet
of co
extruded EPS foam. The special type of wax coating can be arranged so as to
prevent contact of undesirable substances such as water, with the powdered
iron that
is completely covered by the special type of wax coating, until a suitable
time. The
special type of wax coating can be arranged so as to melt or otherwise change
when
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exposed to an electromagnetic field, microwaves or other suitable medium. The
melting or change to the special type of wax coating can allow the powdered
iron to
become exposed and thereby react with oxygen gas that may be present, after
exposure to the electromagnetic field, microwave or suitable medium. In this
way
trays, formed from the EPS foam with coated iron powder contained therein, can
be
used to package perishable gouds and when the tray with perishable goods has
been
over wrapped with a gas permeable web of plastics materials, can be located in
a
master container with a suitable gas, and all hermetically sealed so that the
master
container contains the over wrapped tray with perishable goods and a suitable
gas.
Immediately after hermetically sealing the master container, the master
container can
be exposed to an electromagnetic field, microwave or other suitable medium, so
as to
change the coating and thereby expose the iron powder and allow reaction of
the iron
powder with any oxygen gas that may be generated within the master container
as a
result of reduction of oxymyoglobin.
Immediately prior to or after loading goods such as ground or sliced meats
into the tray cavities, the trays 5320 can be exposed to a suitable level of
microwaves
or a magnetic field sufficient to cause coating SCM to be altered and thereby
allowing the IPD to react with any oxygen that is present and in contact with
the IPD.
In this way and due to the close proximity of the IPD to the oxymyoglobin, the
oxygen that is released by reduction of the oxymyoglobin, can be quickly
absorbed
by the iron powder IPD as soon as it contacts therewith.
Pre-conditioning of the goods, prior to loading into the trays can reduce the
quantity of oxymyoglobin formed immediately after slicing or grinding of the
goods
but before packaging and sealing in the master container. The pre-conditioning
can
include the process of exposing the goods to carbon dioxide or any suitable
gas at
any suitable pressure or high pressure immediately after and/or during slicing
and/or
grinding. The goods can be exposed to the gas at high pressure in such a
manner that
the gas becomes highly soluble in liquids and oils present in the goods, and
dissolves
in the liquids and oils. The goods can be exposed to high pressure gas for an
adequate period of time to allow saturation of the liquids with soluble gas.
Saturation
of liquids and oils will therefore occur at the high pressure. Therefore, when
goods
are removed from exposure to high pressure gas and returned to exposure to
normal
ambient atmosphere for subsequent packaging into finished package andlor
master
container, gas (or gases) that have dissolved in the liquids and oils will be
then
exposed to a lower gas pressure. Gas that has dissolved under the high
pressure into
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liquids will be "released" and return to a gaseous condition. The release of
gas will
occur at the surface of goods and during this event, any oxygen that is
present in
atmospheric air will be inhibited from contacting the surface of the goods.
This
procedure can therefore provide a method to slice and package goods while
reducing
and minimizing the formation of oxymyoglobin immediately prior to packaging
and
consequently minimizing the otherwise corresponding formation of metmyoglobin
after packaging in the manner described herein. The pre-conditioning process
can
also include the method of lowering the temperature of the goods to any
suitable
"pre-conditioning" temperature that may be 28 degrees F prior to slicing
and/or
subsequent immersion in high pressure gas with exposure thereto.- After
removal of
the goods from immersion in and exposure to high pressure gas at a lower
temperature the goods will be exposed to ambient atmospheric conditions which
will
be at a higher temperature and lower gas pressure. After packaging the goods
in the
finished package and/or master container, the packaged goods can be stored and
1S maintained within a suitable temperature range that may be higher than the
"pre-
conditioning" temperature. The pre-conditioning temperature may be maintained
within a range of approximately 29 to 32 degrees F. The suitable post
conditioning
temperature range may be maintained between 33 to 36 degrees F. The difference
between the pre-conditioning temperature and the post conditioning temperature
may
be less than 15 degrees F. Goods may be pre-conditioned by passing through a
first
tube at a suitable pressure where the first tube has a diameter of 'X' and is
centrally
located within a second tube that has a diameter of 'X' + I inch or more and
thereby
providing a space between the outer surface of the first tube and the inner
surface of
the second tube. A temperature controlled liquid such as brine or glycol can
be
provided in the space between the first and second tubes and thereby provide a
cooling or heating devices that will allow temperature controlling of goods
that are
present in the first tube. A specified and controlled quantity of, any
suitable gas at
any suitable temperature and pressure can also be provided in the first tube
with
goods so as to provide a controlled devices of dissolving suitable gasses into
the
goods. The goods with the gas can be held in the first tube for a suitable
period of
time so as to allow the gas t~ dissolve into the liquids and oils in the goods
at a
suitable temperature. The first tube can be filled with compacted goods in
such a
manner so as to restrict any gas, that is provided therein, from escaping or
leaking
there from. The first tube may be provided with mixer therein to allow mixing
of
3S goods contained therein. i he first tube may be fitted with scraper and
substantially
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remove any solids, such as frozen liquids, ice and/or solids that may
accumulate on
the internal surfaces thereof.
Refernng now to FIGURE 56, a cross-sectional view through tray wall and
flap 5212 is shown. For illustration purposes, a section of web material 5246
is
shown bonded to plane 5248. Recesses 5236, and 5230 are therefore shown as
enclosed channels. Cavity 5220 is fully enclosed and sealed from external
communication save through perforations 5234 by bonding at interface 5242.
Gases
can therefore communicate through the perforations 5234 and into the cavity
5220
and recess 5236. The gases can therefore come into direct contact with
deposits 5244. The deposits 5244 are preferably applied to tray and flap
surfaces that
will not come into contact with any goods that are subsequently located in the
tray
cavity.
Referring again to FIGURES 57-58, a cross-sectional view through
crest 5260 is detailed in FIGURE 57 with hinge 5252 between the flap 5210 and
flange 5218. In FIGURE 58, tray 5200 is shown in a horizontal disposition with
the
opening in tray cavity facing upwardly. The tray base is profiled so as to be
higher at
the center of the tray base than at the lowest point of the tray cavity (at a
radius
connecting the tray base to the upwardly extending tray wall) and a clearance,
designated by arrow 5254 is shown. The clearance 5254 is the distance
(clearance)
measured from the lowest point of the tray 5200, at the side flaps and the
highest
point of the under surface of the tray base. The clearance 5254 is arranged so
as to
suitably accommodate and "mate" with the crest 5260 when another tray (not
shown)
is located above and placed onto a lower tray 5200. In another alternate, the
clearance 5254 may be enclosed by over wrap material to provide a cavity into
which
purge may enter through suitably located apertures in the tray. Suitable
liquid
absorbing material with a suitable capacity may be provided between the over
wrap
and underside of the tray base. The crest 5260 and clearance 5254 prevent the
base
of a stacked tray from contact with an overwrap on the bottom tray. In this
manner,
the goods are prevented from touching the base of an adjacent tray.
Embodiment 7
Refernng now to FIGURES 60-61, another preferred embodiment of a
tray 5300 with flaps is shown. Tray 5300 has similar features to tray 5200;
therefore,
those features ill be alluded to by the same reference numerals. Tray 5300
with
depression therein is shown after over wrapping with overwrap web 5302.
Web 5302 may include a plastic web of material such as pPVC. The depression
may
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be substantially filled with goods such as ground beef prior to over wrapping
with the
over wrap 5302. Over wrap 5302 may be stretched in such a manner as to contact
the goods in the depression. The web of materia15302 may be printed with
information that gives detail of the contents of the over wrapped tray.
Further more
the inner surface of the over wrap 5302 may have been processed and a heat
activated coating applied thereto, by any suitable method, and in those areas
that will
come into contact with planes 5258 and 5256 as shown in FIGURE 55. A suitable
heat source can be provided to activate the heat activated coating so as to
cause
bonding of the web 5302 to flaps 5212 and 5210 at planes 5256 and 5258 and at
locations showm as shaded sections 5304. Alternatively, the areas shown as
5258 and
5256 may be coated, by any suitable method, such as by "ink jet", with any
suitable
bonding material such as a heat activated coating. Apertures 5306 may be
provided
as shown. Apertures 5306 can be provided after bonding of the web to plane
5256
such that communication directly into recess 5238 is provided. A cross-
sectional
view is shown in FIGURE 61 through where web 5302 has been bonded to
plane 5256 thereby providing space 5308 and recess 5310. Apertures 5312 in
flap,
apertures 5314 in wall of trzy and apertures 5306 in web 5302 are provided. In
this
way a communication is provided between the tray cavity to the outside of the
over
wrapped tray following a path that will readily allow gases to communicate
therethrough but will restrict escape of liquids such as purge. The
communication
follows a path through aperture 5314 into space 5316, through aperture 5312
into
recess 5310, through recess '310 to space 5308, through space 5308 to recess
5318,
through recess 5318 to recess 5238 and through aperture 5306.
Referring now to FIGURE 62, a stack of 4 finished packages of the tray
shown in FIGURE 60 is shown. A cross-sectional view is shown in FIGURE 63,
through the stack of packages. It can be seen that with this arrangement an
upper
tray is in contact and rests on the flange of a lower tray. As can also be
seen,
clearance provided in the underside of the base of tray mates with the upper
profile of
a lower tray whereby the contents of a lower tray are located in close
proximity to the
upper tray but are not in contact with the underside of the upper tray.
Embodiment 8
Referring now to FIGURE 65, a preferred packaging tray 3200 with flaps, is
shown. FIGURE 65 shovrs a flap 3202 attached to a tray 3200 by a hinge 3204 to
flange 3206. Tray can also be provided with sinvlar flaps attached by hinges
to all
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four sides of the tray at hinge lines between flaps and flanges. However,
FIGURE 65
shows a tray that has two flaps, on opposing sides, where one only flap can be
seen.
Packaging tray 3200 includes a substantially flat base that may have
depressions, ridges, apertures and/or penetrations provided therein, with
upwardly
extending walls terminating at a continuous flange 3206. A ledge 3208 is
provided
in two of the four walls in a horizontally disposed position and level, across
the face
of the side wall and between the flange and the base of tray. The other two
walls
have flaps 3202 attached thereto, at a hinge connecting the flaps to the
flange.
Apertures 3210 provided are provided in ledge 3208. Tray 3200 with flaps 3202
may
be thermoformed from a sGitable material such as solid or foamed polystyrene
(EPS),
polyester, polypropylene or other suitable material. Apertures 3212 are
provided in
flaps at optimized locations that will restrict passage of solid or liquid
matter
therethrough. An alternative aperture construction is also shown as slot 3234
cut
through a compressed section 3240 of tray in cross-section FIGURE 68 and in an
enlarged view, FIGURE 69, showing details of the slot 3234 provided in a
section of
the flap along ridge 3214. Slots may also be located at other locations. The
region
surrounding the slot is compressed to provide a section of thinner cross-
sectional
thickness. Slot 3234 includes an incision in the compressed section of the
ridge and
may be provided with ar. "H" profile. The slot with "H" profile provides two
adjacent flaps, 3236 and 3238, respectively, that can open when a differential
in gas
pressure is provided on opposite sides of the flap, however, when the gas
pressure
differential has equalized the two adjacent flaps shown as "H" flaps, can
close to the
former condition before opening.
Flaps 3202 are folded downwardly, against the upwardly extending adjacent
tray walls 3216 as shown in end view of flap in FIGURE 66, prior to over
wrapping.
Flaps 3202 can be provided with a fastening lug 3242 that is profiled so as to
"mate"
with a corresponding fastening recess 3244 provided in tray 3200. The
fastening
lug 3242 and fastening recess 3244 holds flap 3202 in a downwardly located
position
in convenient readiness to be inserted into a bag prior to sealing and
shrinking.
Flaps 3202 may otherwise prevent automated loading of the tray with perishable
goods therein, into the bag.
Perishable goods such as fresh ground beef can be placed in the tray cavity
prior to tray and perishable goods being over wrapped and shrink wrapped with
a
material such as Clysar AFG Anti Fog Polyolefin Shrink Film. Shrink film may
be
in the form of a preformed fabricated printed pouch (or bag) or alternatively,
unrolled
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from a continuous web of rolled material that is formed into a tube on a
machine
such as a flow overwrapper, and cut into convenient sized sections that can be
heat
sealed (or cold sealed), so as to completely cover the assembled packaging
tray and
contents, prior to heat shrinking. The assembled tray with flaps, perishable
goods
and sealed overwrap are then passed through a heat shrink tunnel that causes
the
overwrap material to shrink and provide a taut and relatively tight cover over
the
packaging tray and goods. Flap 3202 is provided with a continuous rim 3246.
The.
continuous rim 3246 is provided in such a manner so as to contact the inner
surface
of the outer cover 3218. Rim is in continuous contact around the perimeter of
the
flap and substantially restricts passage of matter between the rim and the
outer
cover 3218 as shown in FIGURE 112.
Refernng now to FIGURE 112, a cross-section through the tray with flaps is
shown after outer cover 3218 has been heat shrunk into a finished position.
Apertures 3220 are provided in the outer cover. A space 3222 is provided
between
the flap and the outer cover such that apertures 3220 provide direct
communication
between the space 3222 and external atmosphere. A finished package 3224 is
shown
in FIGURE 113. A plurality of finished packages can be assembled in a group
that
may include a total of twelve finished packages in three adjacent stacks of
four
finished packages. The group of twelve packages can be transferred by
automatically
into a thermoformed, substantially gas barrier, outer master container as
shown in
FIGURES 35-36. The barner master container 3226 containing the finished
packages may be located within a vacuum chamber and substantially all air
evacuated from the vacuum chamber and from within the finished packages and
the
barner master container. In this way, substantially all atmospheric air can be
removed from within the finished packages via a route that follows a path
through
apertures 3210 (FIGURE 65) into space 3228 (FIGURE 66), through apertures 3212
(FIGURE 65) into space 3222 (FIGURE 112) and through apertures 3220
(FIGURE 112). The vacuum chamber may then be filled with a desired gas such as
any single, oxygen free or oxygen enriched blend of gases including nitrogen,
carbon
dioxide and/or any other suitable gases. The gases will therefore
substantially fill all
voids and spaces within the barrier master container and the finished packages
contained therein, by following the reverse route of the path along which
atmospheric
gases had previously been evacuated. In this way, finished package 3224
provides a
suitable package with space therein that can be filled with desired gases as
required,
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while restricting the escape of liquid or solid matter, from within the
finished
package, to external atmosphere.
Referring again to FIGURE I12 and FIGURE 113, it can be understood that
when a plurality of finished packages are assembled in a stack, the base of
tray 3230
S with adjacent flaps will be in intimate contact with the upper surface of
the finished
packages. The flaps will be in adjacent contact with the flange regions of the
lower
package, thereby supporting the weight of packages stacked above. Therefore,
the
perishable goods contained in any package located beneath a package stacked
above,
will be protected from damage.
Embodiment 9
Refernng now to FIGURE 114 an isometric projection of a finished
package 2500 constructed according to the present invention is shown and a
cross-
section through an empty package 2500 is shown in FIGURE 116. Tray 2502 is
thermoformed from a suitable material such as expanded polystyrene. Flaps 2504
are
connected to the tray by way of hinges 2506. Flaps can rotate about the hinges
such
that upper surface of flanges 2508 can contact directly and in alignment with
flanges 2510 of the flaps.
Refernng now to FIGURE 115, a perishable goods 2600 such as ground meat
is located in tray 2502 and a web 2512 is positioned directly above and over
the tray
and perishable goods. Web 2512 includes a transparent sheet of a suitable
material
such as plasticized PVC that has been coated with a heat activated adhesive
covering
the areas of the web that will come into contact with flange 2508 thereby
providing a
method of sealing web 2512 to the flanges 2508. After the web has been heat
sealed
to the flanges 2508, it is severed along the perimeter of flanges 2508. The
web is
hermetically sealed around the full flange extending around the perimeter of
the tray.
Flaps 2514 and 2504 can then be rotated about hinges 2506 and flanges 2510 of
flaps
are sealed to flanges 2508 of the tray as shown in FIGURE 114.
Refernng again to FIGURE 115, flanges 2516 and 2518 are conveniently
formed into a portion of the end walls of the tray. Web 2512 can be sealed to
the
flanges 2516 and 2518 as shown. Aperture 2520 can be provided in the location
shown such that direct communication between the gas contained between the
tray
and the web 2512 and external atmosphere is enabled. The location of aperture
2520
inhibits the egress of any liquids that may accumulate within the package from
escaping therethrough. Additionally or alternatively, aperture 2522 is also
shown. A
plurality of finished packages can be stacked together such that face 2524
engages
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with face 2526. Such engagement of faces provides a secure method of stacking
finished packages.
Embodiment 10
Refernng now to FIGURE 117, another preferred embodiment of a finished
package constructed in accordance with the present invention is shown. The
package 2544 includes a tray 2526 and a tray cover 2528. Tray and cover can be
formed from suitable materials such as expanded polystyrene (EPS). Cover 2528
has
a window 2530 cut therein as shown and web 2532 is stretched taut and heat
sealed
to flanges 2534. Tray 2526 and tray cover 2528 are hermetically sealed
together at
flanges 2536 and 2538. Walls of tray and the cover can be printed directly
thereon
with information describing the contents of the package with all legally
required
information, pricing, weight of contents and cost per unit weight. Recesses
2540
(four) in ridge 2542 are conveniently provided to allow for evacuation of air
from
between stacked packages. Recesses 2540 can also provide for location of bands
of
i5 printed paper that may provide further information and details of package
contents.
Referring now to FIGtTRE 118, a cross-section through the end section of two
stacked and finished packages 2544 of FIGURE 117 is shown. The perishable
goods
contents of the packages have been omitted for clarity. Faces 2546 and 2548
engage
between the stacked finished packages. Engagement of the faces causes the
outward
urging of ridge 2550 of the lower package. The weight of the upper package is
thereby transferred through the walls of the lower tray cover while inhibiting
the
inward displacement of flange 2552. Such an arrangement minimizes the
likelihood
of undesirable pressure being applied to the perishable goods contents of the
lower
tray by depressing the flange 2552 downwardly.
FIGURES 119-121 show an enlarged section of flange 2552, including side
elevation, FIGURE 120, and a plan view FIGURE 119, of the underside of
FIGURE 120, and a further end view, FIGURE 121, is shown with grooves and
slots
that allow direct communication between the inside of the finished package and
atmospheric gases on the outside. Web 2554 is heat sealed along a continuous
seal
path 2556 and intermittent seals 2562 are shown with slots 2558 therebetween.
Slot 2560 is therefore in direct communication with slots 2558 and 2564 and
grooves 2566. Apertures 2568 are located adjacent to slot 2560 and directly
between
continuous seal 2556 and intermittent seats 2562. Web 2554 can include a sheet
of
plasticized PVC and is tensioned prior to sealing as shown thereby providing a
transparent cover across the window. In this way direct communication from
within
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the package to atmosphere is provided through apertures 2568, slot 2560, slots
2558,
slot 2564, and grooves 2566, while minimizing the possibility of any
accumulated
liquids escaping that may be present within the package.
Refernng now to FIGURE 122, three empty packages 2608 with web sealed
thereto, are shown stacked together. A section through a finished package 2610
is
shown in FIGURE 124, and a section through an individual package is shown in
FIGURE 123.
Referring now to FIGURE 125 three finished packages 2570 are stacked
together within a flexible gas barrier container 2572. A gas barner lid 2574
is
hermetically heat sealed to gas barne: container 2572 after substantially all
air has
been evacuated and replaced with a suitable gas that may be substantially
oxygen
free.
Embodiment 11
Referring now to FIGURE 126, another alternative embodiment of a tray with
flaps constructed according to the present invention is shown. Tray 2578
includes a
first 2576 and second flap (not shown). Flap 2576 is attached to tray 2578 by
hinge 2580. Ridges 2582 are formed in flap and corresponding ridges 2584 are
formed in tray such that when flanges of flap and tray are in contact,
portions of
ridges are also in contact. Web 2586 is heat sealed to flanges 2588 and 2590.
Apertures 2592 and 2594 are provided in the web such that when flanges of the
flap
and tray are parallel to each other and in closest proximity, apertures are in
alignment
providing direct communication therethrough. Concentric depressions 2596 are
shown in FIGURE 126 and in the detail of cross-section FIGURE 127. Tray 2578
may be formed from a three layer construction of expanded polystyrene where
the
inner layer includes an "open" cell structure that will absorb liquids such as
water and
blood. Depressions are provided on the inner surface of the tray, to allow
contact of
liquids, that may be present in the tray, with the inner cells of the tray and
allowing
absorption of liquids by the open cell structure.
Embodiment 12
Referring now to FIGURES 128-130, another preferred embodiment of a tray
with flaps constructed according to the present invention is shown. FIGURE 130
shows a cross-section through a tray 2400, FIGURE 129 shows a cross-section
through a tray 2402 that contains ground meat with a web 2404 stretched over
the
ground meat and sealed to flanges 2406, 2408 and edge portion 2410. FIGURE 128
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CA 02387349 2002-04-03
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shows a cross-section through a portion of a master container 2412 with
finished
packages 2414 stacked therein. A flap 2415 is shown that has been severed from
tray 2402 and web 2404 is also sealed to flap 2416. A space 2418 is provided
between web 2404 and inner surface of the flap 2416 providing direct
communication between recess 2420 and aperture 2422. Flap 2416 and tray 2402
are
therefore attached together by web 2404 and a gap 2424 is provided between
flap 2416 and the tray 2402. An aperture 2422 is provided in web 2404 at flap
2416
portion and an aperture 2426 is also provided in web 2404 at tray portion.
Recesses 2420 are provided in the flap 2416 such that when web 2404 is sealed
thereto recess 2420 provides direct communication therethrough from atmosphere
to
the space between the flap 2416 and web 2404. Recesses 2420 are conveniently
located in wall of flap 2416 between flange 2406 and horizontal edge portion
2410
shown in FIGURE 129. Severing of flap 2416 is optional and alternatively a
hinge
may be provided by compressing flange 2428 with a profile so as to facilitate
easy
hinging of flap 2416 and tray 2402 relative to each other.
Flap 2416 is arranged such that it can be "hinged" about the gap 2424 such
that flanges 2406 and 2408 contact directly with web 2404 material
therebetween.
Flanges can then be sealed together through web 2404 such that web 2404
material
seals together in a desired manner. The apertures 2422 and 2426 are positioned
such
that they become aligned after sealing of the flanges. Web 2404 material is
then
most likely to become lightly bonded together around the perimeter of
apertures 2422
and 2426. An adhesive may also be applied to the contacting surfaces of web
2404
around the perimeters so as to cause substantial bonding and providing a
substantially liquid 'tight' seal there around so as to inhibit escape of any
liquids
therebetween. This arrangement provides a direct communication from space 2418
to any atmosphere external of the package, via apertures 2422 and 2426, space
2430
and recesses 2420. The location of apertures 2422 and 2426, space 2430 and
recesses 2420 are arranged such that any liquids (or solid matter) that may
accumulate within the package are inhibited from escaping from space 2418.
With
this arrangement, gasses can communicate directly between space 2418 and while
liquids and other solid matter is substantially restricted and held within
space 2430 or
2418.
Tray can be formed from foamed polyester or from expanded polystyrene
foam (EPS). Web 2404 may include a suitable grade of plasticized PVC (pPVC)
which may be printed with various colors and graphics and a heat activated, or
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pressure sensitive adhesive may also be applied during the printing process or
separately as desired and required to provide sealed finished packages.
Completed packages 2434 can be stacked into master container 2412 until it
is filled. A lid including a gas barrier web can be then sealed to the flanges
of 2412
as described in U.S. Patent Application Serial No. 09/039,150. Packages 2434
are
stacked such that the ridg: s 2436 on the base of a first package "nest"
adjacent to
ridges 2438 of a second package. A space can therefore be maintained between
the
bottom of the second package and the web and contents of the first package.
In a further embodiment, 2412 can be located within a chamber such as is
shown in FIGURE 148 prior to sealing the gas barrier web to the flanges of
2412.
Embodiment 13
Referring now to FIGURE 70, another embodiment of a tray with flaps
constructed according to the present invention is shown. FIGURE 70 shows a
cross-
sectional through tray detaili~.~g a preferred profile. Rib 7920 is formed in
flap 7922
adjacent to recess 7924. Rib 7920 is formed so as to contact wall of tray as
shown
when flap is folded into position. Recess ?926 is formed in the flap 7922 with
an
aperture or slot therein but does not contact the outer surface of the wall of
tray and is
provided with space 7928 therebetween. A suitable adhesive such as a solvent
is
applied to the surfaces of the flap 7922 and the wall of tray such that when
flap 7922
contacts the wall of tray, both parts bond together. The bond between the flap
7922
and the wall of tray can be arranged to follow a continuous path close to the
perimeter of the flap 7922 and thereby provide a substantially liquid "tight"
seal
around space 7928. Each flap (4) can be applied with adhesive in a similar
manner
to that described for flap 7922 then, in Iike fashion, bonded to walls of tray
to
produce a finished tray. Apertures 7930 can be provided in the lower section
of the
wall of tray such that liquids that may accumulate within the tray can pass
through
apertures 7930 and enter space 7928. Slots, slits or holes can be provided in
recess 7924 such that direct communication through recess 7924 into space 7928
and
through apertures 7930 can be provided. The surface of the flap and the wall
of tray
in direct contact with space 7928 can be treated so as to absorb liquids such
as water,
purge and blood.
Referring now to FIGURES 71-?2, an enlarged cross-section through a
portion of EPS sheet is shown and an enlarged cross-section through EPS sheet,
after
thermoforming and assembly of tray and flaps in finished and bonded position,
are
detailed. In FIGURE 71, a cross-section through a portion of sheet EPS foam
with
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CA 02387349 2002-04-03
skin 7932 and skin 7934 is shown. EPS sheet, as shown in FIGURE 71 can be
extruded in normal production such that skin 7932 and skin 7934 is
substantially
nonporous and will resist absorption of liquids, while the inner layer of EPS
foam 7936 can be produced so as to absorb liquids. In a preferred embodiment,
the
EPS sheet with skin 7932 and skin 7934 can be extruded and wound onto rolls in
readiness for use in thermoforming and production of trays with flaps as shown
in
FIGURE 52. In another preferred embodiment, the EPS sheet material may include
three layers of expanded polystyrene sheet where an inner layer of open celled
foam,
that has been arranged to absorb desired liquids, is "sandwiched" between two
outer
layers of closed cell expanded polystyrene sheet that will resist absorbing of
the
liquids. After thermoforming the trays with flaps, from the three layer
material or
alternatively from material with outer skin 7932 and 7934 a solvent or other
suitable
agent, can be applied by spraying, or any other suitable method, to selected
areas of
flaps) and wall{s) of tray such that only those selected surface areas, that
will
become enclosed between the flaps and the trays, after folding and sealing
into the
required position, will have the solvent applied thereto. The solvent, or
other suitable
agent, can be applied in sufficient quantities to the selected surface areas,
so as to
dissolve the skin 7932 or 7934 at surfaces 7938 and 7940, shown in FIGURE 72
thereby exposing the inner, liquid and water absorbing EPS foam, for
subsequent
contact with any liquids that may enter space 7928. In this way a finished
tray, with
flaps folded and sealed into the desired configuration, can be produced so
that only
the surfaces adjacent to and in contact with the space 7928 will be
substantially
liquid and water absorbing. It can be seen that any liquids that may be
present on the
inside of the tray can pass through apertures 7930 and into space 7928.
Liquids can
then be absorbed by the exposed EPS foam in contact with the space 7928
however,
due to the liquid absorbing resistance of skin 7932 and 7934, the liquids may
not be
visible to any person looking at the tray with flaps from outside the space
7928.
Embodiment 14
Referring now to FIGURES 73 and 74, another embodiment of a tray with
flaps constructed according to the present invention is shown. A cross-section
through a finished package in shown in FIGURE 73 and a three dimensional view
of
a finished package 3400, is shown in FIGURE 74. The finished package 3400
includes a tray 3402 with perishable goods contained therein and an outer
cover of a
substantially gas barrier shrink material 3404. Apertures 3406 are provided in
the
gas barrier outer cover and a oeelable, gas barrier label 3408 is hermetically
sealed
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CA 02387349 2002-04-03
_')g_
over the apertures 3406. The finished package 3400 has spaces 3410 and 3412
and
other space contained within the outer cover 3404. A substantially oxygen free
gas
including any suitable gas, selected to extend the keeping qualities of the
perishable
goods, such as a blend of carbon dioxide and nitrogen, can be provided in the
spaces
inside the package 3400 after evacuating other gasses contained therein, such
that all
the spaces are filled with oxygen free gas. The finished package can be stored
for a
period of time and then the gas barrier label 3408 on the tab 3414 can be
removed by
peeling, thereby allowing atmospheric gas to enter through the apertures 3406
and
3416 and into the spaces around the perishable goods and contact the
perishable
goods.
Embodiment 15
Refernng now to FIGURE 76, another embodiment of a finished package
constructed according to the present invention is shown. A cross-sectional
view with
details of a preferred configuration including a tray with flaps that are
folded into the
finished position and extend below the base of tray is shown in FIGURE 75. As
described in earlier embodiments of this present specification, a tray with
flaps may
include a rectangular flat base with radiused corners and upwardly extended
walls
that terminate at a flat horizontally disposed, common flange. A space or
cavity is
therefore defined between the walls. Flaps are connected directly to the
peripheral
edge of the common flange at a hinge along a hinge line. A single flap may be
attached to a single wall or alternatively up to four flaps may be attached,
one to each
wall. The packaging tray with flaps can be thermoformed from suitable plastics
materials such as expanded polystyrene (EPS) sheet. Flaps of various
configurations
have been described herein with apertures conveniently provided to allow gas
or air
2S exchange therethrough while inhibiting and restricting the escape of other
matter
such as liquids including blood therethrough. Such apertures and
configurations
allowing gas exchange therethrough can be provided in this present embodiment
if
desired, however, the purpose of the description of this present embodiment is
to
disclose an improved packaging that will also protect the perishable goods
contents
of the finished package when stacked together in a master container as shown
in
FIGURE 16.
Referring now to FIGURE 75, a loaded tray 3700 with flaps 3702 is
completely covered with an outer cover 3704 and it can be seen that the outer
cover 3704 is domed upwardly and is stretched over the upper surface of the
perishable goods 3706 such that the uppermost part of the perishable goods
3706 is
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extended above the common flange 3708 under the outer cover 3704. In this
manner
the perishable goods 3706 are held firmly to the base 3710 of tray 3700 by
applying
tension on the outer cover material. An adhesive 3712 may be provided between
the
outer cover 3704 and the common flange 3708 so as to seal, hermetically or
otherwise, the outer cover 3704 to the common flange 3708 along a path that
will
become an outer edge of the finished package. Additionally and as shown,
adhesive 3712 may be provided between the flaps 3702 and the tray walls 3714
so as
to seal the flaps 3702 in position to the walls as may be desired,
hermetically or
otherwise. Adhesive 3712 may also be provided between the underside of the
base 3710 and between the base and the inner surface of the outer cover 3704.
Outer
cover 3704 may include a suitably printed, heat shrinkable, stretchable,
sealable,
transparent, oxygen and gas permeable web of material with a "memory" that may
be
applied after loading the perishable goods into the tray cavity. The outer
cover 3704
may be applied directly from a continuous web or roll of the material or
alternatively
may be fabricated into suitably sized bags, such as those supplied by Robbie
Manufacturing, Inc., prior to sealing over the loaded tray with flaps. The
outer
cover 3704 may be suitably perforated with apertures to allow gas and/or air
exchange therethrough and can be heat shrunk after sealing over the loaded
tray with
flaps by passing through a suitably adjusted heat tunnel. Alternatively, the
outer
cover 3704 may be applied from a continuous web and stretched during
application
thereof and then sealed to provide a sealed outer cover 3704 that is stretched
taught
around and over the loaded tray with flaps as shown in FIGURE 75.
FIGURE 77 shows a cross-section of a tray after the application of the outer
cover 3704,. that may be manufactured from any transparent suitable material,
but
before stretching by depressing the outer cover 3704 into the recess 3716 as
shown in
FIGURE 78. FIGURE 78 shows the same cross-section as in FIGURE 77 after outer
cover has been depressed so as to contact the adhesive between the base of
tray and
the inner surface of the outer cover 3704. By a mechanical device, the outer
cover 3704, that is located adjacent to the underside of the base 3710 of
tray, can be
depressed and stretched so as to contact the adhesive 3712 located between the
inner
surface of the outer cover 3704 and the under surface of the base 3710 of tray
so as to
provide bonding therebetween. A recess 3716 can therefore be provided as
shown.
In this way, the outer cover 3704 can be stretched over the entire surface of
the
tray 3700 with perishable goods contained therein. Therefore, when another
finished
package of similar configuration is located and stacked above and onto a
similar
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CA 02387349 2002-04-03
lower package, the underside of the finished package will not contact the
upper
surface of the dome of the lower package. In this way the lower packages are
protected from damage when stacked and transported or when displayed in stacks
at
a point of sale to consumers.
Referring now to FIGURE 79, a cross-sectional view through an assembled
and finished master container 3722 is shown inside a closed and sealed
corrugated
cardboard carton 3724. Two finished packages 3726 and 3728 are shown inside
the
master container 3722. As can be seen, the extended flaps of the upper
finished
package provide a recess to accommodate the upper surface dome of the lower
finished package thereby providing protection to the perishable goods
contained
therein. The master container 3722 may be thermoformed from a web of flexible,
substantially gas barrier, plastics material such as Curlon Grade 9315-II as
manufactured by Gurwood of Oshkosh, Wisconsin and can be provided so as to
tightly hold the finished packages. A substantially gas barner lid 3732 that
is
provided from a web of plastics material such as Curlam Grade 2500-K as
manufactured by Curwood of Oshkosh, Wisconsin, is shown heat sealed to the
flange
of the master container 3722. The seal 3734 between the lid and the master
container
will, most desirably, be a peelable seal that can be peeled with relative ease
by any
person wishing to open the sealed master container. A desired gas 3736 is
contained
within the hermetically sealed master container and an oxygen scavenger 3730
is
located therein. Further, the lid of a master container may contain a relief
valve to
allow escape of any excess gas that may be released from solution in the meat
and to
accommodate for an expansion of the master container.
The sealed, gas barrier, master container 3722 is located in a corrugated
cardboard carton 3724. The corrugated cardboard carton 3724 may be
manufactured
by the Weyerhaeuser Corporation, of Tacoma, Washington from 69/40/69, 5100
flute
corrugated cardboard and such a construction will withstand substantial
loading.
An enlarged view of the seal arrangement is shown in FIGURE 80 and an
alternative configuration showing flange of container in position after
folding
inwardly is shown in FIGURE 81. In this embodiment the corrugated cardboard
carton is just large enough to contain the master container but the flange of
the
master container is folded inwardly to allow the sides of the master container
to be in
close contact with the inner surface of the carton, thereby reducing the size
of the
carton to a minimum.
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The size of the master container and the corresponding size of the carton can
be suitably arranged to contain one or more finished packages.
Embodiment 16
FIGURE 131 shows another embodiment of a tray constructed according to
S the present invention. The tray 1902 includes flap 1900. Flap 1900 is
attached to
tray 1902 along an outer edge 1904 of tray flange 1906 and a further flap (not
shown)
can be attached to the outer edge along the opposite side of the tray which is
parallel
with the first flap and is similar in operation thereto. After sealing of
second and
third webs to flanges 1906 and 1908, flap 1900 can be folded downwardly so
that
radius 1910 in FIGURE 132 engages with recess 1912. Flap 1900 includes a hinge
that can be folded along a hinge line through an arc shown more clearly in
FIGURE 132. Radius 1910 and recess 1912 "mate" and can be arranged so that
they
"snap" into a matingly engaged position, thereby holding the flap 1900 firmly.
Refernng now to a cross-sectional view of the stacked trays in FIGURE 133,
flap
base 1918 is shaped so as to correspond with profile of flanges 1906 and 1908
and a
ridge 1926 is located along the external edge of flap base 1918 such that when
a
finished package is stacked above another similar package they will "nest"
together
and the upper tray is prevented from contacting the contents of the lower
tray. The
base of the tray can be formed with a profile providing an upwardly extending
depression that extends above the highest point of the contents in the lower
tray. In
this fashion, the finished packages can be stacked within cartons for
distribution and
shipped long distances without causing damage to contents of the trays in the
lower
position. First web tray 1920 has recessed base to clear goods in the tray
below.
Lip 1928 can be heat sealed after folding of the flap by heat seal bars 1930
to ensure
that flap 1900 is retained ir. folded position as shown in the stacked
finished
packages FIGURE 133. Ridges 1932 can be formed into flaps to improve rigidity
and stability of the finished pack.
Embodiment 17
Referring to FIGURE 8?, another embodiment of a tray, 3100, with flaps is
shown. A cross-section is shown in FIGURE 83, where both flaps are folded
inwardly and the package hay been inserted into a Clysar AFG shrink bag 3114.
The
tray can be "stretch-wrapped" with PPVC as an alternate to a PP bag as shown
in
FIGURE 83.
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Tray 3100 includes a base with four upwardly extending walls, terminating at
flanges 3104. Two flaps 3102, 3103 are provided such that they can fold
inwardly.
Recesses 3106 are provided in the flaps to allow communication of gasses
therethrough. Tray 3100 further includes a base rim 3108 that extends around
the
perimeter of the base. Depressions 3110 and perforations 3112 can be provided
at
the tray base 3126. Apertures 3116 are provided in shrink bag 3114. Tray 3100
may
be thermoformed from any suitable material. Apertures 3116 provide direct
communication from external atmosphere through space 3118 and recesses 3118 to
tray cavity. Perishable goods can be located into tray cavity and flaps 3102
folded
inwardly. Assembled tray and perishable goods can then be located within a
polypropylene shrink bag, such as Clysar AFG shrink bag 3114 which is then
heat
sealed and heat shrunk around the tray and goods to form a finished package. A
plurality of finished packages may be assembled and stacked together to
provide a
group of assembled finished trays which is then hermetically sealed within a
substantially gas barrier master container as described in US Patent
Application
09/039,150 with a gas barrier lid. When the finished packages are stacked, the
base
rim 3108 of one pack will rest directly above flaps 3102. In this way,
finished
packages can be stacked together without causing undesirable damage to the
contents
of the package. Perforations 3112 absorb liquids as described herein.
Alternatively, in a preferred embodiment, the Clysar AFG shrink bag 3114,
may be replaced with a stretch wrap material such as plasticized PVC.
Referring now to FIGURE 135 wherein a view of a section of tray, after
folding and banding of the flaps to the tray wall, is shown. A plan view of
the scrap
view section, prior to folding and bonding of the flaps, is shown in FIGURE
134. A
preferred method for production of trays with flaps includes a thermoforming
process
and a "cut in place" procedure. The term "cut in place" is a common term used
by
those skilled in the art of tooling manufacture and use of thermoforming
equipment.
This term describes a thermoforming production method including the use of a
thermoforming tool with a cutting devices incorporated into the tool so as to
permit
cutting of the subject thermoformed component from a web of plastics material
immediately after forming and before ejection and removal of the components)
from
the thermoforming tool. The scrap view section shown in FIGURES 134-135
details
a single corner section of a four cornered tray such as the tray of FIGURE 55,
however, all four corners of the tray with flaps are similar. Referring again
to
FIGURES 134-135, flaps 5268 and 5270 are shown attached to a tray 5272 at a
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hinge 5274. The tray with flaps is shown in FIGURE 134 prior to folding flaps
and
bonding. The tray with flaps is shown in FIGURE 135 after folding of flaps and
bonding. The flaps can be printed by ink jet devices, prior to folding and
bonding in
the manner disclosed above with reference to FIGURE 55. Adhesives can also be
applied by ink jet printers to the flaps and tray. Hinge lines 5276 and cut
lines 5278
are all parallel and in the same plane. The cut lines 5278 and hinge line 5276
terminate at points 5280 and 5282. If desired a further hinge line 5284
provides
devices to fold sections 5286, which can be folded and bonded to the base of
tray.
Panels 5288 and 5290 can be printed with any information or graphics as may be
desired and are arranged to be elevated and angled so as to be more easily
visible by
an intending purchaser of the tray with goods therein.
Referring now to FIGURE 136, a cross-sectional view through a corner of the
tray with flaps, after the flaps have been folded and bonded, is shown. The
"cut in
place" forming method allows a method to provide walls 5292 and 5294 that can
contact each other, as shown, and be bonded together after folding the flaps
into the
finished position. In this way, a substantially more rigid tray structure can
be
provided that would otherwise require a heavier wall section for trays that
have not
been provided with flaps as herein disclosed. With ink jet application of
adhesives,
as described herein, an efficient devices of economically applying the minimum
quantity of adhesives is provided. In this way, adhesives can be applied in a
pattern
that allows for maximum surface area bonding of trays and flaps while
minimizing
the quantity of adhesive material required.
In yet another preferred embodiment, packaging including a combination of
features disclosed in any of the trays above may be combined to construct a
finished
package. For example, a package including a tray with any of the flaps
disclosed
herein may be constructed to provide desired features and inserted into either
a
Clysar AFG shrink bag or alternatively a stretch wrapped in a pPVC stretch
film over
wrap or shrink wrapped with printed Clysar AFG anti fog shrink film.
In yet another preferred embodiment, packaging including a combination of
features disclosed above may be combined to construct a finished package.
However, perforations may be provided in depressions to allow any free liquids
to
pass therethrough to a space between the base of tray and the outer shrink
bag.
Indentations may be provided in the under (or outer) surface of the tray that
can
allow open cells, that may be present in the EPS structure of the tray, to
absorb the
liquids.
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Any of the foregoing trays with flaps will be used in a method to
automatically or manually performing the following steps:
Providing a tray with flaps, that has been thermoformed from expanded
polystyrene (EPS). The tray having dimensions that will provide for the
efficient use
of the internal dimensions and capacity of typical, refrigerated road and rail
transport
vehicles.
Trays will retain a substantially oxygen free gas within cell structure of the
tray and/or exposing the tray andlor the tray material prior to and/or during
thermoforming and production of the tray, to a gas that excludes oxygen and
allowing the gas to exchange with any gasses contained within the cells of the
EPS
thereby substantially displacing any atmospheric oxygen from the cells or
otherwise
ensuring that gasses contained in the cell structure substantially excludes
oxygen.
Providing perishable goods onto the base of the tray. The perishable goods
having been treated and processed to enhance the keeping qualities thereof.
Over wrapping the tray with goods therein with a web of gas permeable
material such as pPVC, to produce a finished package and then seal the over
wrapping web of gas permeable material to portions of the tray by a heat
sealer or
other suitable adhesives and then perforate the over wrapping web of gas
permeable
material at desired locations.
Placing the finished package or a plurality of similar finished packages into
a
gas barner master container.
Displacing substantially all atmospheric gas, and particularly atmospheric
oxygen, from within the master container, with a suitable gas or blend of
suitable
gasses.
Sealing a lid over the opening in the master container to form a hermetically
sealed package containing the trays with perishable goods and suitable gas.
Placing the master container inside a carton such as can be manufactured
from corrugated cardboard and enclosing the master container.
Locating a plurality of closed cartons onto a standard (GMA specified) pallet
(Dimensions of 40" x 48") so ~s to maximize the efficient use of the upper
surface
area provided by the pallet thereby producing a loaded pallet.
Storing the loaded pallet for a period of time in refrigerated space.
Delivering the finished pallets to a point of sale such as a supermarket.
Performing all aspects of the process in temperature controlled conditions
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Embodiment 18
Referring first to FIGURE 88, a tray is shown in a three dimensional
disposition. The tray is arranged with a base 6540 and four upwardly extending
walls terminating at a flange 6542 with a cavity 6544 surrounded by the walls.
Each
of the walls may be rigidly fabricated by bonding together, two or more layers
{shown as 6536, 6552 and 6560 in FIGURE 89). Each layer is attached directly
together or in series to the flange 901, of the tray, via hinges that allow
folding of
each layer together and against each other, prior to bonding the layers
together, to
provide rigid wall{s). In this way the tray walls can be rigidly constructed
with
higher compression resistance and at a lower cost than would otherwise be
incurred
for a single layer wall of a similar compression resistant rigidity.
Referring to FIGURE 90, a plan view of a thermoformed pre-form is shown
which can be manufactured from any suitable material, of any suitable
thickness but is
most preferably thermoformed from extruded polypropylene sheet with a
thickness of
approximately 0.018". The polypropylene sheet is then thermoformed to produce
a pre-
form, which is constructed so that it can then be folded and bonded into a
stackable tray
profile. The pre-form consists of a cavity 6617, with a series of semi-rigid
flaps, all
connected by at least a single hinge to the flange 6542. Cavity 6617 has a
base 6540 with
four upwardly extending walls terminating at a continuous flange 6542. Flange
6542 may
be arranged with four straight sections connected via rounded corners but the
other
packaging tray configurations may be fabricated. At the outer perimeter of
flange 6542,
adjacent flange flaps, 6536, 6574, 6598 and 6582 are attached via hinges shown
as 6618,
6614, 6612 and 6594 respectively. Located at each corner of flange 6542, and
between
each adjacent pair of adjacent flange flaps, additional flaps are provided.
Between
adjacent flange flaps 6536 and 6574 a pair of generally triangular adjacent
flaps 6552 and
6564 are located but severed completely from direct attachment together by cut
6628.
Flap 6552 is attached to adjacent flange flap 6536 via hinge 6626 and flap
6564 is
attached to adjacent flange flap 6574 via hinge 6568. Similarly, flap 6576 is
attached to
adjacent flange flap 6574 via hinge 6570 and flap 6580 is attached to adjacent
flange
flap 6582 via hinge 6592. Additionally, flap 6580 is attached to adjacent
flange flap 6582
via hinge 6584 and flap 65x0 is attached to adjacent flange flap 6598 via
hinge 6588.
Finally, flap 6606 is attached to adjacent flange flap 6536 via hinge 6604 and
flap 6610 is
attached to adjacent flange flag 6536 via hinge 6624. The pair of flaps 6610
and 6606 are
severed along cut 6608, the pair of flaps 6552 and 6564 are severed along cut
6628, the
pair of flaps 6576 and 6580 are severed along a cut 6578 and the pair of flaps
6580 and
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CA 02387349 2002-04-03
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6590 are severed along cut 6588. Said flaps 6552 and 6610 can be folded toward
each
other until they contact what becomes the inner surface of adjacent flange
flap 6536, and
adjacent flange flap 6536 can then be folded toward adjacent tray cavity wall
6636 until
the surfaces of flaps 6552 and 6610 contact a surface of adjacent cavity wall
6636. This
can be repeated simultaneously, separately or in correspondingly opposite,
adjacent flange
flaps such that all flaps are folded and held together for bonding at any and
all contact
points between the corresponding flaps and generally as detailed in FIGURE 89.
Referring now to FIGURE 89, a side wall of packaging tray shown in
FIGURE 88 is detailed, after folding of flaps shown therein which can be
bonded, by any
suitable bonding means, at contac: points 6562, 6558, 6556, 6554 and 6550.
Bonding
can be arranged to follow a path near what becomes a perimeter of adjacent
flange
flap 6536 so as to hermetically seal space 6548 therein.
Referring now to FIGURE 91, a cross section through flange 6542, cavity
wall 6636 and adjacent flange flap 6536, details a preferred embodiment
wherein
hinge 6618 is located parallel to hinge 6630 with an additional flap section
6632 between
hinges 6618 and 6630. Adjacent flange flap 6536 is bonded to wall 6636 at
6634.
Referring again to FIGURE 90 in a preferred embodiment, an additional
flap 6572 is shown attached to adjacent flange flap 6574 via hinge 6566 and
additional
flap 6602 is shown attached to adjacent flange flap 6598 via hinge 6600. Flaps
may also
be similarly attached via hinges to adjacent flange flaps 6536 and 6582 if so
desired. In
this arrangement pairs of flaps 6576 and 6580, 6564 and 6552, 6610 and 6606,
6580 and
6590 can be deleted, allowing flaps 6572 and 6602 to be folded respectively
against what
become internal surfaces of adjacent flange flaps 6574 and 6598 prior to
bonding there
together to provide a structure generally similar to that shown in FIGURE 89.
Referring now to FIGURE 92, a plan view of a preferred pre-form is shown,
wherein a centrally located cavity 6704 is connected via hinges 6716, 6708,
6720 and
6718, to flaps 6702, 6706, 6710 and 6714 respectively. Additional flaps 6700
and 6712
are attached via hinges to flaps 6702 and 6710. Ribs can be provided to all
parts of the
tray cavity, walls and flaps and can be arranged in any suitable profile so as
to maximize
rigidity of the finished tray but are shown only in flaps 6700 and 6712.
Refernng now to FIGL:RE 93, two pre-forms are shown stacked and nested
together. In this way pre-forms can be manufactured and then conveniently
stacked in a
nesting configuration, minimizing the volume of space required during storage
and
shipping thereof. Pre-forms can then be fabricated at the point of use for
packaging
3 S goods.
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Referring now to FIGURE 94, a cross section through a tray assembly fixture
arranged to fold and bond pre-forms in an enclosed chamber is shown. Only one
view of
the assembly fixture is shown which is rigidly constructed from suitable
materials
wherein a base frame 6814 is connected to a platen 6816. Base frame 6814 and
platen 6816 can be securely connected there together by any suitable means but
most
preferably by way of a quick release arrangement so as to allow the rapid
separation of the
two components. In a preferred embodiment, several similar assembly fixtures
can be
attached to a horizontally disposed continuous conveyor and arranged to
operate
automatically as a complete machine and this will be generally described in a
later part of
this disclosure. Platen 6816 is securely attached to a profiled fixture 6812,
which is shaped to correspond with the internal, cavity surface profile of a
pre-form
such as shown in FIGURE 92. A pre-form 6820 is shown in position and mated
with
fixture 6812. Part 6818 is hing~;d at 6811 and part 6806 is hinged at 6810.
Parts 6818
and 6806 are arranged to dimensionally correspond to the flaps of pre-form
6820,
and can be attached to a suitable driving arrangement such as pneumatic
cylinders
that will drive each part to close in a sequence as required. Part 6818 is
shown in an
open disposition whereas pact 6806 is shown in a closed position and firmly
holding
a flap of pre-form 6820 against a wall thereof. A source of vacuum may be
attached
to fixture 6812 or single chamber (6804 and 6802) so as to assist in securely
holding
the pre-form in place during folding and bonding of flaps. After flaps have
been bonded
into position the vacuum may be released to allow easy removal of the folded
and bonded
tray. Additional hinged parts (.not shown), similar to 6818 and 6806, may be
attached to
other sides to fixture 6812 as may be required to correspond with additional
flaps that
may be attached via hinges to pre-form 6820. A typical pre-form is shown in
FIGURES 92 and 93. All hinged parts 6818, 6806 and any others can be arranged
to fold
flaps against the side walls of pre-form 6820 and to hold there against
securely during
bonding of flaps to correspondingly adjacent side walls. A single chamber is
shown in
two parts, 6802 and 6804, that can be opened and closed as required to allow
pre-forms
such as 6820 to be located on fixture 6812 and sequentially unloaded by any
suitable
means in an automated and continuous process. The single chamber (6802 and
6804) is
attached to a shaft 6800, which in turn is attached to a drive such as a
pneumatic cylinder,
which can provide alternating upening and closing of the chamber. Ports can be
provided
in the single chamber with valves arranged to allow any suitable gas at any
suitable
pressure therein and connection to a suitable source of vacuum. The single
chamber can
be arranged to close over fixture 6812 after locating a pre-form (6820)
thereon and a
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seal such as 'O' ring 6822, can be installed along the contacting face between
the
single chamber (6802 and 6804) and platen 6816. In this way, an enclosed and
substantially gas tight enclosed space 6808 can be provided. Prior to closing
the single
chamber against platen 6816, hinged parts 6818 and 6806 can be activated by
driving air
driven cylinders. After closing the single chamber, space 6808 can be
substantially filled
with any suitable gas at any suitable pressure via valves and pons (not shown)
and to
ensure that cavities between flaps and cavity walls are filled with the
selected gas and
thereby substantially excluding atmospheric oxygen. Hinged parts 6818 and 6806
can be
arranged to carry any suitable sealing mechanism, such as RF welding and
arranged to
bond flaps to side walls of pre-form 6820 directly. In this way cavities such
as
space 6548 described above and in association with FIGURE 89 can be filled
with
any suitable gas at any suitable pressure. In summary, a preferred sequence of
apparatus operation, as shown in FIGURE 94 can be as follows:
A. Provide a pre-form 6820, locate on fixture 6812, and apply a vacuum
source to hold the pre-form securely to fixture 6812.
B. Apply any suitable adhesive to selected surfaces of flaps of pre-form
and fold hinged parts such as 6818 and 6806 so as to fold and close flaps
against the
side walls of the pre-form. [Hinged parts 6818 and 6806 may be arranged with a
means to partially close and thereby allow substantially complete evacuation
of air or
gas therefrom prior to bonding].
C. Close single chamber over pre-form and seal chamber against
platen 37.
D. Evacuate space 6804 and provide any suitable gas at any suitable
pressure therein.
E. Seal flaps to side walls of pre-form.
F. Open chamber and allow removal of pre-form with flaps bonded to
side walls.
Referring again to FIGURE 94, assembly fixture detailed therein can be
arranged in groups wherein each assembly fixture is attached, via quick
release
connection, to a pair of parallel horizontally disposed, continuous chains,
with a
driving motor such as a servo electric motor, horizontally disposed to provide
a
conveyor. In this way a complete machine can be arranged with the upper
section
thereof, enclosed and a suitable gas provided in enclosure, such that when pre-
forms
are located on fixtures {6812), if so desired, the gas in contact with pre-
forms is
oxygen free.
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Referring now to FIGURE 95, a side view and end view of two finished
packaging trays 6828 and 6830 stacked together are shown. Ribs 6824 and 6826
locate interlock with the base of the upper tray.
Referring now to FIGURE 97 and FIGURE 98, another preferred packaging tray
(6920) embodiment is shown with a cross sectional view 98 therethrough. Tray
6920
may be manufactured from any suitable material but in this instance a material
such as
polyethylene is preferable. A cavity 6918 is surrounded by upwardly extended
side
walls 6912, 6906, 6902 and 6900 all terminating at flange 6900. Flaps 6906 and
6912 are
visible and ribs 6910 and 6906 are shown in flap 6906 and ribs 6916 and 6914
are shown
in flap 6912. Flaps, 6907 and 6912 (including those not visible), have been
hermetically
bonded to side walls of tray. Refernng now to section 98 in FIGURE 98, a cross
section
through ribs 6910 and 6908 is shown. Hinges 6922 and 6924 are arranged to
allow
folding of flap 6906 against wall 6930. Hermetic seals are shown at 6926, 6932
and
6936. Hermetic seals shown as 6926 and 6932 follow a path completely around
the
perimeter of rib 6910 and hermetic seals shown as 6932 and 6936 follow a path
completely around the perimeter of rib 6908. In this way a spaces 6928 and
6934 can be
completely enclosed and hermetically sealed separately from each other.
However, prior
to bonding ribs so as to enclose and hermetically seal spaces 6936 and 6934,
any suitable
gas such as carbon dioxide at any suitable pressure but most preferably at a
relative high
pressure, such as 80 psi, can be provided therein. In this way a rigid tray
can be
manufactured with reduced material content and therefore at relatively lower
cost.
Referring now to FIGURE 99, a tray 7100 with lateral ribs arranged in a
similar manner to those (6916, 6914, 6910 and 6908) disclosed in FIGURE 97 is
shown. Section 100 shows spaces 7116 and 7122, enclosed and hermetically
sealed
within ribs 7118 and 7124, along seals 7114, 7120 and 7126 which can be filled
with
high pressure gas such as C02. Hinges 7108 and 7112 are located so as to
provide an
outwardly extending flange, after folding flap against wall 7140, and to which
a web
of material shown as lid 7142 can be hermetically sealed so as to fully
enclose
cavity 7138. Apertures such as 7136 can be provided to allow liquids to enter
cavity 7128 and seal at 7132 prevents escape of such liquids from space 7128.
Ribs
such as 7130 can be provided.
Referring now to FIGURE 84, two thermoformed trays 6500 and 6514 are
shown in a partially nesting disposition. The profile of tray 6500 is arranged
with
upwardly extending walls terminating at flange 6502 with ribs 6506 and 6508,
formed into the walls. Ribs formed in tray 6500 such as 6506 and 6508 extend
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inward toward the center of cavity 6504 and ribs such as 6512 and 6510 in tray
6514
extend outwardly away from a centrally disposed cavity.
Refernng now to FIGURE 85, the two trays 6500 and 6514 in FIGURE 84
are shown sealed together to form a single tray 6518. Flanges 6502 and 6516
are
hermetically sealed together around the full length of what has become a path
close
to the tray perimeter. FIGURES 86-87 show details of enclosed spaces such as
6526,
6530 and 6528. Ribs are also hermetically sealed such that ribs formed in the
walls of the
inner tray are sealed against the corresponding rib in the outer tray to
provide fully
enclosed spaces such as 6530 shown in FIGURE 87, that can be filled with high
pressure
I O gas. Seal paths 6522 and 6524 are shown as examples of hermetic sealing
and
enclosing of spaces such as ti530. FIGURE 87 shows rib 6508 hermetically
sealed to
rib 6520, at 6532 and 6534 enclosing space 6530.
Referring now to FIGURE 101 a cross section through a tray similar to
tray 6500 shown in FIGURE 84 is detailed in a preferred embodiment wherein a
tray
with a base 7312, and upwardly extending walls 7308 terminating at flange 7300
is
provided with rib 7308 formed therein. A separately formed rib 7314 is shown
adjacent to rib 7308 in a position prior to bonding and also after bonding to
tray wall
along seal path 7310. A hermetically sealed and enclosed space 7306 can be
filled
with high pressure such as C02. In FIGURE 102, a cross section through ribs
7310
and 7308 is shown with space 7306 enclosed therein.
Referring now to FIGURE 103, a thermoformed tray, 7408 is shown in a
three dimensional view located above a form cut blank, 7414. Ribs are provided
in
the base 7404 and walls, 7402, 7406, 7412 and 7416 in a vertically disposed
arrangement. Any suitable rib configuration may be provided in the walls and
base
2S of any suitable size tray, but most preferably rigid ribs such as 7410, as
shown in
FIGURE 103, are provided with the recess accessible from the outer side of
each
wall, with the ridge extending inwardly. Trays 7408 and blanks 7414 can be
manufactured in any required size, from any suitable material but most
preferably
would be produced from mono-layer extruded polyethylene terephthalate (PET)
sheet. PET sheet may be extruded with multiple layers and both or a single
outer
layer may be provided with enhanced heat or RF (radio frequency(RF) or micro
wave) sealable properties. Enhanced RF sealability may be provided by
including
any suitable additive such as suitable metallic elements or compounds in the
outer
layers, by blending into the polymer prior to extrusion.
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Hinges shown at 7434, 7420, 7432 and 7426 are arranged so that flap
portions 7418, 7422, 7425 and 7430 are all attached, thereby, to central
rectangular
portion 7424. In this way flap portions can be folded upwardly about hinges so
as to
contact the walls of tray 7410. Flap and base portions of blank 7414 can then
be
sealed to the walls of tray 7408 so as to provide a hermetic seal around the
perimeter
of each rib after providing gas such as C02 at an elevated pressure in the
recess of
each rib. In this way a rigid tray can be manufactured with substantially less
material
content than would otherwise be required for a tray manufactured from a single
component.
Embodiment 20
Refernng now to FIGURES 268-270, a preferred tray with flaps is shown.
Tray 7202 includes a crest 7200 constructed on the perimeter of the tray
opening on a
wall of the tray 7202. A similar crest is also constructed on opposite
sidewall so as
to form two convex areas having a first radius. Referring now to FIGURE 269, a
flap is shown with a flap base 7204 having a concave indentation 7204 of a
second
radius. When folded, as in a finished package, flap base 7204 is substantially
level
with the tray base 7216. Preferably, two such flap bases are provided, each in
opposing sides from the other. Referring now to FIGURE 270, a plurality of
finished
stacked packages using the trays of FIGURE 268 is shown. Preferably, the flap
base
concave indentation radius is smaller than the radius of tray crest, so that
when
stacked, flap base of upper tray 7212 makes contact with tray crest of lower
tray 7214 at two locations 7208 and 7210. In this manner, trays are prevented
from
rocking back and forth if only one contact point is provided. Preferably, a
space is
provided between upper tray 7212 and lower tray 7214 which is also shown in
FIGURE 270. In this manner, the underside of tray base 7216 is prevented from
touching the sealed or overwrapping web on lower tray. The sealed or
overwrapped
web material substantially holds the fresh meat portions to the tray base.
Preferably,
the web material is oxygen permeable. Finished packages can thus be stored and
packaged in any of the master containers disclosed herein. The disclosed tray
profile
allows stacking of several layers of trays in a vertical stack, wherein each
loaded and
over wrapped tray is located directly above and in contact with a lower tray
to
maximize density of a finished master container. Preferably, the profile of
the flaps
is an upwardly arched base that corresponds with the profile of the tray upper
flange
profile. Preferably, ground meat is extruded with a profile that corresponds
to the
inner profile of the cross section across the length of the tray such that
when loaded
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into the tray, the upper surface of the extruded grinds portion is in firm
contact with
the tray over wrap so that it holds it in place and slightly below the upper
edge of the
flanges. The end flanges are arched to match the arched base and end flap
profile of
the lower tray profile. Continuous bonding of each flap around it's perimeter
to
ensure that the end edge butts up and contacts the adjacent flaps provides for
maximum structural stability and minimum twist after fabrication and bonding.
Thus, the double walls (inner cavity and outer flap) improve crush resistance.
Trays with Iron Powder
Powdered iron is often used as an agent for scavenging free, residual oxygen
gas in packaged perishable, foods; for example Keplon Co., Ltd. of Kariagawa,
Japan have manufactured deoxidizers such as Keplon - TY for this purpose. As
exemplary of the application of the method to the present invention, reference
will be
made with regard to FIGUP.E 49, but it should be readily apparent that the
method
herein described can be eas~.ly applied to any of the trays made from the
present
invention. Powdered iron may be applied to the inner surface of the outer
cover 4120, in such a manner so as to become activated by water that may be
provided in the adhesive layer 4142. Furthermore when the outside-surface of
foam 4138 (see detail in FIGURE 49) is arranged to have a capacity to absorb
liquids, such liquids can be retained and substantially prevented from
escaping from
within the finished package. Additionally, a suitable adhesive can be provided
between the tray flange rim 4144 and the outer cover 4120 where the continuous
flange rim 4144 is in contact with the outer cover.
Powdered iron can be used as an oxidizing agent and removal of oxygen gas
from within a hermetically sealed, gas barrier package. Powdered iron may be
applied, in combination with other suitable sealing substances and agents, to
the
surface and most preferably to an inner surface, of the outer cover 4120 at
locations
that will become in direct contact with underside of the base of tray. The
iron
powder can be applied to outer cover 4120 in such a manner so as to allow
subsequent activation by water that may be contained in the adhesive layer
4142
when applied to the under surface of the base of tray, at the time of over
wrapping the
tray with perishable goods therein, and when cover 4120 contacts the base of
tray.
Prior to application to the inner surface of the outer cover 4120, the
powdered
iron particles may be coated with a suitable coating including a suitable
protecting
substance or blend of protecting substances, that can provide a protecting
layer over
the complete outer surface of the iron powder particles thereby protecting and
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isolating the iron powder particles from direct contact with water or other
substances
that may cause the iron powder to oxidize. The protecting layer can thereby
remain
in the protecting condition until the coating is altered to allow water to
permeate
therethrough or otherwise contact the iron particles. The coating may be
altered at,
for example, a convenient time after complete or partial assembly of the
finished
packages by exposing to an electromagnetic field of such intensity or in such
a
manner as to induce generation of heat in the particles of iron. Generation of
heat in
the iron particles by, for example, exposure to an electromagnetic field, rnay
be
induced by a suitable frequency of alternating electric current. Generation of
heat in
IO this manner may cause the protecting coating to release water or allow
water from
adhesive layer to contact and thereby activate the powdered iron to oxidize.
Oxidation of iron powder in this way can result in absorption of residual
oxygen that
may be present inside the maser package. Any suitable coating that possesses
the
required chemical and physical properties may be used to coat the iron powder.
In
this way the iron powder particles can be maintained in a protected and
"dormant"
condition until required to absorb oxygen such as after sealing of the package
and
when enclosed within a master container.
In this way air and gasses can be removed from the finished and sealed
packages by evacuation and then replaced by gas flushing with a desired gas,
while
liquids such as blood cannot readily escape. Furthermore, gasses can readily
flow
through the communicating passage from inside to outside of the package (but
still
inside the master container) to enable rapid equilibration of gasses when
oxygen gas
is released by reduction of orymyoglobin after sealing of the master
container. Any
residual oxygen that may remain present in the sealed master container can be
absorbed by the oxidizing ir.~n particles after activation with the
electromagnetic
field, causing release of water or other suitable substances and direct
contact with the
iron particles.
Referring now to FIGURES 137-139 three cross-sectional views of selected
sections of EPS trays with flaps are detailed. FIGURE 137 shows a section of a
tray
with a flap attached at a hinge and where the flap is "open" and not folded so
as to be
in contact with tray 5501. FIGURE 138 shows a flap folded into a finished
position
and contacting tray 5501. The :'lap may be formed with a recess 5506 that can
be a
arranged to be a continuous recess that follows a path close to the perimeter
of the
flap. The tray can be arranged to have a ridge 5508 that follows a path
corresponding
to the recess 5506 such that when the flap is folded about the hinge so as to
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intimately contact the tray wall and base, the ridge 5508 will mate with the
recess 5506, as shown in enlarged view of FIGURE 139. Accordingly, the flaps
with
heat activated adhesive applied in recesses 5506 can be folded, as shown in
FIGURE 138, so as to cause intimate contact with the tray base 5512 and/or
walls 5514 thereby providing a tray with folded flaps. The tray with folded
flaps can
be held in such a folded condition so as to hold ridges 5508 firmly against
adhesive
and in continuos contact with 5516 along the full length of the ridge and
recess. The
tray with folded flaps can be transferred automatically into and through a
microwave
oven source of heat such that adhesive 5516 is activated by exposure to a
suitable
level of microwave heat source. and thereby bond the flap and tray together at
_.
ridge 5508 and recess 5506. The bond can be arranged along a continuous path
and
enclose the space between the flaps and the tray so as to provide a
substantially liquid
tight seal. Selective heating of adhesive 5516 can be provided by microwave or
magnetic field devices so as to cause bonding without application of excessive
heat
that could otherwise cause undesirable distortion to the EPS tray. Any
suitable heat
activated adhesive may be provided by any suitable device. In another
preferred
embodiment the heat activated adhesive may be provided in the recess 5506 by
computer controlled robots such as in the form of a heated and softened
continuous
extruded bead that may be subsequently heated so as to provide good bonding in
the
recess, followed by cooling thereof to provide hardening of the heat activated
adhesive. Heat activated adhesives may be applied to the tray with flaps or
any other
suitable packaging materials by any suitable method prior to bonding.
Subsequent
exposure to microwave or other suitable source of heating, that can be
selectively
applied in such a manner so as not to cause undesirable damage or distortion
to the
packaging materials, can produce a package according to the present invention.
A
suitable device for adhesive application to selected surfaces of packaging may
be
provided by the known process of ink jet printing.
Any suitable substances for enhancing the keeping qualities of goods can be
provided into the spaces between the flaps and the tray walls. Water, liquid
and
purge absorbing substances can be provided in those spaces which may be
arranged
so as to be non absorbing prior to exposure to and capable of absorbing
liquids only
after exposure to microwaves or a magnetic field.
Apparatus for Appl~g. Adhesives and Iron Powder to Tray
Trays constructed according to the present invention may have one or more
features which lends itself to be stackable or allows the channeling of gases,
while
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retaining liquids. Trays with flaps are preferably constructed with adhesives
to form
the finished tray. This description therefore provides a method and apparatus
for
applying adhesives and other substances to the trays.
Referring now to FIGURES 140-142, an apparatus constructed according to
the present invention that can be used to apply substances to the surface of
packaging
materials, such as EPS trays, for bonding thereto is shown.
In FIGURE 140 a cross-sectional view through a diagrammatically
represented apparatus is shown where a horizontally disposed motor driven
conveyor
5400, can be intermittently indexed by driving for a set distance or movement.
Magnets 5402 can be located in the conveyor 5400 in convenient positions. A
web
of tray 5404 impressions can be arranged to mate with the conveyor 5400 and
can
thereby be earned by the conveyor. The distance traveled by the conveyor in
each
movement or index is equal and can be arranged so as to carry a single tray
impression a distance equal to the machine direction length of each
consecutive tray
impression. Such an arrangement can therefore position each tray impression
adjacent to a station or processing device for a desired period of time
followed by
further movement of the tray impression to a subsequent station to allow
further
processing. FIGURE 140 shows a first, second, and third station which are
marked 5406, 5408 and 5410, respectively. Station 5406 is arranged to apply an
adhesive 5414 by a nozzle spray device 5412 to an exposed surface of the tray
impressions. Station 2 is arranged to dispense iron powder 5416 or other
suitable
substance, from a conveniently located hopper 5418 with valve 5420, directly
above
an exposed surface of a tray impression that has had adhesive applied thereto.
Magnets 5402 which may be arranged as permanent or as electrically induced
(electromagnets) magnets, are conveniently located in the conveyor such that
when
iron powder 5416 is dispensed from hopper 5418, it will be attracted toward
the
magnets 5402 and be deposited in a pattern on the exposed surface of the tray
impressions. The pattern of iron powder deposits can be determined by the
profile/shape of the magnets 5402 which can be adjusted as required to provide
a
suitable pattern. The powder 5416 may be then bonded by adhesive to- the tray
impression 5424. Third station 5410 can be arranged to apply drying or curing,
such
as a radiant heater 5422, to the adhesive sprayed and tray impressions 5424
and
thereby cause setting and/or drying of the adhesive applied at the first
station 5406
with iron powder 5416 thereto. The iron powder applied at second station 5408
can
thereby be suitably bonded to the tray impression 5424. Additional stations
may be
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arranged, adjacent to the conveyor 5400 so as to apply additional layers of
adhesive
and/or additional substances as may be required.
Referring now to FIGURE 141, a cross-sectional view through a section of a
diagrammatically represented apparatus is detailed and showing a profiled
vacuum
plate mating with a section of an EPS tray that is located between a manifold
5426
and a vacuum plate 5428. Manifold and the vacuum plate can be attached to
moving
devices such as pneumatic cylinders that can be operated as desired to move
the
vacuum plate and the manifold toward and away from each other in an automated
cycling and repetitive sequence. The vacuum plate and the manifold can be
closed
together so as to conveniently clamp an EPS tray {or other material)
therebetween for
a period of time. The EPS tray can be arranged with perforations 5430 therein.
The
perforations can be located in a recess shown as 5432 in the enlarged view in
FIGURE 142. The vacuum plate can be provided with vacuum ports 5434 therein
and located so as to provide connection between the under surface of EPS tray
and a
suitable vacuum source 5436. In this fashion a vacuum source can be applied to
the
under surface of the EPS tray with communication through the perforations
5430.
The manifold can be provided and arranged with suitable openings that connect
selected exposed sections, such as sections 5440 and 5442, on the exposed
surface of
the tray to a source of powdered substances "ADSP". In this way powdered
substances, such as heat activated adhesives, can be provided into the
manifold
openings and by applying a vacuum source to the underside of the tray, the
powdered
substances can be deposited onto the exposed surfaces of the tray and/or in
recesses
such as recess 5432. After the powder 5416 has been deposited into the
recesses 5432 the manifold and vacuum plate can be opened pneumatically
allowing
the EPS tray to be removed therefrom and subsequently passed into and through
a
suitable heat and/or suitable energy source, such as a microwave oven. The
powder 5416 can be arranged to contain substances such as water or suitable
metal
elements, so that when the tray with powder 5416, 5444 is exposed to a
microwave,
magnetic field or other suitable source of heating energy, the powder will be
heat
activated and bond together and to the surface of the tray and in the recess
5432. The
powder 5416, 5444 can thereby be securely bonded to the EPS tray at selected
locations on the exposed surfaces of the EPS tray. This method of using a
magnetic
field, microwave or other suitable source of heating energy can selectively
heat the
powder 5416, 5444 without application of excessive heat to the EPS tray.
Powder
application apparatus including the vacuum plate and the manifold material
clamping
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devices with all required driving and controlling apparatus can be integrated
into a
typical thermoforming equipment, such as an Irwin Magnum or a Commodore 730-
12 MM continuous thermoformer (as manufactured by Commodore Machine
Company of Bloomfield, New York. The disclosed powder application with
selective microwave heating of the powder 5416, 5444 can be located between a
thermoforming station and a trim press of the thermoforming equipment. In this
way, a heat activated adhesive can be applied to specific locations of any
suitable
material such as the flaps andlor tray walls of EPS trays such as a tray with
flaps
described above.
Apparatus for A~plying_Adhesives and Iron Powder to Outer Cover
Referring now to FIGURE 143 an embodiment of apparatus constructed
according to the present invention to apply adhesive materials and powdered
iron to a
web of material such as stretch or shrink wrapping materials is shown.
The description disclosed herein provides details of a method and apparatus
for producing stretch or shrink wrapping material that can be used in the
production
of those packages disclosed above, having an outer cover web material. The
stretch
or shrink wrapping material with powdered iron attached thereto absorbs any
residual
oxygen that may be present within the master container and also the cell
structure of
EPS materials used in the production of the finished package.
The apparatus shown in FIGURE 143 includes a series of rollers, a hopper
containing powdered iron, a tray containing solvent based adhesive, an oven
and a
continuous web of outer cover material 4300 that is arranged to follow a path
over
rollers, through oven and onto a web winder assembly as shown. The sketch
includes a cross-section through the apparatus.
A suitable tension is applied to web outer cover materia14300 which is
arranged to follow a path over idler roller 4302 and then to contact imprint
roller 4304, over roller 4306, between oven segments 4308 and onto a roll 4310
at a
web winder assembly 4312. Web 4300 is wound onto roll 4310 by web winder
assembly 4312 at a suitable tension and speed. In this manner, imprint roller
4304 is
arranged to apply a suitable adhesive, which may be solvent based, onto web
4300 in
a registered print pattern and in rectangular areas 4314 as shown in FIGURE
144
where a section of finished web material 4316 is detailed in plan view, with a
cross-
sectional view shown in FIGURE 145, after processing through the apparatus
shown
in FIGURE 143. The method includes transferring the adhesive 4318 from the
tray 4320 via contact with roller 4322 which in turn transfers the adhesive to
transfer
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roller 4324 which in turn transfers the adhesive onto the imprint roller 4304.
Transfer of the adhesive from the transfer roller 4324 to imprint roller 4304
occurs
only at selected areas on the roller 4304 that correspond with the rectangular
areas 4314 such that areas 4314 only are imprinted with the adhesive applied
thereto
and leaving other sections of the outer cover 4300 free of adhesive. The outer
cover
web material 4300 can be printed with information and graphics as required on
the
opposite side of the web to the applied solvent based adhesive in rectangular
areas 4314 and in registered relationship to the rectangular areas 4314, such
that
when the web 4300 is cut by slitting along the length of the outer cover web,
and
wound conveniently onto rolls, the web 4300 can be applied, in an earlier
described
manner to cover the finished packages and with the rectangular area 4314
adjacent to
and in direct contact with the base of trays.
Refernng again to FIGURE 143, powdered iron is dispensed from the hopper
evenly across the web, so as to fall directly downward toward web 4300 above
roller 4306. Roller 4306 includes a tube manufactured, most preferably, from a
non
metallic material such as fiberglass and is cylindrically ground on both
internal and
external surfaces to provide a finished tube of specified internal and
external
diameters. External diameter is arranged so as to have a circumference equal
to two
(x 3 across the web) consecutive imprints (6 imprints in total) of rectangular
areas 4314 per single revolution of the roller 4306. Correspondingly, during a
single,
full revolution of the roller 4306, 2 times 3 imprints (6) are applied to the
web 4300.
Corresponding to the imprint areas 4314, magnets 4305 are located and fixed to
the
internal surfaces of roller 4306 in a pattern that corresponds with the
rectangular
areas 4314 in positions such that when the powdered iron is dispensed from the
hopper it is drawn by the magnets so as to be deposited substantially within
the
specified rectangulai~ areas 4314. When the powdered iron contacts the areas
4314,
on the web 4300, the powdered iron bonds to the solvent based adhesive applied
by
imprint roller 4304. The powdered iron thereby becomes fixed to the web 4300
by
adhering to the solvent based adhesive. The web 4300 then passes between the
oven
segments 4308 that are arranged to have sufficient capacity to cure and dry
the
solvent based adhesive prior to further processing and/or winding of web 4300
onto
the roll 4310 by web winder assembly 4312.
Web 4310 may be further processed by applying solvent based adhesive onto
rectangular areas 4314 after the powdered iron has been applied and cured
together
therewith by passing through the oven segments. This process may be repeated
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several times and as may be required to produce the most effective finished
outer
cover web 4316 materials.
In yet another preferred embodiment other web materials such as perforated
polyethylene and polyester may be laminated to web 4300 and over the powdered
iron. Most preferably the powdered iron will thereby be applied and retained
between the outer cover 4300 and the polyethylene and for polyester webs in
such a
manner so as to allow oxygen to transmit through the outer webs and contact
the
powdered iron and after reacting therewith, inhibiting the escape of any odor
that
may be produced as a result of oxygen reacting with the powdered iron, and/or
other
substances contained therein. Solvent based adhesive can also allow
transmission of
oxygen therethrough while inhibiting transmission of odors therethrough.
Alternative oxygen absorbing materials that are suitable for the application
may be applied with the iron powder or in place thereof.
The finished web material4316 can be slit and wound onto conveniently
sized rolls for subsequent use as the outer cover of packages similar to the
finished
packages described above.
Tray Sealing Apparatus
Webs suitable for use as trays and covers have thus far been disclosed. A
method for sealing a cover to a tray web now follows.
Referring now to FIGURE 146, a tray sealing apparatus is shown to produce
packages, including a tray, a web and perishable goods contents shown as
ground
meat. The perishable good ~ may be portions of beef, pork, or any other
suitable
perishable goods. A horizontally disposed, continuous conveyor 2326 including
a
number of carrier plates 2302 suitably attached to chains is arranged adjacent
and
below a series of stations. The conveyor 2326 is driven by a driver that
intermittently indexes in a forward direction indicated by arrow 2328, at a
rate of one
carrier plate per index. Trays 2300, as described in any of the previous
embodiments, are dispensed into apertures in the carrier plates 2302 at a
first
station generally denoted by the number 2330. With each progressive forward
indexing movement of the conveyor, stations will perform a function. Cutting
devices at a second station generally denoted by 2304 severs flaps. Product
such as
portions of ground beef is leaded into the tray at a product loading station
2306, and
a web of material 2308 is heat sealed to flanges at a heat sealer station
2312. Scrap
material from web 2308 is wound onto scrap roll 2310. Preferably, tray
apertures are
provided by heated pin devices at station 2314. Flaps are turned over by
rotating
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about hinge so as to then locate flanges adjacent to tray 2300, at flap
turning
station 2316. Preferably flanges of flaps are then sealed to flanges of tray
at
station 2318 and flange trimming is performed as may be required at station
2320.
Labeling is done with a tray labeler at station 2322. The finished tray with
perishable
goods packaged therein is ejected from the conveyor at an ejector station
2324.
Referring now to FIGURE 147, a preferred tray constructed according to the
present invention is shown in an inverted position. The tray 2402 includes
those
apertures made by the apparatus of FIGURE 146.
Method and Apparatus for Evacuatin~~ Master Containers
Trays constructed according to the present invention provided structures
which allowed the evacuation of ambient atmosphere and flushing with inert
gases.
Trays according to the present invention are also stackable atop one another
to allow
placement within a master container. Therefore, a method for evacuating a
master
container appropriately follows.
Referring now to FIGURE 148, details of a vacuum and modified atmosphere
packaging and sealing apps~.atus is shown. The apparatus 3564 can be used to
hermetically seal a web of material over the open end of a plastic bag or
pouch. The
web of material and pouch may include substantially gas barrier materials and
the
hermetically sealed pouch and web can be used for any useful purpose, such as
vacuum packaging meat primal portions or to contain one or more retail
packages,
thereby providing a master package which can be subsequently packaged inside a
suitably sized shipping carton.
The apparatus 3564 includes a lower vacuum chamber 3566, that is suitably
mounted with a driver (not shown) attached to a shaft 3568, an upper vacuum
chamber 3570 with a moveable heat bank 3572, attached to a driver (not shown)
via
shaft 3574 and suitably mounted between the upper and lower vacuum chambers,
and
a web unwinding assembly 3576 arranged to allow controlled unwinding of web
material 3578 from roll 3584. A conduit 3582 is connected to upper vacuum
chamber 3570 and a conduit 3584 is connected to lower member 3566. Both
conduits 3582 and 3584 can be connected to a suitable source of vacuum and/or
supply of suitable gas. The upper vacuum chamber 3570 is fitted with a
suitable
rubberized sealing member 3586 which is attached to the rim of the vacuum
chamber 3570 and a corresponding and matching sealing member 3588 is mounted,
in similar fashion, to a rim of member 3566, so that when the upper and lower
vacuum chambers are closed and held together, members 3586 and 3588 are in
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intimate contact with each other, thereby providing an enclosed vacuum chamber
that
is sealed from ambient atmosphere with space 3590 contained therein. Web
unwind
assembly 3576 is arranged to unwind material 3578 from roll of material 3584,
as
required, and locate the web between the upper and lower vacuum chambers. In
this
way suitable portions of the material 3578 can be automatically unwound by web
unwind assembly and clamped between sealing members 3586 and 3588. Referring
now to FIGURE I50, it can be seen that rim at 3588 is extended beyond rim at
3592
such that when web 3578 is clamped between members 3566 and 3570 a space 3594
between the web 3578 and the rim at 3592 is provided. Sealing members 3588 and
3586 are parallel and follow adjacent paths at parallel perimeters of the
respective
members 3570 and 3566 along corresponding rims at 3586 and 3588, such that
when
the vacuum chambers 3570 and 3566 are closed together a completely sealed and
defined space 3590 is provided therein. In this way space 3590 can be
evacuated and
substantially all air contained therein removed, as required, and then space
3590 can
be filled with suitable gas such as nitrogen, C02 or any other suitable blend
of gases,
at a suitable pressure, via conduits 3582 and 3584.
Referring now to FIGURE 149, a three dimensional sketch is shown of the
lower vacuum chamber with a portion of the lower vacuum chamber shown in
FIGURE 150. The vacuum chamber can be manufactured from any suitable material
such as stainless steel. It can be seen that vacuum chamber 3566 includes a
rectangular profiled component with vertical walls and a rectangular
depression 3596
provided therein; two parallel and continuous rims, an inner rim 3592 and an
outer
rim 3598 are provided with a recess 3600 between the parallel rims. A suitably
sized
pouch 3602 can be located into the depression 3596 and the "mouth" 3604 of the
pouch can be cuffed over the rim 3592 such that the mouth of the pouch is
tensioned
around and over the external and upper surface of rim 3592. A vacuum source
can
be provided to recess 3596, via conduit 3584, such that the pouch can be drawn
against the internal walls of the depression 3596, prior to closing the upper
and lower
vacuum chambers together. In this way the mouth portion of the suitable pouch
3602
can be tensioned across the rim 3592 in such a manner so as to ensure that no
creases
are present in the pouch mouth section that is located directly adjacent (and
above)
the rim 3592. Any suitable stretching devices may be provided that will
stretch the
mouth section of the pouch and ensure that no creases are present, thereby
allowing
subsequent and effective sealing of the web 3578 to the pouch when required.
Following loading of goods into the pouch 3602, heat bank member 3572 can be
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activated so as to provide heating and sealing of a section of web 3578 to the
mouth
of the pouch around the full continuous length of rim 3592. An automatic
cutting
device 3606, can be arranged so as to provide suitable cutting and severing of
the
web 3578 after sealing to the pouch. In this way web 3578 can be hermetically
sealed
to the mouth section of the pouch 3602 so as to completely seal and enclose
any
space and goods that may be located in the pouch prior to sealing of web 3578
thereto.
Any suitable method of manufacturing a suitable pouch with adequate gas
barrier properties may be employed to manufacture the pouches. For example the
pouch may include a suitably sized; multi-layer plastics tube, extruded from
an
annular die with specified layers of material that provide all gas barrier and
sealing
properties and features required. Such a tube may be extruded and cut into
suitable
lengths and then heat sealed to close one end of each length of tube, in any
suitable
fashion, to produce pouches and, if required, a valve may be fitted to the
wall of the
pouches. The valve can be arranged to allow excess gas such as carbon dioxide,
that
may be generated in the pouches after sealing with goods, such as carbonized
retail
packaged ground meat, therein.
Referring again to FIGURE 149, a grouping of several identical such
members 3566 may be arr2nged by attaching to the upper surface of a suitable
conveying device such as a horizontally disposed carousel style, circular
table, of
suitable size arranged with suitable driver to intermittently rotate the
carousel. In this
way, pouches could be automatically loaded into each lower vacuum chamber
3566,
consecutively and immediately prior to loading goods into the pouch. After
loading
the goods, the carousel can rotate so as to locate the loaded member 3566
directly
under upper vacuum chamber 3570 and web unwind assembly so as to allow sealing
of a section of web-3578 thereto. In this way, an automatic and semi-
continuous
packaging process can be arranged to automatically open the pouches, load into
member 3566, fill the pouch with goods, evacuate and gas fill the pouch with
goods
therein and then heat seal a web of material 3578 over and to the mouth of the
pouch.
An automatic ejection device can be provided that may include a method of
relaxing
tension in the pouch mouth and lifting the sealed and finished pouch (with
goods
therein) from member 3566 and then locating the finished pouch into a carton
prior
to closing the carton closed aid sealing the finished pouch therein.
Referring to FIGURE 213, yet another preferred embodiment of an
apparatus 8300 for producing a master container with finished packages is
shown.
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Equipment 8300 includes an upper chamber $306 and a lower chamber 8310. A
master container 8316 with finished packages 8308 is contained within lower
chamber 8310. The operation of this apparatus is in many respects similar to
the
previous embodiments. Master container 8316 is loaded with finished
packages 8308, and located in the lower vacuum chamber. A web 8314 is passed
through the chamber to cover the opening in the master container 8316. The
upper 8306 and lower 8310 chambers close, providing a substantially air tight
seal.
Air is evacuated through any number of ports 8304 and 8312. a suitable gas is
flushed into the chambers. The cycle can be repeated any number of times to
expel
IO the air and/or oxygen from the master container 8316 and packages 8308. The
master container is then sealed with web 8314. The vacuum chambers separate,
and
a new master container is evacuated, flushed and sealed.
In yet another preferred embodiment, the packages need not have apertures,
but rather are sealed or wrapped with a web that expands to fill the voids in
the
master container to expel the air. This is possible because the web preferably
has
memory, to contract to its relaxed state. The packages need not be evacuated
because
packages can be wrapped in a low oxygen atmosphere according to the invention,
thus eliminating the need for values.
Method and Apparatus for Packaging=Labeling and Wei ping
Trays containing perishable goods are preferably weighed and labeling prior
to sealing. Therefore, it is appropriate to describe a method and apparatus of
the
invention for such a task.
FIGURE 151 shows a packaging machine constructed according to the
present invention to apply labels) to the second web and also an alternative
printing
device to print directly onto the second web. Reference is also made to patent
application PCTIAU93/00484, which is herein incorporated by reference.
FIGURE 151 shows a side elevation of the packaging apparatus and FIGURE 152
shows a plan view of the upper side of the packaging machine of FIGURE 151.
Packaging machine 1800 is arranged in two sections to provide a space so as to
allow
a sufficiently clear area to install a scale 1802 with load cells 1828.
Packaging
machine 1800 is mounted and attached to the floor (also shown) independently
of
scale 1802 such that they are not in contact with each other. Second web
unwind
roll 1806 is provided with braking devices attached thereto. Drive 1804 is
arranged
to unwind second web from rill 1806 of second web 1812. Printer 1808 is
located
between second web roll 180ti and third web roll. Printer 1808 is attached to
driver
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to move in X, Y and Z axis in horizontal and vertical planes. Printer 1808
includes a
mechanism to print onto labels and then apply labels to second web or
alternatively
print directly onto second web. Third web roll 1810 is located above second
web 1812 and is fitted with braking devices as well to maintain tautness of
the web
as it is unrolled. Packaging apparatus 1800 includes a vacuum chamber
assembly.
The assembly includes a number of components including a lower 1816 and
upper 1824 vacuum chamber, a lower 1820 and upper 1822 plate and a sealing
plate 1818.
FIGURE 154 shows a cross-section through the vacuum assembly
- constructed according to the present invention. Sealing plates 1818 are
arranged in a
conveyor which is driven by a motor as required providing intermittent
movements
of the conveyor 1826. Lower vacuum chamber 1816 is independently moved by
pneumatic driver (not shown) so as to apply pressure to underside of sealing
plate 1818. Plate 1820 is located between sealing plate 1818 and plate 1822.
Plate 1822 has vacuum port 1830 provided therein. Upper vacuum chamber 1824 is
located above plate 1822. All components are in vertical alignment and when
lower
chamber 1816 and upper chamber 1824 are retracted and moved in the vertical
plane
away from each other, plates 1818, 1820 and 1822 which can be spring loaded
also
"expand" away from each other so as to allow free movement of first 1836 and
second 1832 webs between plate 1820 and plate 1822 or between plate 1818 and
plate 1820 as may be selected according to requirements or preferred operation
of
apparatus. As is shown in FIGURE 154, third web 1834 enters the vacuum chamber
assembly between plates 1822 and 1824 and exits the vacuum chamber assembly
between plates 1820 and 1822. Also it can be seen that second web 1832 enters
vacuum chamber assembly between plates 1820 and 1822. A space 1838 is shown
between the second 1832 and third 1834 webs with port 1830 opening into
space 1838. During the operation of the packaging apparatus, after closing of
lower
vacuum chamber 1816 and upper vacuum chamber toward each other thereby
providing a closed and sealed vacuum chamber, a vacuum source can be applied
to
port 1830 and thereby evacuate substantially all air from the space 1838.
Evacuation
of air from space 1838 can cause second 1832 and third 1834 webs to become
laminated together after removing substantially all air from the space 1838.
Slots
shown as 1840 are provided between the faces of plates 1816 and 1818, 1818 and
1820, 1820 and 1822, and 1822 and 1824. These slots provide spaces between
each
of the components also, "O" rings are fitted along the outer edges of each
slot to
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provide a seal when the components are in contact with each adjacent
component. A
vacuum source can be applied to each of these spaces, simultaneously, thereby
providing a method to hold them together with a force equal to that provided
by the
ambient atmospheric air pressure prevailing at the time. The holding force
that urges
the components together is therefore approximately equal to the width of the
slots
between each component, times the length of the slot, multiplied the
difference of the
prevailing atmospheric air pressure minus the air pressure within the slots
defined by
the equation:
F = WL(Pa PS)wherein,
F is the force,
W is the width of the slot,
L is the length of the slot,
Pa is the atmospheric pressure, and
PS is the pressure inside the slot.
The width of each slot can be arranged, by enlarging (or decreasing) so as to
provide a level of force that exceeds the desired and opposing force of gas
pressure
within the closed chamber. A pair of "O" rings are also provided around all
shafts
that penetrate the chamber and spaces provided between each pair of "O" rings
can
also be evacuated.
Refernng again to FIGURE 151, printer 1808 is equipped so as to either
apply a label or print desired information onto second web 1812. Load cells
1828 are
located along a beam 1854 that extends across and under the full width of
sealing
plates 1818. Beam 1854 can be elevated and lowered. Scale 1802 and beam 1854
is
arranged to elevate load cells 1828 upwardly so as to contact underside of
trays in
apertures of sealing plates 1818 and lift the trays from apertures in sealing
plates 1818 in conveyor. Trays are lifted to an extent that prevents any
contact with
anything else apart from the load cells 1828. The weight of each separate tray
can
thereby be determined and this information is transferred to a printer 1808.
Printer 1808 prints information onto labels (prior to application of label
onto second
web) or directly onto the second web 1812. Second 1812 and third web 1856 are
then laminated together before heat sealing to flanges of first web trays.
FIGURE 153 shows one embodiment of a single register detail of second
web. The single register detail includes a frame 1842 of heat activated
adhesive that
can be printed directly onto web. The frame is arranged with dimensions that
correspond to the flange of third web tray such that the frame 1842 covers
flanges
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and located above third web tray. Other details of package contents are also
shown
and boxes 1846 provide areas onto which information can be printed at the time
of
packaging. Barcode 1847 contains product information, such as date of
packaging
and weight, which can later be used to determine price at the point of sale.
FIGURE 155 shows a cross-section view through a laminating assembly
including a first 1848 and second 1850 driven rubber coated roller arranged in
horizontal disposition and with devices (not shown) to be urged toward each
other so
as to press and laminate the second 1832 and third 1834 webs when the webs are
passed between the rollers. Rollers are driven by a variable speed motor (not
shown). Laminating assembly can be located between the third web roll 1810 and
the vacuum chamber assembly and provide a method to laminate second 1832 and
third 1834 webs together before entering the vacuum chamber assembly.
Method and Apparatus for Facka~i~ Trays
Trays with flaps constructed according to the present invention can be sealed
by a first and second web. Webs are sealed to the flap in the non-folded state
in two
or one heat sealing stations. Ilpon bending of the flaps, the webs are
stretched, thus,
providing a taut appearance and protection for the perishable goods inside:
The following description provides apparatus and methods for production of a
package of the type shown in FIGURE 158, with a pre-stretched second web 1004.
The preferred use of this embodiment is for the packaging of shallow products
such
as boneless pork loin chops, butterfly steaks, thick-cut bone in pork chops
and New
York Strip, super trim beef and pork cuts that are generally not displayed in
the
package by shingling but are laid flat and adjacent to each other and spaced
apart so
that a consumer can inspect carefully.
FIGURE 168 shows a sketch of a side elevation of a preferred packaging
machine constructed according to the present invention that can be used to
produce
packages of types described herein in this disclosure. The packaging machine
includes a frame supporting a driven conveyor with two roller chains located
one on
each side the packaging machine and engaged with a first 1044 and second 1128
set
of sprockets, each pair of the sprockets is located at opposite ends of the
frame.
Sealing plates, 1012, as shov~m in FIGURES 159-162 are attached to the roller
chains
via attachment points. First and second stations, generally denoted by 1014
and
1016, respectively, are located on the upper side of the packaging machine
with web
unwind arrangements rolls 1130 and 1132 and scrap web wind-up arrangements
at 1120 and 1138. Continuous conveyor 1010 carnes sealing plates 1012 in the
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direction indicated by arrow 1126. Details of a preferred sealing plate 1012
can be
seen in FIGURES 159-162. Preferably, first and second stations 1014 and
station 1016 are mounted onto the upper side of the packaging machine frame
adjacent to the upper section of the conveyor 1010. A loading section 1018 is
preferably located adjacent to and down stream of station 1014. Conveyor 1010
is
supported within the frame and is attached to a powered indexing device for
moving
the conveyor 1010 and sealing plates 1012, intermittently and in a direction
from
loading section 1018 toward first station 1014. Preferably, each intermittent
movement of conveyor 1010 travels one pitch which is equal to at least the
distance
required to move a sealing plate 1012 the full distance of the length ef the
sealing
plate. Preferably, with each movement of the conveyor, a sealing plate is
located
directly between the lower vacuum chamber 1020 and the lower clamp plate 1022
shown in FIGURE 167. Preferably, a sealing plate is also located directly
beneath
heat bank 1024, as shown in FIGURE 159. Preferably, this arrangement transfers
a
package that has been sealed in first station 1014, to a subsequent location
at second
station 1016. Preferably, the driving devices for the packaging machine,
machine
components and conveyor are a pneumatic cylinder and electrically powered
driving
motors of suitable size and capacity. The pneumatic cylinders are attached to
shafts 1030 (attached to heat bank 1024), 1032 and 1028 (attached to water-
coded
clamp 1036) and, 1034 and 1026 (attached to cutting device 1038), and provide
independent reciprocating movements to each shaft and attachments generally in
the
directions shown in the diagrams by arrows drawn adjacent to each attachment.
Similarly, pneumatic cylinders (not shown) are attached to upper 1056 and
lower 1020 chambers to provide reciprocating movements parallel with shafts
1030,
1028, 1032, 1026, and 1034 to provide movement and apply pressure as required.
Preferably, an electrically powered drive motor 1042 is attached to conveyor
sprocket 1044 so as to intermittently drive the conveyor 1010 as required such
that
the upper section 1046 of the conveyor travels in a direction from right to
left.
First Heat Sealing and Vacuum Chamber
FIGURE 167 shows a cross-sectional view through a first station vacuum
chamber assembly 1014 constructed according to the present invention which
details
the first 1002, second 1004 and third 1006 webs prior to sealing the webs
together.
This vacuum chamber has a plate, separating the second and third webs, unlike
the
chamber of FIGURE 154. Meat is loaded into tray (first web 1002) and then each
loaded tray is placed into ape:-tures in sealing plate 1050. The conveyor
indexes
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forward such that a loaded tray is located at first station 1014. During
indexing, third
web 1006 and second web 1004 are also indexed forward and a longitudinally
disposed tension can be applied to third and second webs and in a direction
parallel
with the conveyor. Preferably, lateral stretching can also be applied to
second
web 1004 such that it is stretched taut. Upper clamp member 1052 and lower
clamp
member 1022 then close against the middle clamping plate 1054 thereby clamping
and firmly holding third and second webs 1006 and 1004, respectively.
Preferably,
lower vacuum chamber 1020 and upper vacuum chamber 1056 are closed against the
clamping plate assembly such that a substantially "airtight" seal is provided
and the
upward movement of lower vacuum chamber 1020 lifts sealing plate 1050 and
holds
it firmly against the underside of the lower clamp 1022 thereby providing
substantially "airtight" seals around the perimeter of the upper and lower
vacuum
chambers 1056 and 1020. Closing the upper and lower chambers thereby defines a
single enclosed chamber that is substantially isolated from atmospheric
gasses.
During the procedure of closing the upper and lower chambers, the lower vacuum
chamber 1020 lifts the sealing plate 1050 upwardly and tray (first web 1002)
is
carried upward. The upper rim portion of sealing plate 1050 and 1058 contacts
the
underside of second web 1004 stretching second web upwardly until sealing
plate 1050 contacts the underside of lower clamp 1022 at surface thereby
stopping
the upward movement in a closed and substantially "airtight" condition.
Preferably,
the second web 1004 is now stretched taut across the opening of the ring 1058
and
distanced preferably about 1/64" to about 1/2, and most preferably about 1/8"
above
flange 1072 (FIGURE 158) and preferably about 1/64" to about 1/2, and most
preferably about 1/8" below third web 1006.
Preferably, atmospheric air contained within the enclosed chamber is then
substantially evacuated through evacuation ports 1008, to a pressure of less
than 5
ton. Preferably, immediately after evacuation, the chamber can be filled with
carbon
dioxide gas, or a blend of carbon dioxide and nitrogen gasses, to a pressure
of up to 2
bar (28 psi) or more, by injection through ports 1064 and optionally 1008, and
held at
pressure for a period of 1 to 5 seconds or more and most preferably until
water and
goods in the tray have become substantially saturated with dissolved carbon
dioxide.
The gas pressure within the chamber assembly can then be lowered to a pressure
equal to that of the prevailing ambient atmospheric pressure prior to sealing.
Evacuation and gassing of the chamber assembly in accordance with the
invention,
provides a method of filling packages with a chosen gas such that the residual
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atmospheric oxygen that remains within the package does not exceed an amount
about 0.05% by volume of the gas that remains within the package after sealing
the
first 1002, second 1004, and t?~ird 1006 webs together.
Referring now to FIGURE 167, a clamping member 1036, that is preferably
water cooled, can now be moved and positioned so as to clamp third web 1006
against second web 1004 and in turn against the inner edge portion of flange
1072 on
first web tray 1002. Preferably, heat bank 1024 can then clamp and heat seal
second
and third webs 1004 and 1006 to flange of first web 1002, under pressure.
Preferably, heat bank 1024 can now be retracted followed by cutting of second
and
third webs with cutting member 1040 attached to cutting device 1038. The
cutting
member is withdrawn from the cutting position followed by release of clamp
1036.
Preferably, enclosed vacuum chamber assembly can then be opened allowing
conveyor to move forward a single pitch followed by closing the enclosed
chamber
assembly, followed by evacuation, gassing and heat sealing. Preferably, this
cycle
can be repeated in an automatic and continuous mode. Vacuum chamber assembly
constructed according to the present invention and frame to which it is
attached is
built in a manner that will allow continued cycling of the packaging process
and
pressurization without sustaining excessive damage other than normal wear and
tear.
An optional method of using the apparatus whereby a gas is not provided in
the space between third web 1006, the upper barner web, and second web 1004
(so
as to subsequently facilitate urging of the second 1004 and third 1006 webs
together),
before sealing the third web 1006, second web 1004 and first web 1002 (shown
as
tray) together at a path near what will be a perimeter of the package. The
tray 1002
is elevated so as to urge second web 1004 toward the underside of third web
1006
thereby providing stretching means to second web 1004 to sealing webs together
to
form a package. Apparatus for evacuation of substantially all air from the
space
between the third 1004 and the second 1004 webs, through ports 1008 is
optionally
provided.
Preferably, packages are then transferred from the vacuum chamber at first
station 1014 via the conveyor to the secondary sealing apparatus located at
second
station 1016.
Second Heat Sealin~LChamber
Referring now to FIGURE 156, a cross-sectional view of second station 1016,
constructed according to the pr~;sent invention is shown in a partially closed
position.
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Refernng to FIGURES 157-I58 a cross-sectional view through a finished and
sealed package constructed by second station 1016 is shown. Package 1092
includes
a flange with second web 1004 and third web 1006 attached thereto. Shown is
first
web, tray 1002, formed with two flange portions 1072 and 1074. Preferably,
flange
portions 1072 and 1074 are adjacent and concentric to each other, with flange
1074
located on the inner side of flange 1072.
Referring now to FIGURE I56, an assembled package is positioned in the
sealing plate which is located beneath heat bank 1070. It can be seen that lip
1080
has a profile that corresponds and follows the path and plan profile of flange
portion 1074. A section of flange 1074 can be clearly seen in the enlarged
cross-
section in FIGURE 157. Preferably, flange portion 1074 is parallel and
concentric to
flange portion 1072 but follows a path on the inner side of flange portion
1072 and at
a plane shown to be at a distance 1076, about 1/8", below flange portion 1072.
Preferably, heat bank 1070 is pneumatically operated and can extend downwardly
and be retracted upwardly as required to exert a force such as to provide
pressure
onto the lip 1080 and when engaged with flange portion 1074, simultaneously
depressing third and second webs that' are then held, under pressure (sealing
pressure), between the surface of flange portion 1074 and lip 1080 for a set
period of
time (set time). Preferably, the temperature of heat bank 1070, and
correspondingly
lip 1080, can be controlled and is set at a suitable temperature (set
temperature).
Preferably, the temperature of heat bank 1070 is less than temperature of heat
bank 1024 located in first station 1014. Preferably, pressure is applied at
lip 1080
and can be set at sealing pressure. The suitable time of contact and clamping
of third
and second webs to flange portion 1074 can be varied. Time of contact is
defined as
the length of time during each cycle from the first instant of first
contacting between
lip 1080 and flange portion 1074 through the third and second webs, to the
first
instant of no contacting after retraction of heat bank 1070. Thereby, when the
set
temperature, sealing pressure and set time of heat bank 1070 are adjusted as
required,
the selective heat sealing of second web to flange portion 1074 can be
achieved while
third web does not heat seal to second web. This can preferably be achieved
when
first, second and third webs include materials as shown in FIGURES 43 and 44.
Referring now to FIGURE 43 a representation of an enlarged view of a
section through a flange portion of an assembled package is shown. FIGURE 43
shows heat sealing bars and a section of a rubber seal mounted on sealing
plates
around the perimeter of the apertures in the sealing plates. Details of
materials that
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can be used in the first, second and third webs are also shown and described
in detail
below: Preferably, third web 1006 is a co-extruded web including at least two
layers
with a first layer 1082 of Eastman PET 9921 and a second layer 1084 of
material on
the underside of the third web including a blend of 2 grades of Eastman
polyesters in
amounts of about 50% Eastobond 6763 and about 50% Eastobond 9921 or
alternatively the layer on thA underside may be about 100% Eastman PM 15086.
Preferably, third web can be about 0.006" thick, about equally divided between
first
and second layer. Preferably, second web 1004 is a web of pPVC with a
thickness of
about 0.0008". Preferably, first web 1002 includes a thermoformed tray
produced
from a multilayer co-extruded web with an outer layer 1088 of Eastman 9921 and
an
inner layer 1086 including a blend of about 50% Eastman PETG 6763 and
about 50% Eastman 5116 (or Eastman PM14458 or equivalent). Preferably, first
web has a thickness of about 0.012" where the inner layer 1086 is about 0.004"
thick
and the outer layer 1088 is about 0.008" thick. Preferably, under such
conditions the
heat transferred through third web is insufficient to cause bonding between
the third
and second webs but sufficient to cause bonding between the second and first
webs at
flange portion 1074. Preferably, such arrangement provides stretching of
second
web, after sealing of third and second webs to first web at first station
1014.
Preferably, applying gas pressure to the upper surface of the third web, when
located
at second station 1016, so as to cause the second and third webs to depress
downwardly and substantially conform to the contours of flange portion 1074
prior to
providing heat seal 1090 provides an alternative step in the method.
Preferably, second web 1004, will have a feature known as a "memory". The
term "memory", in this context, is known in the packaging industry and is
characterized as a material that will substantially return to its original
shape after
distortion has occurred due to, for example, a consumer "feeling" the goods
contained within the package while the package remains intact, with second web
sealed to the tray flanges. This can cause finger marks and depressions in the
second
web as prospective purchasers of the package examine it prior to purchase
during
retail display of the package. After excessive handling by consumers the
package
can become unattractive to an intending purchaser and financial losses can
result
therefrom. Materials such as polyethylene substantially do not have "memory".
However, plasticized PVC (pPVC) web materials, such as are made by Borden do
provide this important feature. Second web constructed from pPVC may be
perforated by perforating apparatus to improve gas transmission therethrough.
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Preferably, perforations can be provided in second web 1004. The
perforations can allow gas to permeate into a space between second web and
third
web. Preferably, when the gas pressure inside the sealed package is at a
pressure
slightly above ambient air pressure, third web will be stretched outwardly
into a
dome shaped condition thereby providing a gas buffer between third web and the
surface of goods beneath the second web. Second web may be in contact with the
surface of package goods, alternatively a space can be provided therebetween.
Preferably, the seal between second web and first web may be arranged such
that it is
not a continuous seal along the full path of flange portion 1074 and may be
arranged
- 4s an intermittent sealing, completely along one or more sides only or parts
thereof.
In yet another embodiment heat bank 1070 may be mounted at first
station 1014, concentrically with and on the inside of heat bank 1024 within
the same
chamber but with separate moving shafts. Such an embodiment would allow
sealing
at flange portion 1072 and flange portion 1074 without the need to transfer
the
package from first station 1014 to second station 1016 for sealing of flange
portion 1074. Preferably, web cutting devices are located at second station
1016 to
separate the sealed and finished package 1092 from webs.
After passing through stations 1014 and 1016 on packaging machine, the
finished packages are ejected from the machine.
In yet a further embodiment, the tray evacuation arrangement can be set up to
transfer trays containing goods to a vacuum chamber, evacuate any ambient
atmosphere from the trays and then transfer the trays into an enclosure
excluding air.
However, the trays have not been sealed with a lid at the vacuum chamber.
Sealin Pg fates
Sealing plates constructed according to the present invention are members
attached to conveyors to carry trays in the packaging system.
FIGURES 163-166 show the use of sealing plates with trays of the present
invention. Package 1224 contains goods 1214 shown in FIGURE 163. In
FIGURE 163, the first web 1200, second web 1202, and the third web 1204 are
shown sealed together to form a complete package 1224. FIGURE 164 shows a
cross-section through the tray (the first web). Dotted lines are shown in
FIGURES 164-166. The dotted lines in FIGURES 164-166 show the position of the
side walls before insertion of the tray into the aperture 1206 in the sealing
plate
member I20$. Dotted lines in FIGURE 166 show the relative position of the edge
of
the flange prior to the tray insertion into the aperture. The aperture is
sized to suit
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and is slightly smaller than the tray. The aperture is located in member 1208
which
includes a plate means with the aperture therein with the aperture having
dimensions
slightly smaller than the external dimensions of the side walls of the third
web tray
such that when the tray is inserted into the aperture, the side walls are
distorted and
urged inwardly. The solid lines show the side walls after the inward
distortion and
the dotted lines show the relative position of the tray prior to insertion
into the
aperture. FIGURE 164 shows a plan view of a section of a conveyor such as may
be
installed in a packaging machine. Sealing plate 1208 may have a plurality of
apertures, all of a suitable size and arranged to hold a plurality of the
trays in like
distorted condition as herein described.
Refernng to FIGURES 159-162, a cross-section of a preferred sealing
plate 1050 constructed according to the present invention is shown with a plan
view
shown in FIGURE 160. Sealing plate includes attachment points 1094.
Preferably,
attachment points 1094 attach the sealing plates to a pair of continuous
roller chains
that engage with sprockets 1044 and 1128 and are located, one at each relative
side of
conveyor. Preferably, sealing plate 1050 has a depth dimension that is about
equal to
or deeper than the depth of depressions in first web. Preferably, a rubber
seal 1100 is
attached to the sealing plate 1050 by an adhesive and is profiled to provide
flanges 1096 and 1098 that correspond to flange portion 1072 and flange
portion 1074 of first web tray. Preferably, a space between the rubber seal
1100 and
rim 1078 is provided to allow clearance for cutting member 1040 during the
cutting
of the third and second webs after sealing to flange portions 1072 and 1074.
Refernng now to FIGURE 162, a cross-sectional view of the details of
sealing plate 1050 are provided. As an example, a preferred embodiment with
three
apertures 1150 and rubber seals 1100 located around the perimeter of each
aperture is
shown. However, sealing plates may have more or less apertures and
corresponding
rubber seals. Preferably, rubber seals are made optional. Preferably, sealing
plates
are machined from aluminum or other metals or any suitable plastic plate, for
example, about 0.75" thick polypropylene with upper 1152 and lower 1154 faces.
Referring again to FIGURE 164, wherein the arrangement of first web 1200
(tray) with a flange 1210 extending continuously around the perimeter of tray
1200 to
provide a flat ledge to which second web 1202 is sealed. Preferably, tray 1200
has
been distorted such that side walls are urged inwardly and held in position by
the
limiting size of aperture 1206 located in sealing plate 1208 of FIGURE 165.
Preferably, second web 1202 is a gas permeable material such as pPVC of about
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0.0008 inches thickness and first web 1200 is constructed of a substantially
gas
impermeable material such as a co-extruded multilayer sheet of Eastobond
APET 9921 and a blend of about 16% Eastobond PETG 6763 and about 84%
Eastobond 9921. A third web 1204 is sealed to second web 1202 adjacent to
seal 1212 of the second web to the first web.
Alternatively, the tray 1200 can be formed from a web of polystyrene foam
that has been previously laminated to a web of gas barrier material. A second
web of
material can be sealed to the web of gas impermeable material laminated to the
upper
side (inside) of foam tray. Trays according to the present invention are
substantially
impermeable to gases.
Referring to FIGURE 163, webs are shown sealed together by a strip-like
seal 1212 on flange 1210 that follows a path that continues around the flange
near the
perimeter of the package thereby providing a substantially hermetically seated
package. Preferably, goods 1214 are contained within the sealed package and a
suitable gas blend such as may include about 40% carbon dioxide and about 60%
nitrogen is provided within the package. Preferably, sealing of the package is
effected while side walls c~f the tray are urged inwardly. Preferably, side
walls
thereby retain a tension and desire to return to their original relative
position thereby
exerting a substantially outwardly disposed urging around the perimeter of the
depression in the tray but which is retained and held captive by the combined
tensile
strength of third and second webs sealed to the flange. Preferably, third web
is
sealed to the package in such a manner as to allow peeling from the package,
without
rupturing second web and thereby leaving second web attached to the flange.
Preferably, when third web is peeled from the package the tensile strength of
the
second web is insufficient to restrain outwardly urging of the side walls,
thereby
releasing urging and providing a means to stretch the second web into a
substantially
flat condition. The extent of the urging can be controlled such that it will
maintain a
tension in second web.
FIGURE 163 shows a finished package that has been produced by the method
herein described and, after heat sealing of first 1200 and second 1202 webs
together,
has been removed from aperture 1206 in sealing plate 1208.
Method and Apparatus for Producing Laminated Webs
Having discussed the advantage obtained by packaging trays having second
and third webs, another embodiment of producing bilayer coverings is herein
described. Referring to FIGURE 169, an apparatus for producing a pre-stretched
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second web of flexible gas permeable material laminated to a substantially
more rigid
gas barrier material is schematically illustrated.
First 1400 and second 1402 roll of web material including a second web 1404
and a third web 1406 are preferably unwound simultaneously and laminated by
passing the webs through a pair of "nip" rollers 1408 that apply pressure
against each
other and to the webs as they pass through nip rollers 1408. Preferably, nip
rollers 1408 are driven by any suitably powered driver to rotate at a suitable
speed.
Preferably, the laminated web 1412 is rewound onto a single roll 1410 together
to
produce a laminated web 1412. Third web 1406 may include a semi rigid
polyester
material, of about 0.005" to about .007" thick. The construction of this
material is
such that it can be used in a packaging machine to produce packages as
described
herein whereby laminated webs are sealed to a first web of gas barrier
material (tray).
First web may have a depression formed therein into which goods such as red
meat
can be placed before heat sealing the third and second webs to the first web.
Goods
will typically not completely fill the depression and space will remain in the
depression in addition to the goods. A blend of gases or a single gas such as
C02 can
be provided in the space with goods and. thereby can contact the goods. The
gas
substantially eliminates the presence of oxygen and any red color present in
the red
meat may be transformed to a purple color. This is caused in part by the
reduction of
oxymyoglobin to deoxymyoglobin. After storage of perhaps a period of 14 - 28
days
from packaging but prior to retail display at an intended point of sale to
consumers,
the third web can be peeled from the package allowing atmospheric oxygen to
permeate the second web of gas permeable material and to contact the goods.
Atmospheric oxygen can then generate a bright red colored substance such as
oxymyoglobin. Such use involves the sealing of the laminated webs to the first
web
of gas barner material such as a two-layer co-extrusion where the outer layer
includes Eastman APET 9921 of about 0.0035" thickness, and the inner layer may
is
a blend of Eastman polyester materials including about 16% of 6763 and about
84%
of 9921. The thickness of blended layer 1412 can be about 0.0015". Second
web 1404 includes a roll of monolayer pPVC with a thickness of about 0.0008"
to
about 0.0012". Preferably, as second web 1404 is unwound it can be passed
through
a perforator 1414 that perforates the second web by creating small apertures
therethrough. Preferably, second web 1404 can be tensioned in a controlled
manner
by retarding the rate of unwinding of second web 1404 from roll 1400 relative
to the
unwinding rate of third web 1406 from roll 1402. Tension is thereby applied to
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second web 1404 of material prior to passing through the nip rollers 1408 at
which
point substantially all of the air between the two layers of material is
forced out by
the nip rollers 1408. The consistency and texture of elasticized PVC material
including second web 1404 is such that it adheres lightly to third web 1406
unwound
from roll 1402 forming a very light seal that excludes all air from between
the webs.
Second web 1404 is applied to the inner, blended layer of third web 1406,
preferably
a substantially more rigid material unwound from roll 1402. Preferably, an
anti-
blocking agent, such as very fine sand, can be added to the third web upper
(outer)
layer of the co-extrusion so as to preferentially inhibit sticking of second
web to what
will be upper layer such that second web will remain in close contact with
what will
be the underside of third web during storage in a roll 1410 condition and
during un-
winding from roll 1410 in normal operation on a packaging machine.
Second 1404 and third 1406 webs, having been laminated to produce a
lamination and subsequently wound onto the finished roll 1410 can be stored
and
when required for use in packaging can be loaded onto packaging machine as
shown
in FIGURE 170.
Referring now to FIGURE 170, a process to laminate two webs of material
together is shown. The two webs include the third and second webs. The
apparatus
is suited to produce any packages herein described. First web 1416, preferably
of a
substantially gas barrier material is located into an aperture (not shown) in
sealing
plate 1418 mounted on the conveyor 1420. Preferably, sealing plate 1418 being
similar to sealing plate member 1208 shown in FIGURE 159. Preferably, first
web
has a cup-shaped depression formed therein and similar to that shown
in FIGURE 171. Red meat or other perishable goods is loaded into first web
tray 1416 and a plurality of trays are located into the apertures in each
sealing
plate 1418 mounted- to conveyor 1420. The conveyor indexes forward such that a
loaded tray is located between upper vacuum chamber 1422 and lower vacuum
chamber 1424. During indexing of the conveyor the third web tray is also
indexed in
a direction parallel with the conveyor and placed into position between upper
and
lower vacuum chambers. Upper 1422 and lower 1424 vacuum chambers are closed
together such that sealing platy is clamped therebetween to provide a
substantially
sealed and enclosed chamber assembly. Air is evacuated from the chamber
assembly
to a pressure level of approximately 5 torn and a selected gas is injected
into the
chamber assembly. The gas being chosen for its properties of enhancing the
keeping
qualities of goods, in first web tray 1416, such as carbon dioxide or a blend
of carbon
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dioxide and nitrogen is suitable. First, second and third webs are then sealed
together
to produce a package. Upper 1422 and lower 1424 vacuum chambers are then
opened so that conveyor 1420 can carry sealed package to an ejection point.
The
package may be trimmed by a cutting devices located within the chamber
assembly
such that a skeletal scrap web can then be wound onto a single wind-up spool,
or
alternatively, could be separated by de-laminating the third web scrap from
second
web scrap onto scrap wind-up 1426 and 1428 as shown in FIGURE 170. The
package may be trimmed within vacuum chamber in one machine cycle or
alternatively the package may be trimmed from the web in a secondary operation
immediately after the vacuum chamber.
Preferably tray construction may be thermoformed from co-extruded
polyester plastic materials as shown in FIGURE 171. Co-extruded material may
include two layers of a total thickness of about 0.015". The outer layer 1430
is about
0.0135" thick and the inner layer 1432 is about 0.0015" thick. The outer layer
1430
includes Eastman APET 9921 and the inner layer 1432 is about a 50% / 50% blend
of Eastman 13162 and Eastman 6763.
Method and Apparatus for Packa~inQ Perishable Goods
Having described laminated webs, it is now appropriate to describe a method
to package perishable goods using a laminated web. Although the description
preferably applies to laminated webs, one or more non-laminated webs can also
be
used with the method with apparent modification.
FIGURE 172 shows a schematic representation of a side elevation of a
preferred packaging apparatLS including a conveyor with a plurality of sealing
plates
generally denoted 1436 attached thereto. Preferably, a drive motor 1438 is
connected
to conveyor sprockets 1440a, and b and arranged so as to provide intermittent
driving
of the conveyor as required. 'frays with goods therein are loaded into
apertures in
sealing plates at the loading section and the conveyor is driven forward in
the
conveyor direction shown in intermittent increments of one pitch which is
equal to
the distance of a single sealing plate. The conveyor is otherwise stationary
except
during each movement of one pitch. A scale 1442 can be positioned under the
upper
section of the conveyor and is attached to a driver such that when the
conveyor is
stationery the scale can be elevated and lift the tray from sealing plate
1436, and
weigh the tray and goods. Preferably, scale can be interfaced with a label
printing
device. Preferably label will include information such as price, weight and
time of
packaging and then label printing device will apply the label to the upper
surface of
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the second (or third web) in a label position. Label position can be
predetermined
such that when first, second and third webs are sealed together the self
adhesive label
is in a desired location which can be easily seen by any prospective purchaser
of the
finished package after removal of the third web. Alternatively, if the label
is located
on the third web and if the third web is not removed before retail display
then the
label can be viewed. A roll of material 1444 is mounted above the conveyor
adjacent
to a first station 1446 to facilitate unwinding of the material 1443. The
material may
include a single web of material or alternatively the material may include a
roll of
two laminated webs such as described above. Packages produced with material
according to the present invention would he similar to packages shown in
FIGURE 173, whereas packages produced with web conventional material would be
similar to the conventional package in FIGURE 174. First station 1446 includes
an
upper vacuum chamber 1448 and lower vacuum chamber 1450 and both are mounted
to the packaging machine and pneumatic drivers. Pneumatic drivers are arranged
to
move the upper 1448 and lower 1450 vacuum chamber in a reciprocating upward
and
downward motion.
Preferably, vacuum chambers operate such that they move simultaneously but
in opposing directions such that when they are moved toward each other a
sealing
plate 1436 is clamped therebetween to provide a completely enclosed chamber
that is
isolated from ambient atmosphere. Preferably, each vacuum chamber has ports
1452
and is attached to a vacuuri pump (not shown) and sources of gases via ports
1452.
Preferably, the gas sources can be several in number but typically can
include: 100%
carbon dioxide and a blend of carbon dioxide and nitrogen in any
concentration.
Sources of gas can be switched from one to the other such that a selected gas
can be
injected into the chamber as required and at will. For example after
evacuation of the
vacuum chambers, a gas, such as 100% carbon dioxide, can be provided in the
vacuum chamber at a gas pressure above ambient atmospheric pressure, for
example
about 25 psi. Gas pressure may then be reduced to any pressure between about 0
and
about 25 psi before then providing a gas, such as 100% nitrogen, in the vacuum
chambers. A heat bank sealer 1454 is located within the upper vacuum
chamber 1448. Sealing device is also attached to a pneumatic cylinder that
provides
motion in an upward and downward fashion. Sealing device is profiled to
provide a
flat strip like surface, horizontally disposed, that corresponds to the flange
of the tray
and can apply pressure downwardly onto the flange. Preferably, second station
1468
includes lower clamp 1458 and upper clamp 1460. Preferably, clamps 1485 and
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1460 are attached to pneumatic cylinder and can be operated such that when
moved
toward each other a single sealing plate 1436 is clamped therebetween.
Preferably, a
sealing device is located within the upper clamp 1460 with pneumatic cylinders
attached thereto and a cutting device 1462 is located on the outer perimeter
of heat
bank 1464 and on the inside of 1460. Preferably, members 1462, 1460, 1464, and
1458 can be moved independently and in vertical directions. A winding
arrangement 1466 is mounted above the conveyor and is powered by an electric
driver to wind skeletal scrap. The preferred sequence of operation of the
packaging
machine is as follows. Sealing plate 1436, attached to the conveyor with a
loaded
tray contained therein is indexed into position in first station 1446. Lid
material 1443
is unwound from 1444 and located above tray 1436. Chambers 1450 and 1448 are
clamped together with 1436 clamped therebetween. Air is substantially
evacuated
from the vacuum chambers which are then filled with carbon dioxide gas or a
blend
of carbon dioxide and nitrogen. The gases are pressurized to a pressure above
atmospheric pressure to about 25 psi and held for a period exceeding about one
second. Pressure of the gas in the chambers is reduced to about atmospheric
pressure
and sealer 1454 is lowered so as to clamp the lid material against the flange
portion
of the tray. The lid material is then sealed thereto along the complete path
of tray
flange. Vacuum chambers 1448 and 1450 open and the conveyor indexes forward
until sealing plate 1436 is located at second station 1468, between upper
clamp 1464
and lower clamp 1458. Clamps 1464 and 1458 close together thereby clamping
sealing plate 1436 between the clamps. Sealing device 1464 is lowered to seal
the lid
material to tray at flange and cutting device 1462 is also lowered and
retracted
thereby severing the tray and package from web while the tray still located in
the
sealing plate 1436. Skeletal scrap is wound onto scrap winding spool 1466.
Conveyor indexes forward and packages are ejected therefrom.
Cross-sections through the package shown in FIGURE 173 and a
conventional pack of FIGURE 174 are shown alongside for comparison. The
conventional package shows the absence of second web. The tray constructed
according to the present invention include a second and third web sealed to a
tray
flange around the upper periphery of the tray. A tray constructed according to
the
present invention provides a peelable lib to introduce oxygen at a
predetermined
time, thus extending the shelf life of the perishable good stored therein.
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Method and Apparatus for Packaging Finished Packages
Now that trays, webs, and methods have been described, it is appropriate to
consider master packs and their methods for making.
Referring now to FIGURE 175, details of a packaging apparatus constructed
according to the present invention for producing substantially gas barrier
master
containers and heat sealing; a substantially gas barner lid material to the
master
containers to produce hermetically sealed containers is shown. The following
description discloses a method and apparatus for producing the hermetically
sealed
containers for providing a vzcuum andlor selected gases in the containers at
selected
and variable pressures, so as to accelerate the dissolving of selected gasses
into
perishable goods such as red meat that may be contained therein and then
exchanging
the selected free gases with other suitable gases for the purpose of enhancing
the
keeping qualities of the perishable goods. Furthermore, the method provides
methods of removing residual oxygen gas that may be retained within the cell
structure of packaging materials such as EPS, that may be contained in the
hermetically sealed master.
FIGURE 176 shows a cross-section through an apparatus intended to produce
master packs thermoformed from a continuous web of plastics material. The
dimensions of the master containers are arranged so that they can be filled
with
preferably an exact number of finished packages containing perishable goods
such as
any of the finished packages herein described. The apparatus preferably
includes a
horizontal thermofornung, reel fed packing machine, sinular to Model 8530
packing
machine manufactured by Multivac Sepp Haggenmuller GmbH & Co. of Germany.
Preferably, the apparatus includes a frame (not shown) that is arranged with
two horizontally disposed and parallel continuous gripper chains generally
denoted
as 4400 in FIGURES 176, 177 and 178 that run almost the full length of the
frame
and are retained in tracks that are located on each side of the frame. tripper
chains 4400 are arranged to grip the two opposing edges of the lower web 4402
and
apply suitable lateral and longitudinal tension thereto. The machine direction
is
shown by arrow 4470 and the chain is preferably powered by an electrical motor
(not
shown) that is controlled electronically to carry the lower web 4402 in the
machine
direction in intermittent movements. The distance traveled by the gripper
chains,
carrying the lower web, is controlled so as to carry the formed master packs
4402
forward and simultaneously locate a suitable area of the lower web material
4402
between the upper and lower sections of the thermoforming section. Each
~~01 v' AMENDED SHEET

CA 02387349 2002-04-03
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intermittent movement, during each machine cycle, of the gripper chains is
equal in
distance traveled and the apparatus can be arranged to automatically operate
at a
machine speed of a set number of cycles per minute which may be, preferably
about 4 cycles per minute.
During a single machine cycle the following functions preferably occur.
After the gripper chains cycle forward carrying a section of lower web
material 4402
into position between the upper and lower sections of the thermoforming
section 4406 the upper and lower sections close together and thermoform master
packs including , in the present case, three containers. A hole punch 4466 is
arranged to provide apertures 4452 in the lower web located between the
containers
as shown in FIGURE 176 and in an enlarged cross-sectional view in FIGURE 178.
Finished packages are then loaded into the master packs (containers) in the
loading
section 4446 and with each machine cycle the lower web travels forward an
equal
distance. The gripper chain carries the lower web 4402 in the machine
direction a
distance of a single pitch for each machine cycle until the loaded master
packs are
located between upper chambers, generally denoted by 4410 and lower chambers,
generally denoted by 4412. Preferably, a total of five upper chambers and five
corresponding lower chambers are arranged such that the upper chambers 4414,
4416, 4418, 4420 and 4422 can be elevated and lowered as required. Lower
chambers 4424, 4426, 4428, 4430 and 4432, are located directly below the upper
chambers and arranged with powered drivers (not shown) to elevate and lower
the
lower chambers as required. A cross-section is shown in FIGURE 176 and is
typical
for upper chambers 4414, 4416, 4418, and 4420 with corresponding lower
chambers 4424, 4426, 4428, and 4430. Upper chamber assembly 4410 and the lower
chamber assembly 4412 operate simultaneously so as to close toward each other
and
open away from each other, as required. During a single machine cycle upper
chambers and lower chambers close and open once. After upper chambers and
lower
chambers open, gripper chains 4400 carrying the lower web 4402 move and carry
the
master packs forward for one single pitch. A ro114434 of upper web material is
located as shown and upper web material 4444 is unwound, as required, during
each
machine cycle, providing a length of upper web material equal to the distance
of the
lower web forward movement. A side web sealer 4436 is located one on either
side
of the machine in a position that allows sealing of the upper web to the lower
web,
forming a single and continuous heat seal between the upper web and the lower
web,
along the outer edges of t'ae upper web, along path 4438 and 4440 shown in
lfQ2. AMENDED SHEET

CA 02387349 2002-04-03
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FIGURE 176. A gassing member 4442 is located between the upper web and the
lower web such that the upper web and the lower web can be heat sealed
together at
paths 4438 and 4440, thereby encapsulating the gassing member 4442 with the
upper
web 4444 and the lower web 4402, in close and touching proximity to the
gassing
member 4442. The gassing member 4442 is attached and fixed to the machine at
the
entry end to the upper and lower chambers assembly and otherwise floats along
its
entire length. Gas ports 4446 and vacuum recesses 4448 are machined in the
gassing
member, such that the gas ports 4446 provide direct communication from a
suitable
gas source separately to each lower chamber location 4424, 4426, 4428, and
4430,
thereby introducing into the. master. containers chosen gases separately and
during
each cycle of the machine. Vacuum recesses 4448 provide communication between
the master containers and a vacuum source via apertures 4452 in lower web and
vacuum ports 4450.
Preferably, during each machine cycle, upper chamber assembly 4410 and
lower chamber assembly 4412 close toward each other with a clamping force, and
clamping the upper web and lower web with gassing member therebetween, such
that
master packs in lower web are enclosed in the cavities in the lower chamber.
As can
be seen in FIGURE 178, the upper chamber 4414 is clamped against the upper
web 4444 and the lower chamber 4424 is clamped against the lower web 4402 with
the gassing member 4442 between the upper web 4444 and the lower web 4402,
which are sealed along path 4440. Seals 4468 are provided as required and as
can be
seen in this closed position, ahe upper chamber 4414 and the lower chamber
4424
provide a substantially airtight assembly. Preferably, after closing of the
upper and
lower chambers together, a vacuum source is connected to vacuum ports 4450,
which
substantially evacuates all air from within the master packs. Preferably after
evacuation of the master packs, a suitable gas which may be selected from
those
gases listed herein, is provided through gas port 4446 and into the master
packs 4404.
The suitable gas is provided at a pressure that exceeds ambient atmospheric
pressure
and may be provided at a pressure preferably between about 0 psi and about 200
psi
or more. The gas can be retained at the desired pressure for a set period of
time
preferably equal to about one or more seconds. Preferably, after the set
period,
suitable gas pressure is reduced to slightly above ambient atmospheric
pressure so as
to maintain a positive pressure within the master containers but not at such a
high
pressure that may cause rupturing of the seal between the upper and lower webs
at
seal paths 4438 and 4440, after opening of the upper and lower chambers.
AMENDED SHEET
x

CA 02387349 2002-04-03
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The upper and lower chambers assembly is then opened and the master packs
move forward one pitch so as to be located directly between upper chamber 4416
and
lower chamber 4426. The upper and lower chambers assembly is then closed and
the
evacuation and gassing sequence as described for upper chamber 4414 and lower
chamber 4424 is repeated, however, the gas provided through the gas port into
the
closed upper and lower chambers may be a different gas. This sequence of
evacuation and pressurized gassing is repeated during each machine cycle in
upper
chambers 4418 and 4420 with corresponding lower chambers 4428 and 4430.
FIGURE 177 shows a cross-sectional view through upper chamber 4422 and
lower chamber 4432 with heat bank. Upper chamber 4422 and lower chamber 4432
close against each other and heat bank 4458 heat seals the upper web 4444 to
the
lower web 4402, at a path that follows the perimeter fully around each master
container, so as to hermeticall~r heat seal the upper web 44.44 to the lower
web 4402
with suitable gas contained therein. Upper chamber 4422 and lower chamber 4432
open to allow the hermetically sealed master packs 4456 to be earned forward
toward
the exit end of the machine. The master packs 4456 are slit longitudinally
with a
slitter 4462 and cut laterally with a knife 4464 as shown in FIGURE 175, prior
to the
ejection of finished master packs from the machine.
In this way residual oxygen that is retained in the cell structure of the EPS
foam trays, contained in the mater packs, can be exchanged with other suitable
gasses. Preferably, gasses such as carbon dioxide can be provided under
pressure so
as to dissolve in any free liquids such as water and oils contained in the
perishable
goods such as red meat.
Modified and Controlled Atmosphere Packaging
Before disclosure of the preferred methods for conditioning meats prior to
packaging, the inventor, without intending to be bound to the particular
theory, now
wishes to advance the theory for the formation of metmyoglobin in packaged red
meats and solutions to the problems of metmyoglobin formation, with reference
to
FIGURE 179.
Fresh meats that have been chilled during an adequate storage period will
contain large quantities of purple colored, de-oxymyoglobin which is
unattractive to
typical consumers. When the chilled meat is sliced in ambient atmosphere the
de-
oxymyoglobin that consequently comes into contact with atmospheric oxygen,
will
then, by oxidation, convert into oxymyoglobin (referred to as "bloom")
displaying a
bright red color that is attractive to consumers. However, if the sliced meat
(or
~((1~~ AMENDED SHEET =, -~2kQ

CA 02387349 2002-04-03
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ground meat) is intended to be stored in a low oxygen gas atmosphere, case
ready
condition, as a way of extending storage life prior to retail display, the
oxymyoglobin
that has formed after slicing and/or grinding (but before subsequent packaging
in the
low oxygen atmosphere), may provide for undesirable transfer of oxygen gas
into the
sealed environment of the master container. Even though the quantity of oxygen
transferred by the de-oxymyoglobin, is relatively small it can lead to the
formation of
undesirable metmyoglobin on the visible surface of the retail packaged red
meat.
Metmyoglobin is brown in color and is unattractive to consumers. It is
therefore
desirable to prevent andlor minimize the extent of such deleterious formation
of the
metmyoglobin. The apparatus disclosed in the following subject matter details
preventative methods. In order to provide a more detailed description of the
conditions under which the undesirable metmyoglobin may form, the following
known laws of physics and natural processes are referenced:
Normal Conditions for Oxym~ro~lobin Formation
After storage under commercially normal refrigerated conditions in carcass or
vacuum packed conditions, freshly sliced beef will predictably turn bright red
(by
oxidation of purple colored deoxymyoglobin to bright red colored oxymyoglobin)
with a virtually 100% probability, when exposed to ambient air.
Optimum conditions for metmyoglabin formation
It is known that optimum conditions for formation of metmyoglobin, at the
surface of sliced, fresh beef muscle exposed to a gas occurs when the free
oxygen
content of the gas is approximately 5000 to 30,000 ppm.
Graham's Law of Gas Diffusion
The rate of gas diffusion is inversely proportional to the density of the
subject
gas.
Relationship between Density of Gas and Temperature
The density of a gas (and most matter) is inversely proportional to
temperature (i.e.: the gas densit;~ increases as its temperature is
decreased).
Henrys Law
At a given temperature, the solubility of a gas in a liquid is directly
proportional to the pressure of the gas above the liquid.
~la~ AMENDED SHEET

CA 02387349 2002-04-03
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The "Mud Puddle Rin 'g' Effect
According to the present inventors observations and independently performed
empirical trials, the "Effect" can typically occur, immediately following
packaging,
when the following prevailing conditions are generally approximated:
1). The subject sliced beef has been allowed to "bloom" as a result of
exposure to ambient atmospheric oxygen immediately prior to packaging.
2). The temperature of the sliced beef is lower than the gas and packaging
materials surrounding it, immediately after packaging.
3). The sliced beef is placed in an "enclosed space" defined by the "retail
package" including an EPS foam tray (or other) and a high OTR over wrapping
web
(the "web"). The "enclosed space" is not completely filled with the subject
sliced
beef and a remaining space ("the space") is also contained. "The space" is
subsequently filled with a "suitable gas" during evacuation of master
container.
4). The ratio of beef to gas is low, i.e. the volume of "suitable gas" is
relatively low and the volume beef is relatively high, in the "enclosed
space".
5). The "retail package" is placed into a substantially gas barrier "master
container" which is evacuated (including the "retail package") of ambient air
and
then filled with the "suitable gas". The composition of the "suitable gas" can
be
carbon dioxide, nitrogen and residual oxygen at approximately 100 to <500 ppm.
Thereby, substantially filling "the space" and "other space". The "other
space" is
defined by the internal space of the master container but excluding space
occupied by
"retail packages".
6). The temperature of "suitable gas" is lowest at the lowest point in "the
space".
FIGURE 179 is intended to be representational and not a depiction of the
actual "Effect" which is described as follows. Immediately after packaging,
the
highly oxygenated condition of myoglobin (oxymyoglobin), which is present at
the
surface of the beef slices starts to reduce, releasing oxygen gas inside the
enclosed
space 1242. At those sliced beef surface locations shown as 1228, that are in
direct
and intimate contact with the web 1232 (such that there is no gas between the
beef
surface and the web), the released oxygen gas passes through the gas permeable
web,
directly and diffuses into the other space 1240 inside master container but
outside
retail package 1230. This newly released oxygen gas is therefore immediately
separated and essentially excluded from within the retail package. Any further
gas
contact with this area in direct and intimate web contact is limited to any
gas outside
=~~0~, AMENDED SHEET

CA 02387349 2002-04-03
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the retail package, where the oxygen concentration remains relatively low.
However,
oxygen gas that is released from the beef surface that is not in contact with
the web
enters the space 1242 inside the retail package which immediately causes a
significant elevation of oxygen concentration in the small free space under
the web.
Even though the web is oxygen permeable the rate of oxygen gas diffusion
therethrough is such that it can take an extended period of time for the
oxygen
content in the gas under the 'web to equilibrate with the oxygen content of
gas outside
the retail package. Furthermore, the temperature of the oxygen atomslmolecules
as
they are emitted from the surface of the beef is the same as the beef which is
significantly lower than the temperature of the gas in the space and therefore
the
density of the released oxygen is relatively high. This condition results in
two
additional effects. The diffusion rate is lower (Grahams Law) and because the
density is higher, these newly emitted oxygen atoms tend to sink toward the
lowest
point in the package and/or remain in contact with the sliced beef surface for
a longer
period than may otherwise be required. Consequently, the partial pressure of
oxygen
at the surface of the meat increases and, in accordance with Henry's Law the
level
soluble oxygen gas in the meat surface liquid elevates. The temperature of gas
in
space 1242 is higher at the highest point and lowest at the lowest point. It
can be
concluded that oxygen gas emitted from the beef surface will remain in contact
with
the surface of the beef for a more extended period at lower locations and
therefore
higher concentrations will be present at these lower locations. Conversely,
lower
concentrations will be present at higher locations. Correspondingly,
concentrations
of metmyoglobin will form in direct proportion to the concentrations of
oxygen. The
composition of the gas in direct contact with the surface of the beef, a layer
of gas
that is probably less than about 0.01" in depth, is the active gas that has
effect at the
surface of the beef. Under the conditions described above, the oxygen
concentration
in this layer can become signifi;,antly elevated.
The tendency of the relatively heavier oxygen atoms to move toward the
lower levels in the space 1242 can cause it to tend to follow the downwardly
disposed surface of the sliced beef, carried with other gasses and liquids
that are
close to the surface. This condition can therefore result in an increased
level of
oxygen concentration at the surface of the beef which exponentially increases
toward
the lowest point in the space 1242 and is consequently highest at the lowest
point in
the space 1242. This results in correspondingly higher (and darker)
concentrations of
~.~p= AMENDED SHEET
_.:k,:.;,:.,:::a:~'

CA 02387349 2002-04-03
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metmyoglobin at the lowest point in the package and, conversely, visible but
lower
concentrations at the highest point.
A mud pool drying in the sun can appear to be surrounded by parallel rings
that are typically gray/brown in color. These rings are lightest at the
furthermost
point from the center of the puddle and typically darkest at the center of the
puddle,
with a gradual color density change between the two points. The color density
of
metmyoglobin that is formed under the conditions described above gradually
increases between the highest point in the package where the color is the
lightest to
the lowest point in the package where the color is darkest. Hence the
comparison
with a mud pool drying under the sun.
Eventually, any free oxygen gas released by the reduction of oxymyoglobin,
will become either reabsorbed in the form of metmyoglobin or will be diffused
and
equilibrated with the modified atmosphere contained throughout the master
package.
However, the effective, irreversible, deleterious event of formation of
metmyoglobin
at the visible surface of the meat will have already occurred and under the
prevailing
conditions prior to intended retail sale of the meat, will permanently remain
visible.
Subjectively, the above occurs in what can appear to be a confusing manner.
The best most highly oxygenated and therefore red looking beef (as in that
having an
attractive red "bloom") prior to packaging in the low oxygen atmosphere will,
with
an almost certain predictability, emerge as the worst looking beef after
removal from
the master container. Conversely, the worst looking (as in that beef colored
by
purple deoxymyoglobin) prior to packaging in the low oxygen atmosphere will,
with
an almost certain predictability, emerge as the best looking beef after
removal from
the master container.
Other issues of multiple species mass transfer with chemical reaction (i.e. a
potential cause for the mnd puddle ring problem in packaged fresh meat) are
described as follows.
1. Equilibrium beoween a gas and a liquid is governed by Henry's law
which states that the partial pressure of a gas at equilibrium is equal to the
Henry's
Law constant multiplied by the concentration of the gas in the liquid phase at
equilibrium. The gas is oxygen (02) and the liquid is water (H20).
2. Based on the functional relationship expressed in Henry's law, several
conditions can influence the state of equilibrium between free 02 in the
package and
02 absorbed in water.
A. Partial pressure of free 02 in the in-package atmosphere.
'~f~$' AMENDED SHEET

CA 02387349 2002-04-03
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B. Temperature as Henry's constant is temperature dependent.
Conversion of absorbed 02 in water due to chemical reaction. (The work
reported by Zhao and Wells indicates that in-package absolute gas pressure can
vary
in fresh packaged meat, either increasing or decreasing due to a combination
of
factors including composition, storage time, temperature, pre and postmortem
factors, and others. Since total in-package gas pressure can vary, partial
pressure
conditions of 02 can vary causing a migration of 02 in and out of water solely
based
on consideration of factor A. With respect to factor B, it is likely that
there are
thermal gradients that develop across products, from the center to the
surface, for
even slight temperature variations that are experienced within the package.
This
would have two results. The temperature gradients across a product would help
to
cause moisture migration within a product; and the temperature fluctuation
would
promote a change in 02 equilibrium concentration within water. In effect, 02
could
be absorbed into water, the water migrate, and subsequently be deposited
somewhere
else in the product.
As a result of factors A znd B, and the role of chemical conversion, it is
likely
that some aqueous participation is needed. Given this, the question becomes
what
relative O2 concentration and reaction time is needed to produce brown
metmyoglobin color. If the time is sufficiently long, factors A and B would
operate
to move 02, seemingly through the product, to a point to produce the mud
puddle
ring.
Because the in-package gas atmosphere in a closely wrapped product package
is minimal, there is very limited opportunity for bulk convective gas movement
by
mass transfer within the package. The enclosed space near the permeable web,
product and tray are particularly prone to development of a boundary layer
away
from free mixing of gas molecules within a larger, relatively unconfined
headspace.
Boundary layer phenomena may include the establishment of a proportionate
localized gas concentration compared with the free gas concentration. This
situation
would aggravate the 02 conditions outlined above in point 2A and 2B compared
with
a package with a larger headspace volume.
Once formed on a slice of fresh red meat, metmyoglobin is essentially a fixed
stain, with unappealing appearance and is generally unacceptable to consumers.
On
the other hand, oxymyoglobin, which imparts an acceptable red bloom color is
attractive to consumers and is therefore desirable.
AMENDED SHEET

a
CA 02387349 2002-04-03
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The present invention provides methods and apparatus for grinding meats
such as beef by processing boneless beef through a grinding machine (such as
may
be supplied by Weiler & Company of Whitewater, Wisconsin, USA) and
substantially preventing exposure of the ground meat from contacting ambient
air
until the ground meat is delivered in any suitable retail package to a point
of sale,
such as a supermarket. In this way formation of excessive quantities of
metmyoglobin and/or any cause of excessive discoloration can be minimized. In
a
preferred embodiment, the meat can be vacuum packaged after treatment with C02
in
any one of the methods described herein.
Meat Grinding, Blending and Methods for Controlling Fat
Typically meat packing companies slaughter cattle and then process the
dressed carcass by chilling and then disassembling the carcass into portions
of meat
which can then be, in part, delivered to the point of sale to consumers, in
vacuum
packs. However, approximately 40% of the disassembled meat is processed at the
point of animal slaughter by grinding and then blending to provide ground meat
with
a selected fat and lean content as required by the retailer. The fat and
muscle content
of the ground meat may be, for example, 20 % fat and 80% lean. Current
processing
methods require that the boneless meat be firstly coarse ground then blended,
vacuum packaged, delivered to a supermarket or packaging facility close to the
consumer where the coarse ground meat is fine ground and then retail packaged
immediately prior to retail display. This process inherently results in
excessive
exposure of the ground meat to ambient atmosphere during the grinding and
blending
process at the point of slaughter. Furthermore, this process requires that
relatively
large quantities of ground beef' are blended together in a single batch.
Because it is
not possible to disassemble a carcass and provide boneless meat therefrom with
a
precise and selected ratio of fat to muscle tissue, the typical batch blending
process
often requires several attempts to produce the desired ratio of fat to lean
content. The
general industry practice is to deposit selected boneless beef with a fat to
lean ratio as
close to a desired tolerance as possible. The selected boneless beef may have
a fat to
lean ratio of 15% fat to 85% lean +/- 5%. The selected boneless beef is then
coarse
ground and blended in a batch blender such as can be acquired from Weiler and
Company. Typically, a sample of the blended boneless beef is then removed from
the blender and then can be tested to determine fat and lean content using,
for
example, a device known as an Analray testing procedure. After determining the
fat
and muscle content of the coarse ground meat additional fat or lean meat is
added to
~~1.0 AMENDED SHEET

CA 02387349 2002-04-03
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the batch blender and the full batch is again blended for a period of time and
then a
second sample is extracted and tested to determine fat and lean content. If
the fat and
lean content is as required at this point, the batch of coarse ground meat can
be
vacuum packaged and stored in refrigerated facilities prior to delivery to the
point of
retail sale. However if the fat and lean content is not as required then
additional fat
or lean meat can be added to the batch and further mixing is then required.
This
process is often repeated as many as 5 times or more. Each time the coarse
ground
meat is blended again it is damaged by the blending process. This damage may
include "fat smear" or over heating. Heat is generated during this blending
process
and "fat smear" occurs when the meat has been exposed to excessive blending.
This
procedure is expensive in terms of energy, labor and equipment time.
Furthermore,
damage to the ground meat is undesirable and yet damage typically occurs as a
matter of normal process with the currently predominant industry procedures.
During the process described above the meat is exposed to ambient air and
bacteria
such as E. Coli and other dangerous bacteria can be present in the blended
ground
meats. Excessive blending can cause the bacteria to spread throughout the
batch of
meat in the blender.
Ground foods such as ground beef have been produced by processing in meat
grinding and blending equipment and associated equipment, such as blending and
processing equipment manufactured by Weiler Beehive. The equipment can be
viewed at the following web site: www.meatingplace.comJcomlbeehive
Ground meat such as ground beef is produced by processing selected portions
of boneless meat, including fat and muscle tissues, through a grinding
machine. The
relative quantities of fat and muscle contained in any batch of the portions
of
boneless meat is typically arranged to correspond with set industry standards.
The
batch of boneless meat may include about 93% muscle tissue and therefore the
balance of about 7% would be fat. The following list of items 1 to 5, shows
the fat
and muscle tissue content of some typical industry specifications for boneless
meat:
Item Muscle Fat Tissue
Tissue
1 93% 7%
2 90% 10%
AMENDED SHEE-f
,,9s ..

CA 02387349 2002-04-03
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Item Muscle Fat Tissue
Tissue
3 75% 25%
4 6S% 35%
50% 50%
TABLE 1
Although the industry standards are established, it is difficult to produce
large
quantity of boneless beef to any specification or ratio of fat and muscle.
This
difficulty can arise as a result of genetic variation in the animals from
which the
5 boneless meat is harvested, Consequently, there is often variations that
could be as
much as +/- 2% to 3%, which corresponds to a possible variation of up to 6%
and
perhaps even more, in the actual fat or muscle content of the boneless meat.
Typically, consumers can purchase fine ground beef with a fat content that is
specified and clearly marked on any retail package. The fat content may be
specified
to 10%, 25%, or 30% and it is illegal to sell such retail products to
consumers if the
fat content is higher than the amount shown on the retail package. Therefore,
producing retail packages of ground beef with a fat content of, for example,
25%,
may be achieved by grinding a known quantity of Item 2 (listed above) and
blending
this with a known, measured and corresponding quantity of Item 4 (listed
above).
The fat content of the resulting ground beef can be measured but it is common
for the
fat content variation in the initial quantity of the boneless beef items to
vary to such
an extent that a compensating procedure must be accommodated during production
of the product for retail packaging. This compensating procedure can often
result in
production of ground beef that has a muscle content that is higher than is
specified on
the retail package. The consumer, however, only pays for the ground beef
according
to the fat content shown on the retail package. Thus a loss of profit for the
ground
beef producer can be incurred.
A quantity of boneless beef, with a specified muscle and fat content, say
Item 5, is loaded into a hopper which is connected directly to a primary meat
grinder.
The portions of meat are progressively carried, by augers and compressed into
a
tubular conduit with a perforated grinding plate fitted across. The grinding
plate is
typically manufactured from suitably hardened steal and the perforations may
include
AMENDED SHEET
mtAe!~°.....e..v.,:..,.

CA 02387349 2002-04-03
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drilled and reamed holes of a chosen diameter, which may be about 0.5"
diameter,
and which extend completely through the grinding plate. The primary grinder
typically produces coarse grinds with the diameter of the meat pieces
corresponding
with the diameter of the drilled and reamed holes in the grinding plate.
After primary grinding a quantity of Item 5 may be blended with a selected
quantity of coarse ground Item 4. After the blending of Item 5 with Item 4 the
resultant mix is processed through a secondary fine grinding machine prior to
portioning and retail packaging. The secondary fine grinding machine may be
similar to the primary coarse grinding machine except that the grinding plate
can be
drilled and reamed with holes of less than about 0.25" diameter.
Typical fine ground meat for retail packaging and sale to consumers may be
produced with fat and muscle content as shown in the following table:
Item Muscle Fat Tissue
Tissue
1F 90% 10%
2F 75% 25%
3F 65% 35%
TABLE 2
The existing grinding, blending and processing equipment, such as
WeilerlBeehive equipment, has been demonstrated as effective for grinding
meats of
various types. However, little has been proposed to improve the quality of the
ground meats by, for example, arranging equipment in such a manner so as to
substantially prevent contact of the ground meats with air and/or atmospheric
oxygen
during the grinding and blending process. Meats are ground and blended in such
a
manner so as to produce ground meats including a product with a desired ratio
of
muscle and fat content. The conventional equipment does not allow for
continuously
and automatically grinding and blending the ground meats in such a manner so
as to
continuously produce quantities of ground meats to an exact and predetermined
muscle and fat content.
The present invention provides methods, systems and apparatus to
automatically and continuously grind, condition and blend the ground meat
products
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CA 02387349 2002-04-03
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with improved accuracy of muscle tissue to fat tissue ratio, so as to minimize
losses
to the processor. The ground meat can then be packaged in suitable packaging
that
will enhance the keeping qualities of the products and provide a safer method
of
delivering the goods to consumers.
Meat Grinding and Conditioning Apparatus
Having described tray construction, web covers, master container and
associated methods for making and packaging, it is now appropriate to discuss
apparatus and methods for treating the perishable food items that are to be
packaged
by those methods herein described. A logical starting point is a method and
apparatus for grinding and conditioning meat.
Referring to FTGURE 180, a cross-sectional view of a preferred grinding
head 1300 constructed according to the present invention is shown. Preferably,
grinding head 1300 is attached to a source for the carbonation of liquids and
water
contained in ground meats. Meat 1310 is processed through grinding head 1300
of a
meat grinder 1302 and deposited into vessel 1304. Vessel 1304 is substantially
sealed from the external atmosphere. Preferably, entry point 1306 and exit
point 1308 are such that wizen compacted meat 1310 fills the grinding head
1300
adjacent to the cutter 1312 and similarly compacted ground meat 1316 fills the
exit
point 1308 of vessel 1304 adjacent to the end of screw-auger 1314, the vessel
1304
can be filled with a gas such as carbon dioxide under pressure. Preferably,
pressure
is kept above ambient atmospheric pressure therefore assisting the dissolving
process
of carbon dioxide into water in meat. Preferably, screw-auger 1314 is attached
to a
driver (not shown) and rotate,l so that the ground meat is carried forward and
as it
travels down the length of the screw auger 1314, the space between the tapered
flights 1320 of the screw auger 1314 gradually is reduced, thereby compressing
the
ground meat just prior to ejection at exit point 1308, thus providing a seal
of the
vessel 1304 from ambient atmosphere.
This embodiment provides a cost effective method of increasing the pressure
of carbon dioxide and elevating the quantity of dissolved carbon dioxide in
water and
ground meat to a desirable level. Gas provided under pressure into the vessel
may
include, preferably, a suitable blend of carbon dioxide and other gasses such
as
nitrogen, stabilized chlorine dioxide (stabilized chlorine dioxide brand name
Oxine),
helium, and other inert gases, but substantially excluding oxygen, and
including an
amount of carbon dioxide of about 5% to about 100% by volume or weight.
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One embodiment of screw-auger 1314 is shown but alternates may be
arranged in other configurations such as when connected directly to and
parallel with
screw auger 1318 and housed in a tube that has an internal diameter slightly
larger
than the outside diameter of screw auger 1314, that is also in line and
parallel with
screw auger 1318. Such an arrangement passes ground beef through a pressure
box
or vessel and exposes the ground beef to carbon dioxide or other suitable
gasses at a
gas pressure above ambient atmospheric pressure.
Preferably, suitable blends of gasses can be produced and/or blended at the
point of use and injected into vessel 1304 and grinding head 1300 at ports
1322.
Preferably, a stainless steel or plastic extension tube is fitted to the
flanges of the
"downstream" egress/exit point of the pressure box (so as to allow all ground
meat to
pass through the tube) and the blend of gases is injected into the tube so as
to
substantially expel atmospheric gasses and oxygen from the tube such that the
blend
of gasses remains in contact with the meat within the tube. The tube may house
an
auger type screw arrangement to transfer ground meat inside the tube. The
auger has
apertures and holes drilled that connect to a pressurized supply of gas.
When the gas is injected through the drilled holes and apertures, exposure of
the ground meat to the gasses will be maximized. The ground meat can be shaped
or
profiled and cut into portions of specified size and directly loaded into
packaging
while enclosed in a space containing the gas.
Temperature of the gas or blend of gases can be preferably controlled, and
may include individual gases in varying relative proportions so as to optimize
the
cooling of the meat simultaneously while providing sufficient carbon dioxide
to
allow maximized dissolving of carbon dioxide into the water contained in the
freshly
ground meat content liquids.
Gasses will most preferably be injected into the grinding head at a pressure
that will purge or cause to be expelled, substantially all atmospheric gases
from the
grinding head and both upstream and downstream of the grinding head.
Preferably,
covers (not shown) will enclos;, the portions of the grinding process, package
filling
and packaging equipment to limit and control escape of dangerous levels or
quantities of carbon dioxide or other gasses that may cause damage to health
of any
machine operators and/or personnel. Preferably gas extraction fans can be
located
adjacent to the equipment to ensure that safety to operators of the equipment
is
maintained.
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Covers will also preferably restrict egress of atmospheric gasses, such as
oxygen, from contacting the freshly ground beef and/or meat prior to packaging
and
hermetic heat sealing of each package. Such apparatus will substantially
inhibit the
oxidation of deoxymyoglobin contained in those freshly ground meat portions
that
were previously not exposed to atmospheric oxygen.
Alternatively, a suitably concentrated solution of carbonic acid (carbon
dioxide dissolved in distilled water) can be injected into the grinding head
1300 at
port 1322, or mixed with the meat portions immediately prior to grinding such
that it
becomes mixed with the meat in the grinding process. Preferably, subsequent to
grinding, the ground meat can be carried through a tube or "tunnel" that is
filled with
carbon dioxide.
Alternatively, prior to grinding the meat, the portions of meat are passed
through a carbon dioxide tunnel to evaporate a quantity of free water equal to
the
amount of carbonic acid injected into the grinding head. Carbonic acid
solution may
be sprayed onto the portions of meat while passing through the carbon dioxide
tunnel. Preferably, solid carbon dioxide ("snow") may be dissolved into water
to
produce carbon dioxide solution (carbonic acid and water). A measured quantity
of
snow may be injected into the grinding head at a point immediately adjacent
but
located on the up stream side of the grinding head such that, during the
grinding
process, the solid carbon dioxide is blended with the meat so as to
substantially cover
the surface of the meat particles after grinding. Preferably, a controlled and
continuous weighing and feeder device may be used to accurately dispense the
solid
carbon dioxide.
The process of the present invention advantageously inhibits the growth of
bacteria on the surface of the meat portions and particles and maximizes shelf
life of
the meat for a longer period than the shelf life period that would otherwise
be
possible without an increase of dissolved carbon dioxide in surface water and
also
minimizes exposure of ground meat to atmospheric oxygen while in processing
from
grinder to retail pack. This reduces the normal event of the oxidation of
deoxymyoglobin, contained in the meat prior to cutting, to oxymyoglobin and
then
the reduction back to deoxym~roglobin after packaging in the packages that do
not
contain oxygen. Alternatively, freshly ground or cut meat may be passed
through
apparatus for removing and collecting some of the free surface liquid in a
continuous
or batch process such as with a centrifuge. The liquid is then processed by
way of
pasteurization at a temperature that does not cause any undesired effects on
the
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ultimate oxidation of the deoxymyoglobin to oxymyoglobin to produce a
desirable
fresh red color at the point of sale. The liquid can also be exposed to carbon
dioxide
by mixing with solid or gaseous carbon dioxide. After sufficient carbon
dioxide has
dissolved into the liquid, the liquid can be sprayed onto meat or other types
of goods
in a continuous production process.
Alternatively, in another embodiment of the present invention, the
carbonation of the free surface liquid may be achieved by including a further
step in
the process/method of producing modified atmosphere retail packages. Fresh
meat
can be packaged in a substantially gas impermeable plastic package including a
thermoformed tray and flexible plastic lid, hermetically sealed to the tray.
The
process involves locating the tray (with fresh meat) into an enclosed chamber
and
then substantially removing atmospheric air from within the chamber before
then
filling the chamber with a blend of desired gases followed by hermetically
sealing the
lid to the tray. The present invention provides an apparatus and method for,
after
IS substantially evacuating the chamber and filling the chamber with the
desired gas,
compressing the gas (blend of N2 and C02 or 100% C02 ) within the chamber to
an
optimized pressure of between slightly above ambient atmospheric pressure and
up
to 6 bar (6 times the atmospheric pressure). The gas pressure within the
chamber is
then lowered to ambient pressure (1 atmosphere) and the package is then
hermetically sealed. This process of carbonation increases the quantity of
carbon
dioxide that is dissolved intc the liquid in the meat and goods. After
hermetic sealing
of the package, the liquid is substantially saturated with dissolved C02. This
inhibits
further dissolving of COZ into the liquid, that may otherwise cause the
package to
collapse, and can also extend the shelflstorage life of the meat when held
under
refrigeration (at preferably between about -2 to about 4 degrees C).
Meat Carbonation Ec~ui-pment
Referring now to FIGURE 181, another preferred pressure vessel assembly
constructed according to the present invention is shown. The pressure vessel
1600
preferably saturates any given quantity of ground meat, with absorbed or
dissolved
gasses and particularly carbon dioxide gas while also controlling the
temperature of
the ground meat and minimizing or eliminating freezing of the ground meat
during
the process.
An adapter tube 1602 is shown connecting a meat grinder 1604 to the
pressure vessel assembly 1600 and is most preferably provided with an airtight
connection. Compacted meat 1606 is shown within the meat grinder 1604.
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Preferably, the compacted meat 1606 is forced through holes in a plate and cut
by a
rotating blade in a manner as is typically incozporated in most meat grinders
and is
well known to manufacturers and users of meat grinding equipment. Preferably,
compacted meat provides a seal to substantially prevent escape of pressurized
gasses
that may be provided to the pressure vessel. Preferably, a port 1608 is
provided in a
section of the meat grinder 1b04 to allow injection of gasses such as carbon
dioxide
or blends of carbon dioxide nitrogen or any other suitable gas. Preferably,
injection
of the gasses into port 1608 substantially purges air that is in contact with
the meat
just prior to grinding and displaces the air with the desired gas. Preferably,
the
gasses may include a gas blend of carbon dioxide and nitrogen where the
percentage
of carbon dioxide is about 95% and the balance of about 5% includes nitrogen.
Preferably, the interior of pressure vessel 1600 is substantially isolated
from
atmospheric air and is fitted with a removable dome 1610. Removable dome 1610
can facilitate easy access for general cleaning and sanitizing purposes.
Preferably,
the main portion of pressure vessel 1600 is enclosed by a jacket 1612
providing a
space between the jacket 1612 and walls of pressure vessel 1600. Preferably,
temperature is controlled by circulating fluid through jacket through port
1614 and
extracted through port 1616. A cross-section of the vessel 1600 taken along
line P-P,
through the jacket and pressure vessel walls is shown in FIGURE 182 for
clarity.
Preferably, a port 1622 is provided at the apex of removable dome 1610
providing a port to inject gasses and other substances such as 03, F2, H202,
KMn04, HC10, C102, 02, Br2, I2, or any combination thereof and flavors into or
alternatively extract from within the pressure vessel through port 1622.
Alternatively, a gas blend is injected into the pressure vessel through port
1622 and
maintained at a pressure of about 25 psi. Most preferably, a gas blend
including
nitrogen andlor carbon dioxide and/or ozone (03) will be provided into
pressure
vessel via port 1622. Water and oils contained in the ground meat can then
absorb
carbon dioxide until it becomes substantially saturated and cannot absorb any
additional carbon dioxide. Preferably, a controller to maintain and/or adjust
and vary
pressure of the gasses within the pressure vessel, as desired, is also
provided but not
shown. Preferably, a side port 1624 is provided in the wall of the pressure
vessel
through which ground beef may be provided into the pressure vessel 1608 fvr
further
processing in the pressure vessel assembly. Preferably, the size of the
pressure vessel
can be adjusted to suit requirements. The dimensions of length and height may
be
increased or decreased to accommodate the required processing capacity of the
first
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pressure vessel assembly. The lower end of the pressure vessel 1600 is
attached to a
horizontally displaced tube section 1626 within which an auger 1628 is
mounted.
Preferably, auger 1628 includes passageways and holes 1646 provided so as to
allow
injection of gasses therethrough by connection to a source of gasses through
port 1648, thus substantially maximizing exposure of the ground meats to
direct
contact with the gas blend. Tube section 1626 has a length dimension L which
can
be increased or decreased according to requirements. Preferably, auger 1628 is
attached to a driver {not shown) that can provide a force to rotate auger 1628
in a
direction such that ground meat will be transferred through horizontally
displaced
tube section 1626 and toward a.tapered tube section 1632. Preferably, driver
has the
capacity of rotating auger 1628 at a desirable speed which can be adjusted as
may be
required to optimize throughput of ground meat by first pressure vessel
assembly.
Fine ground meat passes into the pressure vessel 1600 and accumulates until
the upper level of accumulated ground meat is adjacent to proximity switch
1650.
Switch 1650 sends a signal to the variable speed drive motor which motor
starts to
slowly rotate auger 1628. Ground meat continues to accumulate and when level
reaches a point adjacent to proximity switch 1654 variable drive motor is
accelerated
to a higher speed. The level of ground meat may continue to elevate and when
the
level reaches proximity switch 1652 drive motor speed is increased to maximum
speed causing the level of ground meat to drop below a level adjacent to 1654
at
which point the drive motor slows down to a lower speed. When the level of
ground
meat drops to a level below 1650 the drive motor is signaled to stop.
Therefore, in
this fashion, the level of ground meat within the pressure vessel 1600 can be
maintained at a point between the lowest proximity switch 1650 and the highest
proximity switch 1652.
Preferably, tapered tube section 1632 has ports 1634 and 1636 to allow
injection of gasses into section 1632 or allow gasses to be extracted from
within the
tapered section by passage. Preferably, additional ports may be provided
through
any part of apparatus walls as may be required to optimize efficiency and
operation
of pressure vessel assembly. A transfer section 1630 is located at the egress
end of
tapered tube section 1632. Preferably, section 1630 is provided with a port
through
which gasses may be injected mto or extracted from within section 1630.
Preferably,
a desired profile can be varied by interchanging an extruded profile section
1640.
Preferably, the continuous length of extruded food product can be severed by a
cutting device such that pieces of extruded food can be provided with
specified and
M'a<a.
'~il'!'v AMENDED SHEET
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CA 02387349 2002-04-03
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desired lengths. The pieces of extruded food can then be packaged into
packages of
suitable size. Such an extruded profile section 1640 is attached to the egress
end of
the transfer section 1630. A cross-section through section 1640 is shown in
FIGURE 183 where a rectangular profile can be seen. Ground meat can be
compressed by auger 1628 and thereby forced through section 1640. Preferably,
compression of the ground meat through the profiled section provides a similar
rectangular profile to the ground beef as it passes through the egress end of
section 1640.
A side view and end view of an alternative extruded profile section 1640 in
the form of a manifold is shown in FIGURES 18S and 184. Preferablyy
manifold 1642 includes a series of three tube profiles through which ground
meat can
be extruded. Such a process can provide three separate streams of profiled
ground
meat. The manifold 1642 may include one or several streams of profiled ground
meat. A tube of similar internal cross-section to the stream of ground meat
may be
connected to each stream of ground meat and thereby contain each stream of
ground
meat separately within a corresponding number of tubes so as to allow transfer
of the
profiled ground meat to other processing equipment such as automatic ground
meat
patty production equipment or a second pressure vessel. The tubes) will
thereby
provide protection to the. ground meat and substantially isolate it from
contact with
external contaminants or atmosphere.
Preferably, a 3 way valve (not shown) can be inserted between transfer
section 1630 and profile sectifln 1640. The 3 way valve can be attached to
section 1630 and section 1640 in a substantially airtight fashion so as to
provide
direct connection to each other or a connection to an alternative tube
connected to
other equipment or to port 1624. Preferably, this provides diverting the
ground meat
to other equipment for further processing or, as may be required at the start
of a
period of production, diversion of the ground meat into a first pressure
vessel through
port 1624 for additional processing to ensure that the ground meat is
substantially
saturated with dissolved carbon dioxide or other gasses. After the ground meat
has
been re-processed, which may require return to pressure vessel 1600 via port
1624
repeatedly, the three way valve can be switched to direct passage of the
ground meat
through the extruded profile section 1640 or other equipment for further
processing
or retail packaging. Preferably, valves (not shown), most preferably automated
valves to close all ports shown in FIGURE 181 and any others that may be
provided,
in a substantially airtight man;~er, are provided to each port but not shown.
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As can be learned and understood with the foregoing description an
adequately effective gas tight seal can be provided by compacted meat 1606
within
meat grinder 1604. Furthermore, auger 1628 can be arranged so as to fit
closely
within transfer sections 1632 and 1630 such that when 1628 is rotating, during
normal operation of the apparatus, ground meat will become compacted within
1632
and 1634 and around auger 1628 and thereby provide an adequately effective gas
tight seal. Therefore, gas pressure within the pressure vessel 1600 can be
increased
to above ambient atmospheric air pressure as required and maintained at a
selected
pressure by a controller to maintain and/or adjust and vary pressure of gasses
within
the pressure vessel 1600, as desired. The.gasses within the pressure vessel
1600 will
therefore be substantially contained between the compacted meat at 1606 in the
meat
grinder and compacted meat 1656, within transfer sections 1632 and 1630 at a
desired pressure. Pressure can therefore be maintained at a pressure most
suited for
rapid absorption by water and oils in the ground meat contained within the
apparatus
during operation and transfer of the ground meat through the apparatus.
Preferably, second and additional pressure vessel assembly of similar
construction to the first pressure vessel assembly, can be provided and
attached to the
first pressure vessel assembly via an adapter tube so as to provide direct
passage of
the ground meat from the egress point at the extruded profile section 1640 by
way of
a tube connected directly to the adapter tube 1602 into the second pressure
vessel
assembly thereby providing direct communication to the second pressure vessel.
After passage of the ground meat through the first pressure vessel it can
therefore be
passed directly into a second pressure vessel. Preferably, the second pressure
vessel
is attached to a vacuum pump via a similar port to that as shown as port 1622
in
FIGURE 181. Preferably, the port shown as port 1624 is not provided in the
second
pressure vessel. A suitable gas such as nitrogen is injected into ports
provided in the
second pressure vessel assembly which are shown as ports 1608, 1634 and 1636
and
the nitrogen gas is also injected through ports and passageways in auger, also
provided in the second pressure vessel assembly and shown as 1628 in the first
pressure vessel assembly. The gas pressure within the second pressure vessel
assembly is maintained at approximately a pressure equal to or higher to the
prevailing atmospheric pressure. The ground meat is passed through the second
pressure vessel assembly and through extruded profile section and into other
equipment as required for packaging and or further processing. Passage of the
ground beef through the second pressure vessel assembly removes free carbon
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CA 02387349 2002-04-03
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dioxide that may remain within the voids contained within the ground meat and
replaces it with a gas such as nitrogen.
A preferred embodiment is to provide a method of substantially restricting the
escape of any gasses, such as carbon dioxide or ozone, from an apparatus, that
may
be hazardous to the wellbeing of operators of the apparatus. This can be
achieved by
locating the apparatus, such as shown in FIGURE 181, within a confined space
such
as an enclosed room or other enclosure that is substantially filled with an
inert gas
such as nitrogen. The enclosure may include several parts and be arranged to
cover
only certain parts of the apparatus. The apparatus can be arranged such that
certain
i0 parts are exposed to allow access or loading. Preferably, the gas contained
in the
room or enclosure will be substantially nitrogen with a residual oxygen
content of
less than 20,000 parts per million. The enclosures or room can be extended to
enclose or house other equipment such as conveyors and packaging apparatus
that
may be used to process and package the ground meat. Such an arrangement would
most preferably isolate the ground beef from contact with gasses containing
oxygen
in concentrations greater that 20,000 parts per million, or greater than 300
parts per
million, and allowing the ground meat, which may be ground beef, to be
packaged in
a vacuum pack or a modified atmosphere package containing a _ gas that
includes a
blend of desired gasses but containing residual oxygen of not more than 500
parts per
million. The gas contained within the enclosures or the room may be
pressurized and
vented to a convenient and safe point into the atmosphere.
Meat Carbonation System
In another preferred embodiment a series of enclosed vessels which may be
pressure vessels, can be connected together, in series, via suitable conduit
means with
a positive displacement pump located between each pressure vessel and
connected to
the conduit means such that a pump can transfer product such as ground meat,
by
pumping means, from a first pressure vessel to a second pressure vessel. Goods
such
as ground meat can be transferred directly from a grinder into a first
pressure vessel
and a first pump can transfer the ground meat from the first pressure vessel
to a
second pressure vessel. A second pump can be provided to transfer the ground
meat
from the second pressure vessel to a third vessel and a third pump can be
provided to
transfer the ground meat from the third vessel to a fourth vessel. Any desired
number of vessels and pumps rnay be assembled in series so as to provide a
method
of transferring the ground meat progressively from the first vessel to
subsequent
vessels as may be required. Gases andlor other goods and materials may be
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transferred by any suitable means into any of the vessels at any suitable
temperature
and pressure. Blending and mixing devices may be installed in the vessels, as
may
be required, and any suitable means of controlling and adjusting temperature
of
goods transferred into and from the vessels can be provided. In this way each
vessel
can be separately and independently controlled and arranged with a holding
capacity
to accommodate any desire3 quantity of ground meat, with selected gases and
other
materials provided therein, and held at any chosen temperature and pressure.
Each
pump can be arranged to separate each vessel such that temperature and
pressure can
be independently adjusted in each of the vessels.
In a preferred embodiment, for example, fat and muscle tissue containedin .a .
quantity of boneless beef can be separated into a first quantity and a second
quantity
where the first quantity includes only muscle tissue which is then ground or
cut into
suitably sized pieces and then transferred directly into a vessel containing a
suitable
oxygen free gas and held at a temperature of 140 degrees F for a period of
time
sufficient to substantially kill any bacteria contained therein. The second
quantity
including only fat can be transferred into a second vessel and subjected to
ultra high
pressure (UHP), exceeding $0,000 psi, so as to substantially kill all bacteria
contained therein while maintaining the second quantity of fat at a
temperature of not
more than I04 degrees F. The first quantity of muscle tissue can be chilled to
a
temperature below 100 degrees F and processed by extrusion to provide a first
continuous stream of muscle tissue with a desired cross-sectional profile that
can be
arranged to be similar to the profile of the muscle component of a typical New
York
strip. The second quantity of fat can be chilled to a temperature below 100
degrees F
and extruded to provide a second stream of fat with a profile similar to the
fat
component of a New York strip. The first stream of profiled muscle tissue and
the
second stream of profiled fat can be then be combined into a single stream of
muscle
tissue and fat and the temperature of the single stream be reduced to about
29.5
degrees F. In this way, a substantially bacteria free, continuous stream of
extruded
muscle and fat having a cross-sectional profile similar to a New York strip
can be
produced which can then be sliced into suitable portions prior to retail
packaging.
In this way, ground meat (and other meats) can be processed so as to
substantially prevent the formation of oxymyoglobin immediately after
grinding.
The ground meat can then be retail packaged in a low oxygen package such as a
master package system as described herein and delivered to the point of sale
in a de-
oxymyoglobin condition. The package can be removed from the de-oxymyoglobin
'~23 AMENDED SHEE-f

CA 02387349 2002-04-03
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condition immediately prior to retail display so as to allow generation of the
consumer appealing red color or "bloom" for the first time after grinding.
Meat Grinding and Conditioning Apparatus
Referring now to FIGURE 186, a meat grinding assembly constructed
according to the present invention includes a first and second meat grinders
that are
in direct communication via a pressure vesse11700. Preferably, first meat
grinder 1702 is fitted with an auger 1704 and meat grinder 1702 is attached to
pressure vessel 1700 via adapter tube 1706 thereby providing direct
communication
to transfer ground meat that has been ground by grinder 1702 directly into the
pressure vessel 1700. Preferably, adapter tube 1706 is provided with a
substantially
gas tight seal at the point of connection to pressure vessel 1700 such that
pressurized
gas that can be provided into 1700 will not escape. Preferably, the adapter
tube 1706
is fitted with a valve (not shown), such that when grinder 1702 has completed
grinding and no compacted meat remains in the grinder, the valve can be closed
thereby closing communication between the pressure vessel 1700 and grinder
1702.
Closing the valve can thereby allow continued processing of any coarse ground
meat
that may remain in pressure vessel 1700 with gas provided therein under
pressure and
above ambient atmospheric pressure as required and until all coarse ground
meat
contained in the pressure vessel 1700 has been processed through second fine
meat
grinder 1738 and into downstream pressure vessel 1730. Furthermore, if so
desired
an additional valve, similar to the valve at grinder 1702, can be provided in
the
adapter tube 1718 so as to allow further processing of the fine grinds in the
pressure
vessel 1730.
Preferably, pressure vessel 1700 is fitted with a removable dome 1708 in
which is provided a port 1710. Preferably, the lower portion of pressure
vessel 1700
is attached to a housing containing auger 1712 which is directly attached to a
variable
speed drive (not shown) that can rotate auger 1712 in a direction that causes
coarse
ground meat to be urged into and through blade 1714 and plate 1716.
Preferably, an
adapter tube 1718 is fitted so as to provide direct communication to pressure
vessel 1730 Preferably, proximity switches 1720, 1722 and 1724 are
conveniently
located in walls of the pressure vessel 1724. Preferably, proximity switch
1720 is
located at a point higher than the location of switch 1724, and switch 1722 is
located
between switches 1720 and 1724.
Pieces of meat are placed into a hopper (not shown) attached to first meat
grinder 1702 and auger 1704 is rotated to cause pieces of meat to be urged
through a
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rotating blade and a perforated plate 1734. Compacted meat 1732 accumulates in
a
compressed condition just prior to passing through blade 1736 and plate 1734,
providing a gas tight seal between the grinder 1702 and the pressure vessel
1700.
Coarse ground meat passes into pressure vessel 1700 and accumulates until the
upper
level of accumulated ground meat is adjacent to proximity switch 1724.
Preferably,
switch 1724 sends a signal to a variable speed drive motor (not shown)
connected to
shaft 1728 which starts motor to slowly rotate auger 1712. Coarse ground meat
continues to accumulate and when level reaches a point adjacent to proximity
switch 1722, the variable drive motor is preferably accelerated to a higher
speed.
The level of ground meat may continue to elevate and when the level reaches
proximity switch 1720, preferably the drive motor speed is increased to
maximum
speed causing the level of ground meat to drop below a level adjacent to
switch 1722
at which point, preferably, the drive motor slows down to a lower speed. When
the
level of ground meat drops to a level adjacent to switch 1724, preferably, the
drive
motor is signaled to stop. Therefore, in this fashion, the level of ground
meat within
the pressure vessel 1700 can be maintained at a point between the lowest
proximity
switch 1724 and the highest proximity switch 1720. Preferably, meat is
compacted at
just prior to passing through rotating blade 1714 and perforated plate 1716,
thereby
providing a gas tight seal between pressure vessel 1700 and pressure vessel
1730.
In this fashion compacted meat remains in a compacted condition at
location 1732 and 1726 providing gas tight seals. Preferably, a desired gas or
blend
of gasses can be injected into pressure vessel 1700 at a desired pressure.
Preferably,
gas pressure is slightly above ambient atmospheric pressure or up to 150 psi
and is
maintained at desired pressure by metering and gas pressure regulating
equipment
(not shown). In this fashion gas can be continuously injected into the
pressure
vessel 1700 and maintained at a desired pressure at a rate equal to the rate
of
absorption of gasses by the ground meat. The meat and ground meat may be
compacted to provide substantially gas tight seals other than as described
herein
while providing for a continuous production process of meat treatment during
the
meat grinding procedure. Production speed can be adjusted to optimize the gas
absorption (and contact with surface of the ground meat) at a desired rate
while
maximizing output of the apparatus and equipment.
In yet another preferred embodiment, pressure vessel 1700 and/or other
pressure vessels attached thereto, preferably are provided with valves, that
can be
opened and closed, and that are provided at all ports, adapter tubes, entry
and egress
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apertures in the pressure vessel(s), so as to enable isolation of the pressure
vessels)
from external ambient atmosphere. Preferably, when isolated, gas pressure
within
the pressure vessels) may be adjusted to a suitable and adjustable pressure
below
and/or above ambient atmospheric pressure. Preferably, the gas pressure, in
the
pressure vessel, may be increased and decreased in a pulsating andlor
oscillating
frequency and pattern that can provide for the efficient removal of
undesirable gasses
and the replacement with desirable gasses at a desired pressure.
Meat Processin,grSvstem
A processing system is disclosed including a meat grinder and a processing
and blending tube with three augers to transfer the meat through the sysiem.
The
tube includes a heat exchanger to maintain temperature and ports for the
introduction
of conditioning gases.
FIGURES 187-189 discloses a preferred apparatus constructed according to
the present invention arranged to process perishable foods such as ground
beef.
Preferably, the apparatus can be assembled in a gas tight manner with
components
manufactured from any suitable materials such as approved stainless steel or
plastics.
Preferably, the assembled apparatus may be arranged in a horizontal
disposition or
with devices to adjust the horizontal disposition to any desirable angle of
repose.
Apparatus 5600 includes an enclosed vessel 5624 of circular cross-section
profile, with end enclosures 5602 and 5604. Preferably, vessel 5624 can be
arranged
to contain any suitable gas at any suitable internal gas pressure and at any
suitable
temperature. Preferably, the temperature of the gas is controlled. Preferably,
vessel 5624 can be fitted witl-~ drivers 5614, 5616, 5618 and 5620 attached
thereto at
suitable convenient locations and as required to provide driving forces to a
round
blending tube, shown as 5622, located inside vessel 5624. Preferably, the
drivers can
be controlled to drive the tube 5622 at a suitable constant and variable
speed. The
tube 5622 engages with four drive wheels, all shown as 5626 for clarity, and
tube 5622 is supported thereon, but otherwise is free from contact with other
components except for suitable contact with seals as may be required at each
end of
the tube 5622. Preferably, drive wheels 5626, are engaged to the corresponding
drivers 5614, 5616, 5618 and 5620. In this way, the tube 5622 is retained by
the
drive wheels, 5626, in a horizontally disposed position or as may be otherwise
required. Preferably, press~.~re vessel 5624 is fitted with vent 5628 which
can be
provided with a valve (not shown) to allow any excess liquids or gases to be
drained
therefrom. A vent with valve and venturi, 5632, can be fitted to vessel 5624.
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Preferably, any desired number of vents with valves and venturis can be fitted
to the
vessel 5624. Preferably, venturis can be arranged to provide gas injection
into
space 5636 in such a manner that will cause the injected gas to flow along
space 5636 and then through tube 5622, in a desired direction at a suitable
velocity.
The tube 5622 is arranged inside the vessel 5624 and passageway 5636 is
thereby provided between the outer surface of the tube 5622 and the inner
surface of
vessel 5624. Gas can therefore be provided inside the pressure vessel and in
the
passageway 5636. Preferably, any suitable gas temperature controller may be
arranged such as by arranging a heat exchanger 5638 connected to the vessel
5624 as
shown. Preferably, a first and second suitably sized tubes, 5640 and 5642 are
attached in direct communication with vessel 5624 such that gas can pass
between
the tubes and the vessel 5624. Preferably, tube 5640 is connected to the heat
exchanger 5638 and another connecting tube 5644 is attached to a gas blower
5646
which in turn is connected to the connecting tube 5642. In this way gas can
pass
through tube 5640, into and through the heat exchanger 5638, through tube
5644,
into and through the gas blower 5646, and through connecting tube 5642.
Preferably,
a barrier 5648 is located in space 5636 which can follow the outer
circumference of
tube 5622 so as to substantially inhibit gas passing therethrough. In this
way, when
gas blower 5646 is activated, gas can be drawn in from space 5636 on one side
of
barner 5648, through tube 5640 and passed through tube 5642 and back into
space 5636 on the opposite side of the barrier 5648. Preferably, this provides
recirculation of any suitable gas along the space 5636, through tube 5622,
back into
space 5636 and again through the heat exchanger 5638. The gas can be re-
circulated
and repeatedly passed through heat exchanger, 5638, to maintain the gas at a
desired
temperature. A tube shown as 5650 is provided to allow suitable gas to be
injected
into the heat exchanger 5638. Preferably, the suitable gas can be provided in
a liquid
or high pressure condition and allowed to expand in the heat exchanger 5638,
and
thereby cause a lowering of temperature. Suitable gas can then pass from heat
exchanger 5638 and into tube shown as 5652 which is connected to tube 5644.
Alternatively, suitable gas can be allowed to escape through tube 5654 and
valve 5656. In this way, by controlling the flow of gas, the internal
temperature of
vessel 5624 and all other items therein can be controlled. During the re-
circulation of
gas through tube 5622 and heat exclanger 5638, a quantity of water, contained
in the
grinds, may evaporate and condense in heat exchanger 5638. The quantity of
condensed water in the heat exchanger may be processed, sterilized and
carbonized,
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by dissolving carbon dioxide therein and then injected into the grinds through
vent
tube 5658. Preferably, tubes 5652 may be provided with pressure regulators and
valves to allow excess gas to escape therethrough, from vessel 5624 at a
suitable rate
and in such a manner as to maintain the temperature of the gas within a
temperature
range of plus or minus about 0.5 degrees F, or at any other suitable
temperature
range. Preferably, the suitable gas andlor any other suitable substances can
be
provided in vessel 5624 at any suitable gas pressure to facilitate dissolving
of the gas
and/or substances into the ground meats contained in the tube 5622. In this
way, the
suitable gas can be controlled to either chill or heat the ground meats being
processed
in tube 5622, and by the apparatus.
Referring now to end enclosure 5602 with a plurality of apertures.
Cover 5660 is located over an inspection access hole so as to provide a
convenient
access into the apparatus for any purpose such as for cleaning. Preferably, a
vent 5662 is provided to allow excess gas to escape. Preferably, vent 5662 can
be
attached to suitable valves with gas pressure regulators as may be required to
control
gas pressure. A tube 5664 is located through a tube in the wall of end
enclosure 5602. Preferably, tube 5664 connects to a nozzle 5666, that can be
arranged to provide temperature controlled water or other liquids, at any
suitable
pressure into the inner space contained within tube 5622. Preferably, the
water or
other liquids can be used to clean the internal surfaces of the apparatus
after use of
the apparatus. Bearings such as bearing shown as 5668 are also located in the
end
enclosure 5602.
Referring now to er~d enclosure 5604, several openings are shown therein
with other apparatus attached thereto. Preferably, three variable speed drive
motors,
5614, 5616 and 5618 are fixed to the end enclosure 5604 and each motor is
attached
to corresponding shafts shown as 5670, 5672 and 5674. A subassembly 5601 is
mounted to end enclosure 5604 in a desired position and can pass ground beef
into
the tube 5622 directly from a grinding apparatus without contacting
atmospheric air.
Preferably, all shafts, tubes, components and assemblies attached to end
enclosures
are sealed in a suitable and desired gas tight manner, thereby retaining any
gas that
may be contained within vessel 5624, at any suitable pressure.
Refernng again to FIGURE 187, three separate augers (two shown), depicted
as 5676, 5678 and 5680 we preferably mounted in close proximity to each other
and
with a member 5682 arranged above auger shown as 5676 separating it from
augers 5678 and 5680. Preferably, augers 5676, 56?8 and 5680 can be arranged
in a
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horizontally disposed and parallel position. Auger 5676 is attached to drive
motor
5614, auger 5678 is attached to drive motor 5616 and auger 5680 is attached to
drive
motor 5618. The end sections of each auger 5676, 5678 and 5674 are arranged
with
shafts and each shaft end mates with bearings located in end enclosures 5602
and
5604. Drive motors 5614, 5616 and 5618 are arranged to drive the corresponding
augers at variable rotating speeds in any chosen direction, either clockwise
or
counterclockwise, as may be selected according to any desired direction and at
any
suitable speed that will enable optimized mixing of the ground meats processed
in
tube 5622. Alternatively one or any number of augers may be located in tube
5622 to
provide the most optimized mixing therein.
Refernng again to FIGURE 187, sub-assembly 5601 is attached to end
enclosure 5604 and can be operated to grind beef and inject the ground beef
directly
into tube 5622. In this way, ground meat can be continuously provided into
tube 5622, at any suitable rate mthin the capacity of the apparatus. Referring
now to
FIGURE 190, the ground beef that flows into tube 5622 can be arranged to fall
directly onto but centrally and between the center lines of augers 5678 and
5680.
Preferably, augers 5678 and 5680 can be arranged to rotate in opposite
directions.
Direction of rotation of auger 5680 can be in a clock-wise direction and auger
5678
can be rotated in a counter clockwise direction. In this way, the ground beef
can be
carried by augers 5678 and 5680 toward end enclosure 5604 and away from end
enclosure 5602. Member 5682 is arranged to allow containment of the ground
beef
between its upper faces and augers 5678 and 5680 for a brief period such that
as
augers rotate the ground beef is earned toward the end enclosure 5604. As
augers 5678 and 5680 rotate the ground beef will then drop and contact tube
5622.
Preferably, tube 5622 can be arranged to rotate at a suitable speed, of
between
about 100 rpm or less and about 500 rpm or more, such that centrifugal force
will
hold the ground beef against the internal surface of tube 5622. When tube 5622
has
rotated by approximately one half of one revolution and the ground beef is
carried to
an upper location and above augers 5678 and 5680, a scraper 5625 can be
provided
to remove the ground beef from contact with tube 5622. The scraper 5625 can be
arranged to cause the ground beef to be directed back onto augers 5678 and
5680.
Auger 5676 can be driven in a direction that will carry any ground beef, that
it
contacts, toward the end enclosure 5602. Preferably, the rotating speed of
each auger
can be adjusted as required. Preferably, auger 5676 can be arranged to have an
extended length, that is longer than 5678 and 5680 such that 5676 extension
extends
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beyond 5678 and 5680 and into a tubular section, shown as 5722, with an
internal
diameter slightly larger than the external diameter of auger 5676. As shown in
FIGURE 187, auger 5676 can then be arranged to carry ground beef from within
tube 5622 and through tubular section 7522 at a desired rate. In this way the
ground
beef will be carried toward end 5604 by augers 5678 and 5680 and toward end
5602
by 5676. The rotation of tube 5622 and its interaction with the scraper 5625
will then
provide further mixing fat and muscle content of the ground beef. By
independently
adjusting the rotating speed of augers 5676, 5678 and 5680 and also tube 5622,
the
period of time that the ground beef is retained within the tube 5622 can be
controlled
to an optimized period of time and thereby allow an efficient method of
blending.
Preferably, after a suitable period of retention, the ground beef will be
transferred
through tube 5642 and will then fall downwardly into tube 5724. Tube 5724 can
be
located directly above and connected to a suitable vane pump shown as 5726,
which
may include any suitable vane pump manufactured by Weiler & Company, Inc.
Preferably, the ground beef can be pumped at a known and controlled velocity
by
vane pump 5726 into tube 5728 which is connected directly thereto. Tube 5728
can
be connected to another measuring device 5730. In this way, ground beef can be
ground and injected into tube 5622, by sub-assembly 5601, and after passing
through
a first measuring device 5730, blended by augers before pumping through a
second
measuring device 5730 located between tubes shown as 5728 and 5732. Ground
beef
can be conditioned and blended at a production rate limited only by the chosen
size
and capacity of the ground beef conditioning and blending apparatus, which may
be
varied in size and capacity as required.
The conditioned and blended ground beef can thus be pumped through
tube 5732 at a desired and controlled temperature with a quantity of suitable
gas such
as carbon dioxide, dissolved in the ground beef to any desired level of
saturation.
Vane pump 5726 can be provided with a variable speed drive motor and arranged
to
pump ground beef at a controlled velocity into other apparatus for subsequent
blending with other ground beef or chosen material and/or further processing.
In a preferred embodiment the conditioned ground beef may be exposed to a
suitable beam of electrons by locating an electron beam generator and
accelerator
such as may be manufactured by Titan-Scan Systems of 3033 Science Park Road,
San Diego, CA 92121. Preferably, the electron beam generator may be located in
such a manner that the suitable beam of electrons produced there with, is
directed
directly at and through a stream of grinds while the grinds are passing
through a tube
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such as tube 5754 shown in FIGURE 191. The cross-sectional profile of the tube
may be arranged to provide maximum exposure to the electron beam. In this way
the
conditioned ground beef can be sterilized at any temperature while maintaining
a
fresh and uncooked condition. Preferably, electron beam sterilization is used
on
fresh ground beef which is in a low oxygen environment to prevent over-
oxidation.
In an alternative embodiment the stream of conditioned ground beef can be
exposed
to irradiation from a source of gamma rays.
Referring again to FIGURE 191, a section of assembled tubes is detailed.
The section of tubes includes a first tube 5744, a second tube 5746 and a
third
tube 5748 which are all joined at a confluence, 5750, to a fourth tube 5754.
The . . . . _
tubes and particularly the confluence may be manufactured from any suitable
plastics
or stainless steel materials and machined so as to ensure that any processed
materials
passing therethrough, will not be subject to significant turbulence until
after passing
through the confluence 5?50. Preferably, any number of two or more tubes
joined, at
a confluence, to a single tube 5754, may be arranged to produce processed
materials
as may be desired. In a preferred configuration, a first processing machine
(not
shown), is arranged to deliver the processed material via tube 5744, a second
processing machine (not shown), is arranged to deliver the processed material
via
tube 5746 and a third processing machine (not shown) is arranged to deliver
the
processed material via tube 5?48. Preferably, the fat content of each stream
of
ground beef can be measured, by any suitable measuring device such as that
shown
as 5730 in FIGURE 195, and the fat content will therefore be known.
Preferably, the
velocity of each stream of material can be adjusted by adjusting the speed of
separate
vane pumps arranged in such a manner so as to provide for velocity adjustment.
By
adjusting the velocity of each stream of processed material corresponding to
the
measured fat content contained therein, delivered quantities of the processed
material, can be adjusted such that when any two or more streams are combined
together, the resultant fat content of the combined stream will be
substantially
constant and as required. I.1 this way, the known fat content of the combined
stream
of processed material can be maintained to within a narrow range of variation.
The
variation may be within a range of not more than +/- 1% of the fat content of
any
item such as Item 1F.
Referring now to FIGilRE 192, a preferred embodiment including a group of
three blending tubes 5756, 5758 and 5760 is shown, each tube being similar in
operation to tube 5622 shown in FIGURE 187. Preferably, the group of three
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blending tubes are each assembled with an auger similar to as described above
in
association with the tube 5622 and auger 5676, 5678 and 5680. Rollers 5762,
5764
and 5766 are arranged to engage and retain the blending tubes as shown. A
pressure
vessel 5768, is arranged to accommodate the group of three blending tube
assemblies
such that drive wheels 5770 are engaged there with and as shown and can be
activated as required so as to rotate the blending tubes. Ground beef can be
provided
into each blending tube by similar apparatus to that disclosed above with sub
assemblies 5601 of FIGURE 187. In this way, three grades of ground beef can be
processed simultaneously in three continuous streams. Each of the continuous
streams of conditioned ground beef can be further processed if desired.
In a preferred embodiment, a plurality of processing machines are arranged to
process material such as fine ground (or coarse ground) meat, such as beef
grinds.
Each of the processing machines may be similar to the apparatus shown in
FIGURE 187. A total of three processing machines can include a first machine,
a
second machine, and a third machine, and can be arranged so that each
processing
machine can process a separate quantity of boneless beef. The first machine,
may
process a quantity of Item 1, the second machine, may process a quantity of
Item 2
and the third machine, may process a quantity of Item 3. The first, second and
third
machines will therefore produce first, second and third streams of ground beef
(processed material) that, after processing, will be pumped, by separate vane
pumps
(for delivery as required), along tubes shown as 5732 in FIGURE 188.
Preferably, any number of one or more processing machines may be arranged
so to provide any number of streams of processed material. Preferably, the
streams
of processed material may be combined and joined together in any chosen
configuration, to produce one or more subsequent streams of processed
material.
Preferably, the velocity of each stream of material may be adjusted, so as to
deliver a
known and corresponding quantity of processed materials with any desired fat
content as required. Preferably, the fat content and muscle content, of each
stream of
processed material can be continuously measured, as described herein, or in
any other
suitable manner. One or more streams of processed materials may be combined to
produce a single stream of processed material. By adjusting the velocity and
consequent delivered quantity of each stream of material (before combining
together
into a resultant single stream) any quantity of any processed material, such
as
Item 1F can be produced to a substantially constant and precise specification.
The
combined stream of processed materials may be further processed through a
grinder
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and/or through processing machines such as that shown in FIGURE 187.
Additionally, the streams of processed materials may be directed through a
tube that
is exposed to sterilization such as by exposure to gamma irradiation, or any
other
suitable sterilizer while contained within the tube.
Subsequent to processing, the beef grinds or processed material can be retail
or bulk packaged in any suitable manner, such as a substantially oxygen free
modified atmosphere master package.
The packaging may be arranged to accommodate a variation in total volume
of the package such as an expansion or contraction in volume. The package
volume
variation may occur as the temperature variation of the packaged processed
material.
The volume variation may correspond to the temperature variation as a result
of any
gases dissolved in the processed materials "boiling off' or again dissolving
in direct
relationship to the temperature variation. Accommodation of the variation in
package volume may be achieved by provision of a suitably sized, flexible,
substantially gas barner package.
Referring again to end enclosures 5602 and 5604 shown in FIGURE 187,
suitably located apertures shown as 5736, are provided therein so as to allow
free
movement of gas therethrough. The velocity of the gas can then be controlled
by
blower 5646 and along a path through tube 5622, into the spaces shown as 5738
and
back through space 5636. Preferably, the velocity and temperature and pressure
of
the gas can then arranged at the most effective settings to control the
temperature of
the ground beef and the rate of gas dissolving therein.
Refernng now to FIGURE 194 and particularly, end enclosure 5604, a
member shown as 5738 is arranged to mate with member 5604 at a close
contacting
face shown as 5740. Members 5604 and 5738 are in contact at interface 5740,
and
fixed relative to each other but not locked together. Member 5738 can move
relative
to 5604 but is retained by interface 5740 and shafts shown as 5670 and 5674
(and
5672, which is not shown). Suitable bearing surfaces are provided between 5738
and
5604 and also between 5738 and 5670, 5672 and 5674. Sub assembly 5601 is
arranged so as to be removable for cleaning purposes and plugs may be inserted
into
the connecting apertures created by removing sub-assembly 5601. When 5601 is
removed and replaced with the plugs, member 5738 can be moved away from
tube 5622 by sliding along shafts 5670, 5672 and 5674 so as to provide a space
between member 5738 and the end rim of tube 5622. Preferably, such an
arrangement may be installed at either or both end enclosures of the apparatus
in
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such a manner so as to facilitate effective cleaning of apparatus after use.
Other
cleaning features may be incorporated into the apparatus. Preferably,
pressurized and
heated water may be provided inside the apparatus with suitable sanitizing
detergents
in such a manner so as to facilitate an automatic cleaning when augers 5676,
5678
and 5680 and tube 5622 are all rotated in common or opposing directions and at
suitable speeds. Alternatively or additionally high pressure steam may be
provided
inside the apparatus to facilitate sterilization and thorough cleaning of the
internal
surfaces of the apparatus. Draining/venting tubes such as 5742 can be provided
with
valves, at any suitable and convenient location on the apparatus.
Lean Muscle and Fat Measuring Apparatus
A lean tissue and fat analyzer is an optional feature of the meat processing
system. Refernng now to FIGURE 189, a cross sectional view of the conduit of
FIGURE 188 is shown as a square or rectangular tube 5730. Preferably, tube
5730
and tube 5702 are similar. Tube 5730 can be manufactured from any suitable
material which includes plastics as well. Preferably, two electrodes, shown as
5710
and 5712 are located on opposing internal sides of tube 5730 and attached to
terminals. Electrode 5710 is attached to terminal 5714 and electrode 5712 is
attached
to terminal5716. An electrical current can be arranged to flow through
terminals 5714 and 5716 and into electrodes 5710 and 5712. Ground beef (ground
meat) is shown as 5715 and in this way, will directly contact the electrodes
as it
passes through tube 5730. The electrical current can therefore pass through
ground
beef from electrode 5712 and to electrode 5710. Electrical current will be
affected
by the resistance of the ground beef and this resistance will vary according
to the
ratio of fat and muscle content of the ground beef and therefore the
electrical
resistance can be measured. The variation in electrical resistance can be
measured
and such measurements can be converted and used to determine the ratio of fat
and
muscle contained in the ground beef in a continuous process. Tube 5730 with
terminals and electrodes together include a measuring device shown as 5718.
Preferably, the measuring device may be installed, and used to measure the
ground
beef fat and muscle content ratio, at any convenient location as may be
required.
Meat Grinder Sub-Assembly
A meat grinder sub-assembly is an optional feature of the meat processing
system. Several embodiment of a meat grinder have been previously described.
However, a meat grinder preferably for use with the processing machine
follows.
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Referring now to FIGURE 193, a meat grinder sub-assembly according to the
present invention is shown. The sub-assembly includes a pressure vessel 5684,
with
an entry port 5686 at an upper location and an exit port 5688 at a lower
location. A
horizontally disposed and tapered auger 5690 is located in a lower portion of
vessel 5684 and arranged with a shaft 5692 that can be attached directly to a
suitable
variable speed driver. Preferably, the tapered auger is suitably profiled and
is fitted
with passageways therein to allow any suitable gas to be injected
therethrough. A
meat grinding apparatus is attached directly to the entry port 5686 and can be
disconnected therefrom to provide access for cleaning as required. Boneless
meat
portions can be . processed by grinder 5694 to produce grinds which are then
transferred directly into vessel 5684 in a continuous stream. Preferably, the
cross-
sectional profile of vessel 5584 is circular and a valve member 5696 is
arranged to
mate with a valve seat 5698, which is located between the entry port 5686 and
the
auger 5690, to provide a gas tight seal when required. Valve member 5696 can
be
opened and closed by valve stem 5697 as required and an:anged to automatically
close as required for any reason. Ground beef that is transferred into vessel
5684 can
contact auger 5690. Preferably, any suitable gas at any suitable pressure can
be
injected into vessel 5684 through ports 5700 and/or 5702. Each port such as
5702
and 5700 is fitted with suaable valve and pressure regulator: As desired, gas
can be
injected into a port such as port 5702 and allowed to exit through a port such
as 5700.
Pressure regulators maintain a desired gas at any suitable pressure in the
vessel 5684.
In this way, the continuous stream of ground beef can be transferred through
the
vessel 5684 by auger 5690 at a desired rate and pressure. As the ground beef
is
transferred through vessel 5684 by tapered auger 5690, the ground beef is
compressed and extruded through a restriction as shown, so as to exclude gas
and
produce a substantially continuous flow of ground beef without gas bubbles
contained therein. In this way the compressed ground beef can provide an
effective
gas tight sealing between vessel 5684 and vessel 5624 of FIGURE 187. The
continuous flow of ground beef is passed through a tube section 5702 at a
desired and
controlled rate. After passing through tube 5702 the ground beef passes
through the
exit port 5688 and can be directed into any suitable container such as tube
5622
shown in FIGURE 187. If desired, a secondary grinder may be interposed between
the vessel 5684 and a valve 5706. Valve 5706 is provided at the exit port 5688
and
can be arranged with an automatic actuator to open and close at a remote
distance as
may be required for any reason. When in a closed position valve 5706 can seal
the
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exit port 5688 in a gas tight manner. As the ground beef passes through tube
section 5702, the fat and muscle content of the ground beef can be measured.
The
measuring device may include the passing of an electric current through the
ground
meat as it passes through the section 5702. Preferably, the electrical
resistance is
measured and a muscle and fat concentration can be obtained.
Meat Pre-Conditioning. System
Referring now to FIGURES 196-197, a plan view and a side elevation view
of an apparatus designed to slice meat while conditioning in an oxygen free
environment is shown. The apparatus is shown in diagrammatic form and includes
a
continuous conveyor 5100, with a driver mounted to a rigid frame (not shown)
and
horizontally disposed to allow horizontal motion in a machine direction in
intermittent or continuous movement. The conveyor is fitted with two
corresponding
and vertically opposed pairs of pressure chambers includes an upper chamber
5102
with a corresponding lower chamber 5104 and another upper chamber 5106 with a
corresponding lower chamber 5108. An enclosed gassing tunnel 5118 is arranged
to
enclose the upper section of the conveyor 5100 with a gassing port 5112
affixed
thereto to provide any suitable gas, such as nitrogen gas or carbon dioxide,
into the
tunnel S 118.
Referring now to upper chamber 5102 and corresponding lower
chamber 5104 the opposing chambers are arranged so as to open and close. Upper
chamber S 102 is mounted to a driver (not shown) to provide elevating,
lowering and
clamping apparatus. Lower chamber 5104 is also mounted to a separate driver
(not
shown) to provide elevating, lowering and clamping. Chambers 5102 and S 104
can
be closed together by moving in opposing directions so as to contact each
other along
a path around the perimeter of openings. In this way a single chamber is so
arranged
in a manner that is airtight and sealed from external atmosphere. An
evacuation
port 5114 and a gas port 5116 are provided so as to allow evacuation and gas
flushing of the closed chamber. As shown in FIGURE 196 two separate pressure
chamber assemblies are arranged such that conveyor 5100 passes through both
chamber assemblies. Trays with sliced beef or other meat primal, placed
therein, are
located into carrier plates in conveyor 5100. The primals are sliced in a
suitable
manner and can then be opened so as to expose the multiple surfaces of the
slices
immediately prior to entry into enclosed tunnel5118. Enclosed tunnel5118 is
arranged so as to substantially exclude atmospheric oxygen gas by flushing
other
3S suitable gases therein. The trays with sliced primal S 122 are located in
carrier plates
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and progressively move through enclosed tunnel 5118 until each tray with
primal is
located directly between an upper chamber 5102 and lower chamber 5104. The
upper and lower chambers close together and around the sliced primal 5122 in
an
airtight and sealed manner. Substantially all air is evacuated from the
chambers and
a suitable gas, including carbon dioxide, is injected through port 5116. The
suitable
gas pressure can be increased to any suitable pressure as desired. The primal
5122
can be retained in the pressure chambers for a desirable period of time so as
to cause
sufficient carbon dioxide gas to dissolve in the oils and water contained in
the
primal 5122. After the primal 5122 has been exposed to the high pressure
carbon
dioxide gas for a suitable period of time, the pressure chambers open and
allow
conveyor 5100 to carry sliced primal 5122 in tray, forward in machine
direction and
through the enclosed tunnel 5118. A second pressure chamber assembly may also
be
closed around the sliced primal 5122 in tray. Any suitable gas at any suitable
pressure can be provided in the second enclosed chamber. Second chamber
includes
an evacuation port 5115 and a gassing port 5117. The sliced primal 5122 in
tray is
intermittently carned through the tunnel 5118 until it emerges at the exit end
of the
tunnel.
In this way, rapid formation of oxymyoglobin is inhibited when the
primal 5122 is exposed to ambient atmosphere.
Plant Layout
Having described meat grinding systems and ancillary equipment, it is
appropriate to describe the integration of equipment to form a whole
production
facility for processing and packaging meats.
Refernng now to FIGURE 198, a plan view of a preferred production plant
layout is shown, including ground meat processing, blending equipment and
retail
packaging plant. The equipment shown in FIGURE 198 is represented by
diagrammatic sketches and is integrated such that ground beef processed by the
equipment shown can be transferred directly from grinders 6400, 6402 and 6404
into
oxygen free vessels shown as 6408, 6410 and 6412, respectively.
The chart set out below provides a list of equipment shown in FIGURE 198.
ID Item
6400 Grinder
'13~ AMENDED SHEET

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m Item
6402 Grinder
6404 Grinder
6406 Grinder (Fine)
6408 Vessel + Mix
6410 Vessel + Mix
6412 Vessel + Mix
6414 VesseIJHo er
6416 VessellHo er
6418 Vessel/Ho er
6420 Positive dis 1. um
6422 Positive dis 1. um
6424 Positive dis 1. um
6426 Positive dis 1. um
6428 Measure fatllean
6430 Measure fatllean
6432 Measure fatllean
6434 Continuous blendin
6436 Control Panel
6438 Valve (diversion)
''.'138-
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m Item
6440 Elevator
6442 Elevator
6444 Dischar a Ports
6446 Dischar a Ports
6448 Dischar a Port
6450 Ma azine
6452 Gas Exchan a
6454 Tra Welding
6456 Grinds Portionin machine
6458 RT 1800 Packa in Machine
6460 Horizontal Vacuum
Boneless beef with a suitable fat/lean composition is loaded into
grinders 6400, 6402 and 6404. Ground beef is produced by grinders 6400, 6402
and
6404 and transferred directly into enclosed vessels 6408, 6410 and 6412 that
are
otherwise filled with a suitable gas at a suitable pressure.
Vessels 6408, 6410 and 6412 can be fitted with blending apparatus so as to
blend grinds therein. Positive displacement pumps 6420, 6422 and 6424 pump
quantities of grinds, in three respectively separate streams from vessels
6408, 6410
and 6412 directly into continuous blender 6434. The quantity of grinds pumped
by
the positive displacement pumps in the separate streams is controlled and
dictated by
the measured fat and lean content of each stream of grinds. Fat and lean
content of
each stream of grinds is measured by measuring devices shown as 6428, 6430 and
6432. Continuous blender 6434 terminates at positive displacement pump 6426
and
blended grinds are transferred directly from 6434 into 6426. Pump 6426 can
transfer
AMENDED SHEET

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the blended grinds in a single continuous stream into either vessel 6418 or
vessel 6416.
Grinds can be stored in vessels 6416 and 6418 as may be required. The
grinding, pumping, measuring and blendsng apparatus can be arranged so as to
produce a single stream of grinds by combining three separate streams into a
single
stream in continuous blender 6434. The single continuous stream of blended
grinds
can be produced according to a specification such as 85% lean and 15% fat.
Alternatively, single stream of blended grinds can be produced according to
any
other desired specification such as 90% lean and 10% fat. In this way two
separate
quantities of specified grinds can be stored with one in each of vessels 6416
and
6418. For example, a quantity of 85% lean and 15% fat grinds can be stored in
vessel 6416 and a quantity of 90% lean and 10% fat grinds can be stored in
vesse16418. Suitable positi»e displacement pumps can be arranged to transfer
specified quantities of grinds from either or both vessels 6416 and 6418 for
separate
or combined grinding in a grinder such as is shown as 6406 in FIGURE 198. Any
suitable number of pumps can be arranged to transfer grinds from either of the
vessels 6416 and 6418 for further blending and/or grinding and subsequent
retail
packaging in packaging machine shown as 6458. If required suitable blending
equipment can be provided for blending of any suitable number of additional
pairs of
streams of grinds, in selected quantities, after pumping from vessels 6416 and
6418
to produce specified quantities of blended grinds that can then be fine ground
prior to
retail packaging.
In this way, ground meat can be processed and packaged while being
contained within a series of vessels and tubes that are filled with ground
meat and
suitable gas that substantiall~r excludes oxygen and any other undesirable gas
and/or
material. Therefore, formation of oxymyoglobin on substantially all freshly
cut meat
surfaces can be inhibited until after packaging and immediately prior to
retail display
or other desired use.
Referring now to FIGURE 199, a plan view of another preferred production
plant layout is detailed including production and packaging equipment.
A preferred layout includes items of equipment in the table below and
identified by a reference numeral.
Production Ec
AMENDED SHEET

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Item Production ui ment Packa 'n a ui ment
#
5900 Grindin machine 5960 Chub/vacuum acka in machine
5902 Grinding machine 5930, Ground beef portioning
5932, machines
5934
5904 Grinding machine 5940, Over wrapping packaging
5938, machines
5936
5906 Ground beef processing 5954, Foam tray erecting machines
machine 5956,
5958
5908 Ground beef processing 5924, Conveyor belts
machine 5926,
5928
5910 Ground beef rocessin machine
5922 Ground beef rocessin machine
5942 Gas blower with heat exchan
er.
5912 Ground beef In'ector
5914 Ground beef In'ector
5916 Ground beef In'ector
5944 Ground beef In'ector
5946 Vane um
5948 Vane um
5950 Vane um
AMENDED SHEET

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Item Production ui ment Packa in a ui ment
#
5952 Vane um
5918 Multi-tube combinin die
5920 Electron beam sterilizer
and/or
'nder
TABLE 3
Preferably, the equipment shown in FIGURE 199, and listed above, is
arranged to continuously produce and retail package, case ready ground meats.
Quantities of specified boneless beef raw materials are processed by grinding
machines 5900, 5902 and 5904 to produce grinds that are transferred directly
into
ground beef processing machines 5906, 5908 and 5910 via corresponding injector
machines 5912, 5914 and 5916. Each grinder processes a quantity of specified
boneless beef raw materials each of which may be selected from the following
table
of raw materials Item 1 through Item 5.
Item Muscle Fat Tissue
Tissue
1 93% 7%
2 90% 10%
3 75% 25%
4 65% 35%
5 50% 50%
TABLE 4
Equipment shown as vessels 5906, 5908 and 5910 is arranged to process
grinds as above described apparatus shown in FIGURE 187. Grinds are injected
into
vessels from the grinders 5900, 5902 and 5904 by injectors 5912, 5914 and 5916
which are arranged to operate as the above described apparatus shown in
FIGURE 193. Conditioned grinds are transferred in a single continuous stream
from
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CA 02387349 2002-04-03
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each vessel, by a pump from vessels into transfer tubes which are then
combined at
confluence 5918 into a single tube. Confluence 5918 includes a manifold
generally
as the above described apparatus shown in FIGURE 191.
Preferably, the fat content of the continuous streams of grinds is
continuously
measured by measuring devices as the above described apparatus shown in
FIGURE 194. Preferably, the fat content of the grinds can be continuously
measured
before injection into the vessels and immediately after transfer from the
vessels and
into the transfer tubes. Preferably by measuring the fat content and
automatically
adjusting the flow rate of each stream of grinds, directly and according to
the
measured fat content, prior to combining the streams of grinds; a combined
stream of
grinds with consistent fat content can be produced. The combined stream is
then
transferred via a tube into a single grinder shown as 5920. An electron beam
generator of suitable capacity may be integrated such that the combined stream
of
grinds passes therethrough prior to injection directly into vessel 5922.
Vessel 5922
may be arranged to process grinds as the above described apparatus shown in
FIGURE 187. A single stream of conditioned grinds is then transferred into a
single
tube that is divided into four separate streams of grinds.
Still refernng to FIGURE 199, the preferred plant layout includes four
packaging systems and a single supply stream of grinds is transferred to each
of the
packaging systems. Preferably, one stream to "chub/vacuum" packaging machine.
Preferably, apparatus constructed according to the present invention includes
three
packaging machines 5924, 5926, and 5928, and a single stream of grinds to each
of
three portioning machines, shown as 5930, 5932, and 5934, respectively.
Portions of
grinds are then retail packaged by automatic loading into trays which are then
over
wrapped by packaging machines shown as 5936, 5938, and 5940. While, an
embodiment has been described and shown to include three processing trains,
any
suitable number of processing trains may be used in accordance with the
present
invention, which may include more or less than the three trains herein
described.
The equipment as dzscribed herein may be arranged to automatically produce
any quantities of coarse or fine ;rinds according to any specifications. The
following
table shows the specified muscle and fat tissue content of three types of fine
beef
grinds.
Item Muscle Fat Tissue
Tissue
'143 AMENDED SHEET

CA 02387349 2002-04-03
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Item Muscle Fat Tissue
Tissue
1F 90% 10%
2F 75%a 25%
3F 65% 35%
TABLE 5
Equipment as described herein maybe arranged to grind, measure, condition,
blend, process and package specified portions of grinds according to any
suitable size
by automatically computer controller. The computer controller may continuously
provide production information including such data as the total fat and muscle
tissue
content of each and alI streams of grinds during the processing. In this way,
a
method to improve efficiency and reduce total losses is provided by producing
grinds
to meet precise specifications according to, for example, the list of fine
beef grinds
shown above.
Plant Layout
Refernng now to FIGURES 200 and 201, another preferred production plant
layout including ground meat processing and blending equipment and a preferred
CAP retail packaging plant layout including packaging equipment is shown. The
equipment shown in FIGURE 200-201 is integrated such that ground beef
processed
by equipment shown in FIGUF;E 200 is packaged in packaging that is processed
by
equipment shown in FIGURE 201. The present invention provides for a method of
grinding meats directly into an oxygen free vessel or hopper and then blend
and
process the ground meat as described herein. The present invention also
provides a
method of saturating the liquids, water and oils in the ground meats with a
suitable
gas or substance such as carbon dioxide, provided at a suitable pressure, to
such a
level that when removed from the processing equipment the ground meat will
emit a
suitable gas such as carbon dioxide.
Items of equipment shown in FIGURE 200-201 that are identified by letters
and/or numbers are listed in the following table set out below:
FIGURE 200 ~ ~ FIGURE 201
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Item Production E ui ment Packa in a ui ment
#
6006 Conveyor (with variable 6122 Magazine
speed
control )
6008 Conveyor (with variable 6124 Magazine
speed
control)
6010 Conveyor (with variable 6126 Magazine
speed
control)
6018 Conveyor (with variable 6128 Tray material evacuation
speed &
control) assin
6020 Conveyor (with variable 6130 Tray material evacuation
speed &
control) assin
6022 Conveyor (with variable 6132 Tray material evacuation
speed &
control assin
6034 Conveyor (with variable 6134 Tray flap erection & welding
speed
control)
6036 Conveyor (with variable 6136 Tray flap erection & welding
speed
control)
6030 Ultra violet sterilization6138 Tra fla erection & weldin
a ui ment
6032 Ultra violet sterilization6140 Conve or
a ui ment
6038 Grindin machine 6142 Conve or
6040 Grindin machine 6144 Conve or
6100 Grindin machine 6116 Ground beef ortionin machine
6104 Grindin machine 6118 Ground beef ortionin machine
6108 Grindin machine 6120 Ground beef ortionin machine
145' AMENDED SHEET

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FIGURE FIGURE 201
200
Item Production E ui ment Packaging equipment
#
6046 Tube connection 6146 Conve or
6050 Tube connection 6148 Conve or
6048 Ground beef ho er 6150 Conve or
6052 Ground beef hopper 6000 Over wrapping packaging
machines
6058 Ground beef hopper 6002 Over wrapping packaging
machines
6064 Ground beef hopper 6004 Over wrapping packaging
machines
6056 Statiflo blender
6062 Statiflo blender
6090 Statiflo blender r..
6092 Statiflo blender
6094 Statiflo blender
6096 Gas in'ection orts.
6054 Positive dis lacement um
6060 Positive dis lacement um
6066 Positive dis lacenie.nt
um
6068 Positive dis lacement um
6070 ~ Positive displacement I I
pump
AMENDED SHEET

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FIGURE 200 FIGURE 201
Item Production ui ment Packa in a ui ment
#
6072 Positive dis lacement um
6074 Positive dis lacement um
6076 Positive dis lacement um
6078 E silon GMS-40
6084 E silon GMS-40
6080 E silon GMS-4U
6086 E silon GMS-40
6082 E silon GMS-40
6088 E silon GMS-40
Electron beam sterilizer
and/or
rinder
The equipment shown in FIGURE 200-201 is listed above and is arranged to
automatically and continuously produce selected grades of retail packaged,
case
ready ground meats. The ground meats may include quantities of muscle and fat
tissue such as shown in the following chart, where item 1F includes ground
meat
with about 90% muscle tissue and about 10% fat tissue, with a muscle to fat
tissue
variation within about ~-/- 0.2%. The packaging equipment shown in FIGURE 201
can be arranged so that the packaging machine 6000 will produce CAP case ready
packages containing ground meats according to a specification equivalent to
item 1F.
Similarly, packaging machine 6002 can produce CAP case ready packages
containing ground meats according to a specification equivalent to item 2F and
packaging machine 6004 can produce CAP case ready packages containing ground
meats according to a specification equivalent to item 3F in TABLE 7.
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Item Muscle Fat TissueMusclelFat Tissue Variation
Tissue
1F 90% IO% +/-0.2% muscle content
2F 85% 15% +/-0.2% muscle content
3F 80% 20% +/-0.2% muscle content
TABLE 7
Referring again to FIGURE 200, variable speed conveyors 6006, 6008 and
6010 are preferably arranged in close and parallel proximity such that each
conveyor
can carry specified quantities of selected boneless beef. In this way conveyor
6006
can be arranged to carry specified quantities of raw material, which may be
boneless
beef selected from the chart shown below, in a direction indicated by arrow
6012,
conveyor 6008 can be arranged to carry specified quantities of selected
boneless beef
in a direction indicated by arrow 6014 and conveyor 6010 can be arranged to
carry
specified quantities of selected boneless beef in a direction indicated by
arrow 6016.
I0 The specified quantities of selected boneless beef can be varied between
the
conveyors marked 6006, 6008 and 6010 such that 6006 carries selected boneless
beef
shown as 2X, in TABLE 8, conveyor 6008 carnes selected boneless beef shown
as 3X and conveyor 6010 also carries the selected boneless beef shown as 3X.
Preferably, variable speed conveyors 6018, 6020 and 6022 are arranged in
close and parallel proximity such that each conveyor can carry specified
quantities of
selected boneless beef. In this way conveyor 6018 can be arranged to carry
specified
quantities of raw material, which may be boneless beef selected from TABLE 8,
in a
direction indicated by arrow 6024, conveyor 6020 can be arranged to carry
specified
quantities of selected boneless beef in a direction indicated by arrow 6026
and
conveyor 6022 can be arranged to carry specified quantities of selected
boneless beef
in a direction indicated by arrow 6028. The specified quantities of selected
boneless
beef can be varied between the conveyors marked 6018, 6020 and 6022 such that
conveyor 6018 carnes boneless beef shown as 1X in TABLE 8, conveyor 6020
carries boneless beef also shown as 1X and conveyor 6022 carries boneless beef
shown as 2X.
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Item Muscle Tissue Fat Tissue MuscleJFat Tissue Variation
1X 99% 1% +1% l - 3% muscle content
2X 93% 7% +/-3% muscle content
3X 75% 25% +l-3% muscle content
TABLE 8
Preferably, the variable speed conveyors 6006, 6008 and 6010 can be
arranged in close and parallel proximity and located inside an ultra violet
light (UV)
tunnel shown as 6030 in FIGURE 200. Tunnel 6030 can be arranged so as to
expose
any of the selected boneless beef to sufficient UV light so as to
substantially sterilize
the surfaces of the boneless beef. A suitable device of turning and/or
rotating the
boneless beef can be provided in the tunnel, so as to ensure that
substantially all
external surfaces of the boneless beef are exposed to the UV light to ensure
the
sterilization of the surfaces. Similarly, the variable speed conveyors 6018,
6020 and
6022 can be arranged in close and parallel proximity and located inside an
ultra
violet light (UV) tunnel shown as 6032 in FIGURE 200. Tunnel 6032 can be
arranged so as to expose any of the selected boneless beef to sufficient UV
light so as
to substantially sterilize the surfaces of the boneless beef. A suitable
method of
turning and/or rotating the boneless beef can be provided in the tunnel, so as
to
ensure that substantially all external surfaces of the boneless beef are
exposed to UV
light to ensure sterilization of surfaces.
Preferably, the variable speed conveyors 6006, 6008, 6010, 6018, 6020, and
6022 can be provided with independent drivers and arranged to pass through a
tunnel
with a device to independently measure the fat and muscle content of the
boneless
beef earned on each individual and separate conveyor. Any suitable method of
measuring the fat and muscle content of the boneless beef may be integrated
with the
conveyors 6006, 6008, 6010, 6018, 6020, and 6022 so as to provide a method of
separate and continuous meas~irement of the fat and muscle content of the
boneless
beef separately carried on each conveyor. Preferably, the variable speed
conveyors 6006, 6008, and 5010 can be arranged to converge and deposit the
boneless beef, carried by each independent conveyor onto a conveniently
located
secondary conveyor shown as 6034 in FIGURE 200. Similarly, the variable speed
conveyors 6018, 6020, and 6022 can be arranged to converge and deposit the
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boneless beef, carried by each independent conveyor onto a conveniently
located
secondary conveyor shown as 6036 in FIGURE 200. Preferably, the speed of each
conveyor can be varied in direct relationship to the variation of measured fat
and
muscle content of the boneless beef corned by each conveyor.
S Preferably, the length of the variable speed conveyors 6006, 6008, 6010,
6018, 6020, and 6022 can be extended so as to allow operators, such as carcass
disassembly workers, to deposit the boneless beef raw material thereon
immediately
after disassembly and separation from an animal carcass source of the boneless
beef.
Furthermore, the carcass disassembly workers can, for example adjust the fat
content
of boneless beef that is deposited onto each of the conveyors 6006, 6008,
6010, 6018,
6020, and 6022 according to requirements. More specifically, if it is
determined by
the fat measuring device that a reduced quantity of fat and an increased
relative
quantity of muscle (lean) tissue is required on any particular conveyor, this
can be
accommodated. Conversely, if it is required to deposit an increased relative
quantity
1S of muscle tissue onto any particular conveyor, this also, can be
accommodated. In
this way, the fat and lean content of the boneless beef that is deposited onto
each of
the individual conveyors can be adjusted to suit requirements which can be
determined by the fat content measuring method through which each of the
conveyors can be arranged to pass. Preferably, boneless beef can be deposited
onto
variable speed conveyors 6006, 6008, and 6010 according to requirements and by
varying the speed of each conveyor and therefore the quantity of boneless beef
carried and deposited onto conveyor 6034, a combined stream of boneless beef
including fat and muscle tiss~.e with a desired and constant relative ratio
can be
produced and corned on the conveyor 6034. Similarly, with variable speed
2S conveyors 6018, 6020, 6022, boneless beef can be deposited onto each
conveyor
according to requirements and by varying the speed of each conveyor and
therefore
the quantity of boneless beef carried and deposited onto conveyor 6036, a
combined
stream of boneless beef, carried on conveyor 6036 and including fat and muscle
tissue with a desired and constant relative ratio, can be produced and corned
on the
conveyor 6036.
Referring again to FIGURE 200 and in particular to conveyor 6034, it can be
seen that boneless beef carried on 6034 will be corned and deposited into meat
grinder 6038. Similarly, it can be seen that boneless beef carried on conveyor
6036
will be corned and deposited into meat grinder 6040. By adjusting the ratio of
fat
3S and muscle content of boneless beef carried on each conveyor 6006, 6008,
and 6010
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and adjusting the speed and therefore the volume of boneless beef carned on
each
conveyor, a single stream, indicated as stream 6042 in FIGURE 200, of boneless
beef
including fat and muscle tissue of a desired ratio can be provided and carried
forward
on conveyor 6034. Similarly, by adjusting the ratio of fat and muscle content
of
boneless beef carried on each conveyor 6018, 6020, 6022 and adjusting the
speed and
therefore the volume of boneless beef carried on each conveyor 6018, 6020, and
6022, a single stream, indicated as stream 6044 in FIGURE 200, of boneless
beef
including fat and muscle tissue of a desired ratio can be provided and carned
forward
on conveyor 6036.
Preferably, in this way, boneless beef stream 6042 may include boneless beef
with a fat and muscle content of about 95% lean muscle and about 5% fat with a
fat
content variation of about +/-0.3%. Preferably, boneless beef stream 6044 may
include boneless beef with a fat and muscle content of about 80% lean muscle
and
about 20% fat with a fat content variation of about +/-0.3%.
Boneless beef stream 6042 is carried forward by conveyor 6034 and
deposited into grinder 6038. ~~onveyor 6034 and grinder 6038 may be enclosed
inside a substantially sealed outer covering with a suitable gas such as
nitrogen
contained therein in such a manner so as to substantially exclude ambient air
from
presence therein. The boneless beef carried in stream 6042 is ground in the
grinder 6038 and transferred through tube 6046 and into hopper 6048. It can
also be
seen that the boneless beef stream 6044 is carried forward by conveyor 6036
and
deposited into grinder 6040. The conveyor 6036 and grinder 6040 may also be
enclosed inside a substantially sealed outer covering with a suitable gas such
as
nitrogen contained therein in such a manner so as to substantially exclude
ambient air
from presence therein. The boneless beef carried in 6044 is ground in grinder
6040
and transferred through tube 6050 and into hopper 6052.
Stream 6042 of ground beef is then transferred by a pump, such as a positive
displacement pump 6054, from hopper 6048 into and through static blending
tube 6056 and into hopper 6058. Stream 6044 of ground beef is then transferred
by a
pump, such as a positive displacement pump 6060, from hopper 6052 into and
through static blending tube 6062 and into hopper 6064. Preferably, positive
displacement pumps 6054 and 6060 can be fitted with variable speed drivers
Hoppers 6058 and 6064 can be substantially filled with a suitable gas such as
carbon
dioxide or any other suitable substance, and both hoppers 6054 and 6060 are
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arranged to have an adequate capacity to accommodate any quantity variations
in
normal production of boneless beef that may result from any variable
requirement.
Hopper 6058 is connected with three positive displacement pumps shown
as 6066, 6068 and 6070. Preferably, any number of pumps may be provided and
connected to hopper 6058. Similarly, hopper 6064 is connected with three
positive
displacement pumps shown as 6072, 6074 and 6076. Preferably, any number of
pumps may be provided and connected to hopper 6064. Preferably, each of the
positive displacement pumps shown as 6066, 6068 and 6070 can be fitted with
suitable, independently controlled, variable speed drivers such that any
required
quantity of ground boneless beef contained in hopper.6058 can be pumped
therefrom
at a desired velocity, and through a measuring device, such as the Epsilon GMS-
40
shown as 6078, 6080 and 6082. Similarly, each of the positive displacement
pumps
shown as 6072, 6074 and 607h can preferably be fitted with suitable
independently
controlled, variable speed drivers such that any required quantity of ground
boneless
beef contained in hopper 6064 can be pumped therefrom and through a measuring
device, such as the Epsilon GMS-40 shown as 6084, 6086 and 6088.
The Epsilon GMS-40-40 Meat Analyzer is a fat measuring device and is
commercially available from Epsilon Industrial, 2215 Grand Avenue Parkway,
Austin, Texas 78728. Specifications for the GMS-40 are available from this
supplier
and information is also available from their web site at www.epsilon-gms.com.
While
this component is specified herein, other suitable fat measuring devices can
be used
as an alternate for fat and/or muscle content measurement.
As can be seen in FIGURE 200, Epsilon GMS-40 measuring devices shown
as 6078 and 6084 are preferably attached directly to junction box X, Epsilon
GMS-
40 measuring devices shown as 6080 and 6086 are preferably attached directly
to
junction box Y and Epsilon.GMS-40 measuring devices shown as 6082 and 6088 are
attached directly to junction box Z. Suitably sized tubes connect pumps
directly to
corresponding Epsilon measuring devices as shown. The fat content of ground
beef
that is pumped by pump 6066 through the connecting tube and directly through
Epsilon GMS-40 measuring device 6078, is measured by device 6078. The fat
content of ground beef that is pumped by pump 6072 through the connecting tube
and directly through Epsil~u GMS-40 measuring device 6084, is measured by
device 6084. The ratio and percentage quantity of fat in each separate stream
of
ground beef pumped by pumps 6066 and 6072 can therefore be measured and
compared and the pumping rate of pumps 6066 and 6072 can be automatically
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adjusted according to the respective fat content of each stream of ground beef
so as to
provide a single stream of ground beef, after combining in junction box X,
with a
desired fat content. In this way selected quantities of boneless ground beef
can be
pumped directly from hopper 6058, containing ground beef from stream 6042 and
hopper 6064, containing ground beef from stream 6044, by pumps 6066 and 6072
respectively and through Epsilon GMS-40 measuring devices shown as 6078 and
6084 into junction box X. Similarly, selected quantities of boneless ground
beef can
be pumped directly from hopper 6058, containing ground beef from stream 6042
and
hopper 6064, containing ground beef from stream 6044, by pumps 6068 and 6074
respectively and through Epsilon. GMS-40 measuring devices shown as 6080 and .
..
6086 into junction box Y. Preferably, selected quantities of boneless ground
beef can
be pumped directly from hopper 6058, containing ground beef from stream 6042
and
hopper 6064, containing ground beef from stream 6044, by pumps 6070 and 6076
respectively and through Epsilon GMS-40 measuring devices shown as 6082 and
6088 into junction box Z.
Preferably, selected quantities of ground meat from stream 6042 and
stream 6044 can be combined in junction boxes X, Y and Z. By varying the
pumping rate of variable speed positive displacement pumps 6066 and 6068, a
selected blend of ground beef, with a pre-determined and known ratio of fat to
lean
muscle tissue, can be pumped into junction box X. The fat content of the
selected
blend of ground beef pumped into junction box X may be, for example,
about 10% +/- about 0.3%. Alternatively, the fat content of the selected blend
pumped into junction box Y may be, for example, about 15% +I- 0.3% and the fat
content of the selected blend pumped into junction box Z may be, for example,
about 17% +/- about 0.3%. By processing ground meats in this way, the fat
content
of any given production quantity of selected ground beef can be controlled
within a
narrow margin of variation, such as about +/- about 0.3% and the muscle and
fat
content selected as desired by adjusting the fat content of raw materials that
are
deposited onto conveyors 6006, 6008, 6010, 6018, and 6020 accordingly.
Furthermore, the energy required to blend the ground beef in the methods
described
herein is much less than is t~rpically required to produce ground meats using
currently
common industry practice.
The selected ground beef blend that is pumped into junction box X by way of
two streams from pumps 606b and 6072 is then transferred through blender 6090.
The selected ground beef blend that is pumped into junction box Y by way of
two
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streams from pumps 6068 and 6074 is then transferred through blender 6092. The
selected ground beef blend that is pumped into junction box Z by way of two
streams
from pumps 6070 and 6076 is then transferred through blender shown as 6094.
Blender 6056, 6062, 6092, and 6094 are all conveniently arranged with gas
injection ports shown as 6096. Preferably, gas injection ports 6096 are
arranged to
provide suitable gas, such as carbon dioxide, into blenders in such a way as
to ensure
that all ground meat that is pumped through the blenders is exposed to gas as
desired
and to an extent that will, for example, ensure that ground meat is saturated
with
dissolved suitable gas as required. Blenders 6056, 6062, 6090, 6092, and 6094
may
include suitably sized continuous static mixing equipment such .as may be
supplied
by Statiflo International, Macclesfield, Cheshire, UK. Preferably, any
continuous
blender may be integrated and located where indicated in FIGURE 200 by blender
reference numerals 6056, 6062, 6090, 6092 and 6094 or in any desired
configuration
that will ensure blending of ground meats as required.
The process described in association with FIGURE 200-201 shows a
combination of equipment that is configured to preferably produce a first 6042
and a
second 6044 stream of ground meat. Stream 6042 and stream 6044 are provided by
measuring the fat content of two pair of three streams of boneless meat where
streams 6012, 6014 and 6016 converge into a first stream 6042 and where
streams 6024, 6026, and 6028 converge into a second stream 6044.
Preferably, the fat and muscle (lean) meat content of stream 6042 is
determined by the following factors: The total quantity of boneless meat
deposited
onto the conveyors that include the streams 6012, 6014, and 6016 and the fat
and
muscle content of the boneless meat. The velocity of the streams 6012, 6014,
and
6016.
Correspondingly, the fat and muscle (lean) meat content of stream 6044 is
determined by the following factors: The total quantity of boneless meat
deposited
onto the conveyors that include the streams 6024, 6026 and 6028 and the fat
and
muscle content of the boneless meat. The velocity of the streams 6024, 6026
and
6028.
The fat and lean content of streams 6042 and 6044 can be determined by
adjusting the velocity of streams 6012, 6014, 6016, 6024 and 6028 and the fat
content of the boneless meat provided into streams 6012, 6014, 6016, 6026 and
6028.
Referring now to FIGURE 200, streams 6098, 6102 and 6106 are shown to be
connected directly to meat grinders 6100, 6104 and 6108. Grinders 6100, 6104
and
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6108 are arranged to fine grind the corresponding stream of ground meat and
transfer
directly into a corresponding portioning apparatus. Grinder 6100 is arranged
to fine
grind ground meat in stream 6098 and transfer the stream of fine ground meat
directly into portioning apparatus. Grinder 6104 is arranged to fine grind
ground
meat in stream 6102 and transfer the stream of fine ground meat directly into
portioning apparatus 6118. Grinder 6108 is arranged to fine grind ground meat
in
stream 6106 and transfer the stream of fine ground meat directly into
portioning
apparatus 6120. Preferably, any suitable variable speed driver may be
integrated into
equipment shown in FIGURE 200 and may be controlled by a central processing
computer.
The fat and muscle (lean) content of the stream of ground meat that is shown
as stream 6098 and which is delivered to grinder 6100, is determined by the
fat and
lean content of a quantity of ground meat from both stream 6042 via pump 6070
and
an additional quantity of ground meat from stream 6044 via pump 6076. The fat
and
muscle (lean) content of the stream of ground meat that is shown as stream
6102 is
also determined by the velocity (and quantity of ground meat pumped
therethrough)
of the ground meat stream pumped into junction box Z by pump 6070 and the
ground
meat stream pumped into junction box Z by pump 6076. By adjusting the speed of
pumps 6070 and 6076 the fat content of the ground meat in stream 6098 can be
selected. The fat content of the ground beef in the stream pumped by pump 6070
is
measured by the Epsilon (or other suitable fat measuring devices) fat
measuring
devices 6082. The fat content of the ground beef in the stream pumped by
pump 6076 is measured by the Epsilon (or other suitable devices) fat measuring
device 6086. The velocity of pumps 6070 and 6076 can therefore be controlled
and
set by the fat measurements provided by 6082 and 6086. In this way, a selected
fat
content can be produced by an automatic controller such as a computer that is
preferably connected to all associated pumps and fat measuring devices.
The fat and muscle (lean) content of the stream of ground meat that is shown
as stream 6102 and which is delivered to grinder 6104, is determined by the
fat and
lean content of a quantity of ground meat from both stream 6042 via pump 6068
and
an additional quantity of ground meat from stream 6044 via pump 6074. The fat
and
muscle (lean) content of the stream of ground meat that is shown as stream
6104 is
also determined by the velocity (and quantity of ground meat pumped there
along) of
the ground meat stream pumped into junction box Y by pump 6068 and the ground
meat stream pumped into junction box Y by pump 6074. Preferably, adjusting the
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speed of pumps 6068 and 6074 the fat content of the ground meat in stream 6102
can be selected. The fat content of the ground beef in the stream pumped by
pump 6068 is measured by the Epsilon (or other suitable fat measuring devices)
fat
measuring device 6080. The fat content of the ground beef in the stream pumped
by
pump 6074 is measured by the Epsilon (or other suitable devices) fat measuring
device 6080. The velocity of pumps 6068 and 6074 can therefore be controlled
and
set by the fat measurements provide by 6080 and 6074. In this way, a selected
fat
content can be produced by an automatic controller such as a computer that is
connected to preferably all associated pumps and fat measuring devices.
The fat and muscle (lean) content of the stream of ground meat that is shown
as stream 6106 and which is delivered to grinder 6108, is determined by the
fat and
lean content of a quantity of ground meat from both stream 6042 via pump 6066
and
an additional quantity of ground meat from stream 6044 via pump 6072. The fat
and
muscle (lean) content of the stream of ground meat that is shown as stxeam
6106 is
also determined by the velocity (and quantity pumped there along) of the
ground
meat stream pumped into junction box X by pump 6066 and the ground meat stream
pumped into junction box X by pump 6072. Preferably, by adjusting the speed of
pumps 6066 and 6072 the fat content of the ground meat in stream 6106 can be
selected. The fat content of the ground beef in the stream pumped by pump 6066
is
measured by the Epsilon (or other suitable fat measuring devices) fat
measuring
device 6078. The fat content of the ground beef in the stream pumped by pump
6072
is measured by the Epsilon (or other suitable devices) fat measuring device
6084
The velocity of pumps 6066 and 6072 can therefore be controlled and set by the
fat
measurements provided by devices 6078 and 6084. Preferably, any quantity of
ground meat with any selected fat content can be produced by an automatic
controller
such as a computer that is connected to preferably all associated pumps and
fat
measuring devices.
The configuration shown in FIGURE 200 preferably provides for automatic
production of three streams of ground meat 6110, 6112 and 6I 14, each with a
selected fat and lean content. A configuration of the required equipment, with
any
chosen capacity and size to suit any rates of production, can be arranged to
produce
any suitable number of one or more streams of ground meat, each with a
selected fat
and lean content, as may he d,;sired.
Overwranpi~ and Web Stretching-Apparatus and Method
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Controlled Atmosphere Packages (CAP) are packages prepared or treated in
an oxygen deficient atmosphere to remove or prevent the accumulation of oxygen
within the package materials. Packages are overwrapped with apparatus having
web
stretching capabilities in one aspect of the invention.
Referring to FIGURES 202-204, details of a controlled atmosphere packaging
system according to the present invention is shown. FIGURE 202 shows a section
of
PVC web materia16200 is about 0.0008" in thickness. Preferably, any suitable
thickness or gauge can be used. Preferably, web 6200 can be coated, fully or
in part
and with any desired pattern such that parts of the web remain clear and other
coated
parts may be opaque. Web 6200 is shown with a suitable heat sealing coating
that
has been applied in two continuous strips along the edges of the web such that
a
continuous, central strip remains clear. The width of the clear section 6202
central
strip may be about 50% of the total width of the web 6200 and the outer two
printed
sections 6204 of about equal width being about 25% of the full width each, of
web 6200 such that when formed into a tube 6214 , a fin seal, 6208, can be
provided
by heat sealing there together. Preferably, a sealed tube including an upper
clear
section through which the tray 6210 can be seen and a lower, opaque section
6212
through which tray 6210 cannot be seen.
Web 6200 can be processed by a modified Hayssen RT1800, for example, in
such a manner so as to form a continuous tube 6214, and shown as PVC web
material
"fin" sealed tube. Suitable packaging trays such as Mono-PakT"" trays 6210
that have
been filled with perishable goods such as ground beef can be inserted into the
tube 6214, by automatic devices (not shown) or any other suitable devices, and
lateral stretching can be induced into the tube 6214. The lateral stretching
can cause
the tube 6214 material to firmly contact the tray 6210 and hold the perishable
goods
contained therein firmly. After the trays 6210 are located inside the fin
sealed
tube 6214 the tube can also be stretched longitudinally. After the
longitudinal
stretching of the tube 6214, lateral fin seals, followed by severing of the
tube 6214
adjacent to the lateral fin seals, can be provided so as to provide a fully
and
hermetically sealed package as shown in FIGURE 204. The lateral and
longitudinal
stretching can be provided pri or to sealing and severing of the lateral fin
seals.
Longitudinal stretching can be effected by the modified Hayssen RT1800 after
modification and as generally descr'bed below.
Referring now to FIGURE 201, items 6000, 6002 and 6004 shown thereon
include three modified versions of the Hayssen RT 1800 (modified RT1800), flow
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wrapping packaging machine. The modifications to each item 6000, 6002 and 6004
refers to the inclusion of a sub-assembly to each machine which is detailed in
a cross-
sectional sketch shown as FIGURES 205-206 so as to enable processing and use
of
pPVC web material on the RT1800 packaging machines. The following disclosure
details the modification that can be incorporated in the RT1800 so as to
facilitate the
use of pPVC web material as the over wrapping packaging material used thereon
to
over wrap such packages as the Mono-Pak EPS foam tray.
The Hayssen RT 1800 is manufactured by Hayssen, a division of the Barry
Wehmiller Company, which is located at 225 Spartangreen Boulevard, Duncan,
SC 29334. Other information describing the RT1800 can be obtained from the
following web site: www.hayssen.com . The RT 1800 incorporates a "rotary die
wheel" in such a manner so as to provide a continuous movement of the web
during
machine operation and package sealing. This arrangement provides a method to
process and seal packages more rapidly than other types of over wrapping
machines
but hitherto the RT 1800 has not been used to over wrap packages with pPVC
(plasticized polyvinylchloride) web material.
It is desirable to use pPVC web material, in this particular application,
because of its most suitable physical characteristics for the packaging of
fresh meats
such as ground meats and poultry pieces. However, the standard RT1800 is not
ideally suited to process pPVC web material and in order to ensure efficient
stretching and sealing of the pPVC web the modifications to the RT1800 are
necessary.
The HAYSSEN RT1800 rotary die wheel concept operates on the principal of
maximizing dwell time. Individual MAGNUM sealing dies are released on demand
as packaging material and product move through the machine. The RT1800
packaging equipment is well known to those skilled in the arts and all details
of the
RT1800 machine construction are readily available from the manufacturer to
potential end users of this popular packaging equipment.
Packaging materials nay include the Mono-Pak~ EPS tray, over wrapped
with plasticized PVC web material, (supplied by AEPBorden or Huntsman).
It should be noted that the readily available, low cost, pPVC web material as
intended for use in this application, has the following properties:
1. Glass clarity
2. Stretch and high extensibility (SO - 100% before exceeding elastic
limit)
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3. Memory, providing a "return to its original condition" after stretching
(within elastic limit).
4. Standard, enhanced oxygen permeability.
5. Rapid heat sealing to itself.
6. Rapid hot "knife" cutting, providing clean cut edges.
7. Generally, the basic RT1800 machine, as manufactured by Hayssen,
would remain similar to existing standard equipment, except for the
modification
described herein. The existing longitudinal fin or lap sealing (as shown as
6208, in
FIGURE 203) may require adjustment to facilitate an enhanced lateral web
1C "stretching" capability for a pPVC web. The longitudinal web stretching
apparatus,
as disclosed herein, should be capable of installation without major
structural and
basic frame modifications to the existing equipment.
FIGURES 205-206 include an assembly intended for optional and
interchangeable use on standard Hayssen RT1800 or similar packaging machines,
shows detail of the following items.
Referring now to FIGURES 205-206, the apparatus constructed according to
the present invention includes a die wheel 6216 shown in part with the axis of
the
wheel marked as axis 6218. A number of die carriers 6220 are also shown. The
complete die wheel 6216 and drive is not shown, however, since a person
skilled in
the art will readily recognize the proposed modification when viewing the
representation of the die wh.;el with die carriers as shown. The wheel die
assembly
fixture may include a standard Hayssen component modified to suit convenient
attachment of the "Stretch Web Clamp Assembly".
The packaged product may include any of the number of trays disclosed
herein, for example, the tray shown in FIGURE 55, over wrapped with standard
(with enhanced 02 permeability) plasticized PVC web material, (supplied by
AEPBorden or Huntsman). The EPS material can be produced with a surface finish
that will not "cling" to the pPVC web material.
Plasticized web of stretch over wrap material is preferably printed or plain
material can be used. Preferably, partial coating of the inside web surface,
with a low
melt heat activated coating ~HAC), can provide for improved performance.
A full width, lateral, impulse, heat sealing, element (e.g. cut from Inconnell
SS sheet or other "marine" grade, SS sheet material) is installed by
attachment to a
horizontally disposed rigid and suitably heat tolerant, non metallic base.
Preferably,
compensation for normal expansion and contraction of the element, during
heating
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CA 02387349 2002-04-03
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and cooling, can be provided. The element is covered with suitable material
(PTFE)
so as to provide a "non-stick" surface that will not "cling" to pPVC web. The
heat
sealing assembly is arranged with the heating sealing element in close,
adjacent and
parallel disposition to a full length strip of a portion of the outer surface
of
roller 6224, as shown in the sketch. When held together under suitable
pressure with
two webs of pPVC material located between member 6228 and roller 6224, a full
length and hermetic seal between the two webs can be produced.
An alternative heat sealing device includes a heat bank. Use of either impulse
or heat bank devices may be determined by manufacturer preference. In the case
of a
heat bank device, the clamping bars 6230 and 6232 would be separated and
insulated
from the adjacent heat bank members 6230, 6232 and 6234, 6228 would require
independent, return spring mounting. A suitable distance or gap (for
insulation and
sealinglcutting control devices), between the elevation of the clamping
surface of the
clamping bar and the elevation of the contact surface of the heat bank, would
be
required. This would allow clamping of the webs) by the clamping bar with
subsequent web clamping, sealing and cutting by the heat bank.
Web clamping bar 6232 includes a strip like component that is arranged in
parallel and close proximity to assembly 6228 so as to provide a clamp to web
6236
at the same time and with similar clamping effect as member 6232 when roller
6224,
6232 and member 6228 are arranged so to do.
Rubber coated roller with camlclutch bearing 6224 includes a heat resistant,
rubber coated and suitably ground, solid steel, hardened, rigid roller. Roller
6224 is
located between two end plates 6240 and 6242 (not shown) and mounted thereto
by
bearing (one located at each end of the roller 6224. The bearings are of
identical
dimensions with "camlclutch" feature provided in one only bearing. Such
arrangement allows the roller ti224 to rotate in a clockwise direction only.
Impulse heat sealing element assembly is arranged to mirror image
assembly 6228.
Web clamping bar 6230 is arranged to minor image web clamping bar 6232.
Rubber coated roller with camlclutch bearing 6244 includes a heat resistant
rubber coated, solid steel, hardened, rigid roller identical to roller 6224
but with a
"cam/clutch" feature provided in one only bearing so as to allow roller 6244
to rotate
in a counter clockwise direction only, as shown by an arrow in the sketch. The
surface finish on both rollers 6244 and 6224 can be arranged so as to cling to
web 6236 when contact occurs between suitably tensioned web 6236.
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Two end plates 6240 and 6242 are arranged to rigidly retain rollers 6244 and
6224 in relative, respective, parallel and separated proximity, allowing the
rollers to
rotate as described above. Both end plates may be fitted with suitable coil or
flat
return springs to hold the rollers 6244 and 6224 in a normal position at a
desired
distance from bars 6230 and 6232 and heating elements 6234 and 6228.
A cam follower is mounted to each end plate 6240 and 6242 so as to engage
with cam tracks (not shown but mounted to main frame of FFS machine) arranged
to
provide a web sealing pressure to web 6236 by causing depression of end plate
return
springs.
The web.stretching bar 6226 includes a strip of suitable material profiled as
shown and provided with an outer surface treatment that can cling to pPVC web
material. Web stretching bar 6226 is attached to two pneumatic cylinders [6246
(shown) and 6248 (not shown)] with slotted fixture apertures so as to
eliminate
locking that may otherwise occur during operation. The web-stretching bar is
shown
in a normally withdrawn (closed) position and also in a fully extended
position, by
dotted lines. When in the normally closed position, the upper and highest edge
of the
bar extends along its full length and is in permanent contact with webs) 6236.
This
contact is arranged so as to ensure a suitable tension is induced in the
web(s). This
can provide a condition allowing the free movement (by stretching) of the web
material over roller's 6244 and 6224 only inwardly and toward the web-
stretching
bar. The cam/clutches installed in the rollers will not allow the web to be
pulled
away from the web-stretching bar. Preferably, web 6236 can be freely stretched
but
is essentially clamped by its tensioned and intimate contact with the surface
of the
rollers and the upper edge of the web-stretching bar.
The Rollers Assembly, includes two off each rollers, 6244 and 6224,
endplates 6240 and 6242, carp followers 6250 and 6252, fasteners and return
springs
as required. When assembled with the complete web stretching assembly and in a
normally closed position, a suitable gap is maintained between the rollers and
the
adjacent contact surfaces o~ items 6230, 6234, 6232 and 6228, thereby allowing
free
stretching of the web 6236, by activation of web-stretching bar 6226.
A pneumatic cylinder is shown, attached to the web-stretching bar 6226 to
extend bar 6226 to the position shown by dotted lines and thereby stretch the
web 6236. Preferably, two cylinders would be provided. Compressed air flow and
pressure controls can be arranged to activate cylinders 6246 and 6248 so as to
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CA 02387349 2002-04-03
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optimize induced tension in web 6236. Any suitable alternative method of web-
stretching bar activation and control may be used.
A vacuum tube may be conveniently located so as to provide a method of
removing scrap web material (excess material for accumulation in a canister.
In this configuration independent pivoted mounting of each roller and
clamping assembly 6256 and 6258 is provided. Each assembly 6256 and 6258 is
held in the normal central position (close together), by controlled return
springs.
Activation of the web-stretching bar 6226 will cause the two assemblies to
move
away from the central position until contact with the packages 6254. Such an
arrangement will provide consistent web stretching with a final web heat
sealing at a
constant distance from the package. In this configuration end plates 6240 and
6242
would require slotting to accommodate outward rotation of each assembly.
Products, pre-filled with ground beef portions/blocks, are automatically
loaded onto the entry end of the Hayssen FFS equipment. Orientation of the
products
may be in normal or inverted disposition. A normal disposition (with package
"open
top" side facing upward) would require a side fin or lap web seal, whereas an
-inverted disposition would require a bottom web seal. Normal operation would
include longitudinal sealing after induction of maximum stretch in web 6236.
Lateral
sealing would occur after longitudinal stretching by web stretching bar 6226.
Activation of the web-stretching bar would not commence until closure of the
subsequent closing of the closest clamp to its rear, on the wheel. In this way
gradual
stretching of the pPVC over wrap, during the wheel rotation, can occur until
the
desired level of stretch and/or tension is achieved when web heat sealing and
simultaneous cutting could be provided immediately prior to ejection of the
finished
package(s). The finished packages could be ejected in a normal and upright
disposition, assuming that the packages were loaded in an inverted
disposition,
alternatively, the packages could be inverted after ejection if the packaging
had been
loaded onto the RT1800 packaging machine in a normally upright position.
By incorporating the move described modification in the Hayssen RT 1800
packaging machine a web stretching arrangement is provided to stretch the over
wrap
material 6236 during the norm ~1 rotation of the die wheel. It is anticipated
that, in
view of the rapid heat sealing and cooling characteristics of thin gauge
(0.0008")
pPVC, the operational speed of the Hayssen RT 1800 could be increased to more
than 1800 feet per minute.
Blending Apparatus
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Referring now to FIGURES 207-208, details of an apparatus that can be used
to blend one or more individually controlled streams of ground meats that can
also be
combined with selected conditioning gases or suitable materials and blended
together
to produced a single stream of blended and conditioned ground meat, is shown.
FIGURE 208 shows a diagrammatic representation of three streams of ground
meats,
6300, 6302 and 6304 that are each pumped through conduits shown as 6306, 6308
and 6310 at independently controlled velocities. Preferably, the apparatus can
be
arranged to provide one or more streams of ground meat but most preferably
three
streams will be provided where, for purposes of example, one stream may have
an
approximate fat content of about 20%r a second stream has an approximate fat
content of about 30% and a third stream has a fat content of about 7%.
Preferably,
the content of each stream can be varied as may be required. Conduits 6306,
6308
and 6310 can be arranged to house independent measuring devices such as the
Epsilon GMS-40 in-line measuring equipment. The streams of ground meat can be
pumped, by positive displacement pumps that are independently driven by
variable
speed drivers, at velocities that are continuously adjusted directly
corresponding with
- the respective fat and muscle content of each stream such that when the
three streams
are subsequently combined together into a single stream of ground meat, the
fat and
muscle content of the combined stream is substantially consistent and constant
at a
chosen composition with percentage quantities of fat and muscle held within a
range
of less than about +l- 1 % fat content. Furthermore, even though the velocity
of each
separate stream of ground meat is independently varied according to the fat
and
muscle content of the respective stream, the resultant single, combined stream
can be
arranged, by adjusting the velocity of each of the streams 6300, 6302 and
6304, to be
at a constant velocity, volume and production rate and as desired within the
capacity
of the apparatus.
Referring now to FIGLfRE 207, a housing 6318 is arranged with six suitably
profiled blades 6312 that are attached together at a central axis 6314 which
in turn
are attached to a driver 631 ~. Blades 6312 are attached at axis 6314 and to a
driver 6316 in such a manner that blades 6312 can be rotated within the
confinement
of housing 6318, which is sealed and separate from external atmosphere.
Blades 6312 are arranged so as to not contact but be in close proximity to the
internal
surfaces of the housing 6318. A total of six spaces or segments shown as 6320,
are
therefore arranged between the blades 6312 that include equal volumes and a
recess 6322 is provided at the axis of the blades 6312 so as to allow direct
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communication between the spaces. The direct communication between the
spaces 6320 may be provided or otherwise, if so desired, not provided. A
conduit 6324 is attached to the housing 6318 with a spiral auger 6326
contained
therein. Auger 6326 may be directly connected to suitable driving devices (not
S shown) that can provide a variable speed rotating of the auger as required
to further
blend the single stream of combined ground meats. Preferably, the streams of
ground
meat can be transferred directly through housing 6318 and into conduit 6324.
Blades 6312 can be rotated about the axis by driver 6316 at a suitable speed.
Preferably, a series of conduits 6330 can be arranged to have direct
communication
with the spaces between the blades 6312, as they rotate adjacent thereto, so
as to
allow injection of any suitable substances such as carbon dioxide into the
spaces at
any suitable pressure ana from a suitable source and in controlled quantities.
Preferably, a known quantity of ground meats can be transferred from conduits
6310,
6308 and 6306 into spaces 6320 with a known and controlled quantity of gas or
other
suitable substance provided therein via conduits 6330, as spaces 6320 rotate
about its
axis 6322, and pass through conduits. Blades 6312 are arranged with edges that
are
parallel and in close proximity to the internal surfaces of housing 6318. As
ground
meat is transferred from the conduits into the spaces 6320 at controlled rates
and
quantities, controlled quantities of carbon dioxide can also be transferred
into the
spaces. Preferably, selected quantities of ground meat and carbon dioxide can
be
transferred, consecutively, into spaces 6320 and transferred as a single
volume of
materials into conduit 6324 and blended therein, in a continuous process of
measured
amounts of ground meat and carbon dioxide. Preferably relatively small
quantities of
measured amounts of ground meat with a selected quantity of carbon dioxide can
be
blended most efficiently in a continuous process. Such a method of blending
can
provide a method of thorough and accurate blending with a minimum energy
requirement. It can now be seen that the apparatus herein described can be
used to
efficiently produce a blend of ground meats that has been pre-conditioned with
such
substances as carbon dioxide and at a chosen rate of production within the
capacity
of the apparatus. The apparatus shown in FIGURES 207-208 can be enclosed in
any
suitable jacket or containr_lent so as to allow any suitable heat exchanging
medium to
contact the housing and thereby, by a heat exchanger means provide precise
temperature control of the apparatus and any goods processed therethrough. The
temperature control can be precise and set at any suitable temperature within
any
suitable temperature range. In a preferred embodiment the conduit 6324 may
include
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a suitable portion of static mixing conduit as may be supplied by Statiflo,
alternatively auger 6326 may be driven by a suitable driver at any suitable
speed.
Conduit 6324 may be connected to a suitable positive displacement pump or
other
suitable pump so that any goods that may have been processed by the apparatus
shown in FIGURES 207-208, can be directly transferred thereto and then pumped
at
a desired rate into suitable holding containers or directly into further
processing
and/or packaging equipment.
Pre-conditioning Apparatus
Referring now to FIGURE 209 a side elevation of a ground meat pre-
conditioning apparatus intended for use in pre-conditioning ground meats and
any
other suitable goods, is shown.
Preferably, the pre-conditioning apparatus is intended for use to pre-
condition
such perishable goods as ground meats in a continuous process (as opposed to a
batch process where the perishable goods may be transferred into a pressure
vessel
which is then sealed prior to removal of any undesirable gases and provision
of
desirable -and suitable gases therein). The continuous process may be arranged
so
-that the ground meats are continuously transferred through an entry orifice
that
restricts the transfer into a vessel in such a manner so as to provide a seal.
The vessel
can be filled with any suitable gas at any suitable pressure and maintained at
any
suitable temperature. The vessel can be arranged to accommodate any suitable
quantity of the ground meats for any suitable period of time or residence
time. The
ground meats can be arranged to exit the vessel after a suitable period of
time by
transfer through a restricting exit orifice. The exit orifice and the entry
orifice can be
arranged to restrict transfer of ground meats therethrough in such a manner so
as to
prevent suitable gases provided in the vessel from escaping therefrom.
A meat hopper 8000, meat grinder 8002 and drive motor 8004 is arranged to
grind meat which passes from the meat grinder 8002 directly into a first
conical
shaped connection to a tube 8010. Tube 8010 includes a length of high pressure
stainless steel tube or other suitable material, and connects with a second
conical
shaped connection 8012 to grinder 8008. First conical connection 8006 is
provided
so as to elevate the pressure of the ground meat as it is transferred from
said
grinder 8002 to tube 8010. Tube 8010 may follow any convenient path and is
arranged to have any suitable length and, save two end portions of convenient
length,
is located in an insulated tank enclosure 8014 that contains a suitable liquid
cooling
medium 8016, such as brine or glycol. Tube 8010 can be completely immersed in
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the cooling medium 8016 which can be maintained at a desired and suitable
temperature that may be set between about 32 and about 33 degrees F. Another
tube 8018 connects the tank enclosure 8014 to a heat exchanger 8020 via a
suitably
sized pump 8022. Tube 8024 connects the tank enclosure 8014 to the heat
exchanger 8020. The pump 8022 is arranged in such a manner that cooling
medium 8016 can be pumped at a controlled rate through the heat exchanger 8020
so
as to maintain 8016 at a desired temperature. Tube 8026 connects the heat
exchanger
with a source of suitable gas 8028, such as carbon dioxide, provided at a
suitable
volume, temperature and pressure. Tube 8030 is arranged to carry any excess
quantities of gas 8028 away from heat exchanger 8020 as may be required.
Tube 8026 is arranged to connect gas 8028 supply to tube 8010 via the heat
exchanger 8020 and connects to the tube 8010 at connection 8032. Connection
8032
is arranged to allow a constant flow of gas 8028 directly into or through
suitable
valves attached to tube 8010 at a position approximately equal distance from
each
1 S end of tube 8010.
Meat, which may have been dipped in or sprayed with any suitable
-bactericide such as natural citric acids, is loaded into the. meat hopper
8000 at a
convenient rate and is processed by grinding in the meat grinder 8002. Meat
grinder 8002 is driven by drive motor 8004 at a suitable speed and ground meat
which may be coarse ground, is forced into the first conical connector at a
suitable
pressure. Ground meat is therefore forced under suitable pressure into and
along
tube 8010. Due to the immersion in the medium 8016, the temperature of the
tube 8010 is approximately equal to the temperature of the medium 8016 and
therefore temperature of the coarse ground meat is affected and will be either
heated
or cooled accordingly. The coarse ground meat can be held in the tube 8010 for
such
a period of time that will allow the temperature of the coarse ground meat to
become
substantially equal to the temperature of the medium 8016 by transfer of heat
through
the walls of the tube 8010. The coarse ground meat can pass through the entire
length of the tube 8010 and into the second conical shaped connection 8012 to
grinder 8008. Grinder 8008 i~ driven by motor 8034 and is arranged to grind
the
coarse ground meats and can be further arranged to produce fine ground meat
from
coarse ground meat. A speed controller can be arranged to control the speed of
motor 8034 and the corresponding production rate or output of the grinder 8008
can
thereby be controlled as may be required to correspond with the speed and
output of
the grinder 8002. Suitable gas 8028 can be injected at a suitable rate, into
tube 8010
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via tube 8026, at a suitable temperature which may be equal to the temperature
of
medium 8016, and at a suitable pressure which may be about 200 psi. Gas 8028
may
be carbon dioxide and can therefore dissolve into coarse ground meat as it
passes
through tube 8010. The diameter of tube 8010 can be arranged to be smaller
than the
internal diameter of grinders 8002 and 8008. The source of gas 8028 can be
arranged
to provide gas at a suitable pressure and in quantities sufficient to meet the
desired
rate of absorption by the ground meat passing through the tube 8010 and also
the
quantity required to maintain medium 8016 at the desired temperature. If the
volume
of gas 8028, required to maintain the suitable temperature of medium 8016
exceeds
the volume of gas required to be provided into tube 8010 then excess gas can
be.
vented to atmosphere through tube 8030. Conversely, if the quantity of gas
8028
required to be provided into tube 8010 is greater than the quantity required
to
maintain the temperature of medium 8016 at a suitable level, such that the
temperature of medium 8016 is otherwise thereby depressed, then a heater can
be
provided. The heater can be arranged to heat gas 8028 as required to ensure
and
maintain the temperature of medium 8016 as required.
y A suitable device to vary the quantity of medium 8016, that is pumped by
pump 8022 through tube 8018 can be provided. Gas 8028 may be injected into the
tube at any suitable gas pressure that may be 200 psi, however, under such
conditions
gas 8028 will be soluble and therefore dissolve in liquids contained in tube
8010,
resulting in a pressure drop as the gas and liquids are transferred along tube
8010
toward grinder 8008.
The quantities of gas b028 and ground meat present in tube 8010 and the
length of tube 8010 can be arranged so as to allow partial or complete
dissolving of
gas 8028 into ground meat while still present within tube 8010.
It may be important that ground meats are not exposed to conditions that will
either partially or fully freeze the ground meats during processing in the pre-
conditioning apparatus. Accordingly, heat exchanger 8020 can be arranged so as
to
provide a method of transferring heat between the ground meat within the tube
8010
and gas 8028, and medium 8016 as required and in such a manner that will
inhibit
and/or prevent freezing of the ground meat during the pre-conditioning
process. Heat
exchanger 8020 can be arranged so as to provide a method to ensure that,
irrespective
of the temperature of the meat provided in the hopper 8000, the temperature of
the
ground meat 8036 will be maintained at a suitable temperature that may vary
within a
limited range of plus or minus about 0.5 degrees F. Ground meat 8036 can be
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CA 02387349 2002-04-03
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processed in the pre-conditioning apparatus so as to saturate or partially
saturate, to
any suitable level, the ground meat with any suitable dissolved gases.
Preferably, any suitable gas such as nitrogen may be provided directly into
grinder 8002 through tube 8038 shown, so as to substantially purge and remove
any
air that may be present with the meat in hopper 8000. The quantity of meat
transferred along tube 8010 and the quantity of gas 8028 injected into the
tube 8010
at connection 8032 can be measured and controlled with motors 8004 and 8034
and
pump 8022, by a programmable logic controller (PLC). Ground meat pre-
conditioning apparatus may be controlled by any suitable controller so as to
provide
an automatic process. The apparatus can be manufactured to suit any required
rate of
production.
An auger or other pump to assist in transfer of the ground meat through
tube 8010 may be located between the meat grinder 8002 and the first conical
connection 8006 or any other suitable location.
A suitable tube (not shown) and valves to open and close the tube, may be
provided to connect the second conical connection 8006 to the meat grinder
8002
thereby allowing any re-cycling of ground meats that has passed through tube
8010.
Such a re-cycling would allow for further pre-conditioning of any goods that
had not
been correctly processed during a first passage through tube 8010.
Vents to allow excess gas may be provided at suitable locations in tube 8010
or at any other suitable location.
Ground meat 8036 may be further processed by direct transfer from
grinder 8008 to any other suitable processor such as a pattie forming machine
or
directly into a vacuum packaging machine. The transfer of the ground meat 8036
may be via an enclosed mode of transfer so as to eliminate or minimize
exposure to
ambient atmosphere prior to further processing or packaging.
The pre-treatment of any perishable goods, such as ground beef, as described
herein can enhance the keening qualities of the perishable goods. Preferably,
the
goods can be placed into a sealed pressure vessel with a known quantity of
suitable
gases at any suitable pressure for a suitable period of time and maintained at
a
suitable temperature. Preferably, the suitable gas pressure may be selected at
a
pressure above ambient air pressure. The quantity of the suitable gas can be
increased by providing additional controlled quantities into the pressure
vessel as
desired. Preferably, the suitable pressure, time and pre-treatment temperature
can be
precisely controlled and arranged so as to allow the suitable gas to dissolve
into any
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CA 02387349 2002-04-03
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water and oils and/or other substances contained in the goods. The quantity of
suitable gas that dissolves into the goods, can therefore be controlled and
may be
equal to the maximum amount that can dissolve therein at any suitable gas
pressure
and thereby saturating the goods with the suitable gas in solution.
Preferably, a
known amount of gas can be dissolved into the goods at a given gas pressure
and pre-
treatment temperature. The perishable goods can then be removed from the
pressure
vessel and packaged in any suitable packaging such as a hermetically sealed
vacuum
package that may include a gas barrier plastic pouch of suitable size.
Preferably,
after vacuum packaging the perishable goads into the suitable gas barrier
pouch at
ambient air pressure, the goods can be stored in ambient atmosphere and
maintained
within a suitable storage temperature range. The suitable storage temperature
range
can be maintained at a suitable level above the pre-treatment temperature.
Preferably
a quantity of dissolved gas can emerge from the perishable goods and partially
inflate
the gas barrier pouch. The size of the gas barrier pouch can be arranged to
accommodate the partial inflation without damage to the hermetic sealing of
the
pouch. The emerged gas then contained within the gas barrier pouch can enhance
the
keeping qualities of the perishable goods. The emerged gas can subsequently
dissolve into the goods a,ain and re-emerge corresponding to any temperature
fluctuations that may occur within the suitable storage temperature range.
Preferably, a quantity of free suitable gas can be maintained in gaseous
condition
with the goods within the packaging and the quantity of free gas can be
arranged and
controlled at a minimum suitable quantity. However, if the temperature of the
goods
in the gas barner pouch is increased as a result of failure of refrigeration
or any other
type of temperature "abuse" to an unacceptable high level (for example 50
degrees F)
for an unacceptably prolonged period so that the quality of the goods is
compromised, additional gas will be released from solution therein and cause
further
expansion of the gas barner pouch. The gas barrier pouch can be sized such
that it
will accommodate a known amount of released gas. The known amount of the
released gas can be limited to such an amount that will be released by goods
at an
acceptable temperature and if the acceptable temperature is exceeded any
additional
release of gas can cause rupturing of the gas barrier pouch (or any other
suitable
packaging material). Rupturing of the packaging, therefore, can be used as an
indication that goods have endured an unacceptable level of abuse.
In yet another preferred embodiment, goods may be treated by exposure to an
adequate quantity of suitable gases at a suitable temperature and pressure in
such a
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manner so as to allow a specific quantity of suitable gas to dissolve in the
goods.
The specific quantity of suitable gas can be arranged so as to equal an amount
that
will saturate the goods with the suitable gas dissolved therein to a suitable
level. The
goods can then be packaged in any suitable packaging of suitable size which
may
include an additional quantity of suitable gas contained and hermetically
sealed in the
suitable packaging with the goods therein. Preferably the total volume of the
goods
with specific quantity of suitable gas dissolved therein plus additional
quantity of
suitable gas can be arranged so as to completely fill the suitable packaging
of suitable
size to provide a finished package with goods and the gas sealed therein.
Therefore,
any change in temperature of the finished package and the goods therein will
result in
a change in the total volume of the goods plus the additional quantity of
suitable gas.
The packaging, the goods with the suitable gas dissolved therein plus the
additional
quantity of suitable gas can be arranged so as to accommodate a known
variation
(increase or decrease) in the total volume, as desired. The known variation
can be
used as an indicator of the temperature history of the finished package. For
example,
the packaging may be provided with a valve indicator that will permanently
open or
break if the temperature of the finished package with the goods, increases to
an
unacceptable level and extent so that the volume of gas therein and
corresponding
pressure thereof increases to an unacceptable level.
Primal Meat Portion Shaping-Apparatus
Referring now to FIGURE 210, an apparatus for shaping primal meat
portions includes a container 2800 and plug 2802. Container 2800 and plug 2802
may be manufactured by injection molding a plastics material such as nylon or
alternatively a gas permeable and porous material such as a chemically foamed
polypropylene or polyester plastic material. Alternatively the container and
plug
may be manufactured from a stainless steel mesh. The apparatus includes a
container 2800, with lugs 2842 and 2844 that are engaged with rails 2814 and
2846.
The rails may include, for example, parallel, round, stainless steel bars,
suitably
mounted to framework, conveniently spaced apart and horizontally disposed,
extending for any convenient and desired length that may have bends and curves
allowing for the powered ~r manual movement of the containers 2800 there along
while maintaining engagement between the lugs and horizontal rails. The
cross-section shown in FIGURE 210 provides detail of the container, plug and
apparatus through one cross-section only. Other views are not considered
necessary
since the profile of the container and plugs, across a different section may
be similar,
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differences may only include variations in for example, length. The mechanism,
container and plug may be arranged in any suitable and desired shape and size
to suit
the requirements for each portion of pre-rigor fresh rcd meat. Generally, the
internal
volume of an assembled container with a corresponding and matching plug in
position, is approximately equal to the volume or displacement of the
corresponding
fresh red meat primal shown as 2822. The plug 2802 can slide inside the
opening of
the corresponding container 2800 such that rim 2810 remains in contact with
the
inside surfaces of the container wall. The displacement of similar fresh red
meat
primal that have been harvested from different animals will vary. Therefore,
in order
to accommodate the variation of similar fresh red meat primals, the internal
volume,
shown as space 2812, of the assembled container and plug can be adjusted to
suit the
actual displacement of the corresponding fresh red meat primal. The fresh red
meat
primal 2822 is located in the container and a plug 2802 is located inside the
upper
portion of the container such that substantially all air has been excluded
from the
enclosed cavity containing the primal, under the plug. The container 2800 is
shown
located in close proximity with a press base 2848, with perimeter wall 2850.
The
press base is mounted onto an elevating shaft 2852 thereby providing a means
to
elevate the press base so as tv contact and retain the lower portion of the
container 2800, and also lower the press base parallel with shown center line,
such
that the 2800 will be suspended on the rails 2814 and 2846 and the press base
will
not contact or interfere with 2800 and allow the container to slide freely
along the
length of the rails when the press base is in a lowered position. An assembly,
including an outer wall 2816 with a series of driven, concentrically mounted
clamps,
about a central clamp and located therein, is positioned directly above and
aligned
with the press base 2848. The wall 2816, and clamps marked 2818, 2828, 2826,
2824 are independently driven in a reciprocating and vertical direction,
parallel with
the center line shown. A concentric slot 2860 is provided around the perimeter
of the
clamp 2816, such that a vacuum can be applied to the upper side of the
container. A
side view of an alternative profiled plug 2856 is shown in FIGURE 211.
The container includes a rectangular, round or oval plan profile with a flat
bottom and substantially vertical walls extending upwardly from the base. The
base
and walls are continuously attached via a suitably radiused confluence. Two
lugs are
conveniently located, one on each opposing side of the container. The
consistency of
container 2800 is such that it will deform slightly when subjected to pressure
but will
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i
CA 02387349 2002-04-03
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return to its original shape when the pressure is released. A bevel 2806 is
molded as
shown to provide an easy penetration by the plug 2802.
Plug 2802 includes a "rigidly" flexible, relatively shallow cup with a flat or
profiled face 2808, and flexible walls with tapering thickness and flaring
outwardly
at an angle of about 5 degrees from vertical. The upwardly extending walls are
connected to the plug face with a radius therebetween as shown. The upper rim,
2810, of plug wall is tapered and flexible.
The profile and dimensions of the plug are arranged so as to provide an easy
penetration into the matching opening of the corresponding container. However
as
the plug penetrates the container opening, the tapered disposition of the
walls
provides for intimate contact and sealing between rim 2810 and inner surface
of
container vertical walls. The container and plug, when assembled together,
provide
an enclosed space 2812 that is substantially sealed and isolated from external
atmosphere. Space 2812 has a volume that can be varied within the limitations
of the
container, by moving the plug position, relative to the container, within the
container.
In all positions, however, the intimate contact between rim 2810 and the
inside
surface of the container walls is maintained in a substantially "airtight"
fashion.
Preferably, containers and matching plugs of different sizes and suitable
profiles rnay be manufactured to suit various sizes of primal portions of
fresh red
meat, however, in each case the container and corresponding plug are sized to
provide a limited but variable i:~ternal volume of space shown as 2812.
Preferably,
primal meat portions, of limited varying size and profile can be accommodated
within the same containers provided for similar primal portions.
It should be noted that animals used as a source of primal meat portions vary
in profile and size but are typically graded prior to slaughter such that the
corresponding primal portions are approximately similar.
This present invention provides for de-boning of carcasses that are still in
pre-
rigor mortis condition, immediately after animal slaughter and preparation
while the
temperature of the carcass remains close to normal body temperature. The de-
boning
of the carcasses at such temperatures is very much easier and provides for
much more
rapid completion of the de-boning process, thereby substantially reducing
costs.
Furthermore, pre-rigor mortis disassembly provides the opportunity to control
and
"mold" the primal meat portion profile such that when the primal portions are
chilled,
the firm, rigor mortis condition occurs after shaping within the container and
plug.
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More specifically, according to this present invention, the pre-rigor mortis
primal meat portion, having been de-boned, is sprayed with or dipped into a
solution
of one or more of the following: carbonic acid, acetic acid, ascorbic acid,
citric acid
and any other suitable substance that can be used to inhibit or eliminate
bacterial
growth on the primal meat portion. Primal meat portion is then placed into a
container of correspondingly suitable dimensions and a plug is inserted into
the open
end of the container. The assembled container, primal meat portion and plug is
located with plugs engaged onto rails 2814 and positioned directly and in
alignment
above the press base. The press base is elevated so as to closely retain the
container.
The wall 2816 is lowered so as to engage with the outer surface of the.upper
portion
of the container walls as shown in FIGURE 210. Clamp 2818 is then lowered and
penetrates opening of the container with radius 2820 end with bevel 2806 and
stretching the container opening outwardly thereby clamping it against the
inner
surface of wa112816 and providing an airtight seal therebetween. Wa112816 is
attached to an upper plate (not shown) forming a chamber that is isolated from
external air. A vacuum source is attached and air is evacuated from between
clamping assembly and plug. Progressively, Clamp 2818 is lowered so as to
compress the plug against primal, followed by clamp 2826 and finally clamp
2828 is
lowered. Clamps 2828, 2826, 2824 are then in contact with the upper surface of
the
plug and all applying suitable pressure. The vacuum source is then
disconnected,
allowing atmospheric air to apply pressure to the outer surface of the plug.
In this
manner, substantially all air can'~e removed from within the container
assembly.
The container assembly can then be immersed into brine or other suitably
treated, bacteria free, temperature controlled medium that may be elevated to
as
much as about 140 degrees F and held for a suitable period so as to cause
death of
bacteria that may be present. Following the desired reduction or elevation of
the
primal temperature, the container assembly can be relocated within a pressure
chamber and exposed to an ultra high pressure on the order of about 30,000 psi
or
more. This procedure can tenderize the primal and also kill bacteria that may
be
present.
Alternatively, sequentially or simultaneously, the container assembly can be
attached to an electrical source so as to provide passing a high voltage
current
through the primal and thereby treat by way of "Ohmic" heating. In this
manner, any
bacteria that may be present with the primal can be substantially eliminated
or killed.
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CA 02387349 2002-04-03
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The assembled container can then be removed from the pressure chamber and
again immersed in a cooling medium when the temperature of the primal can be
reduced to a desired and optimum temperature prior to removal from the
container
and followed by automatic slicing. In this manner rigor mortis occurs such
that the
shape of the primal meat portion after cooling within the container is similar
to the
inner profile of the container, providing a more efficient shape for slicing
with
automatic slicing equipment.
Refernng now to FIGURE 212, an adjustable container arranged to provide a
desired internal profile that can be used to contain, and thereby mold, a
suitable cut
of meat that has been separated by cutting from an animal carcass immediately
after
slaughter of the animal and prior to rigor mortis of the animal carcass.
FIGURE 212
shows details of a molding assembly apparatus constructed according to the
present
invention including an adjustable container 2830, constructed from any
suitable
metallic or plastics material, that provides a desired internal space with a
suitable
profile, is shown. Apparatus can be used to contain in the internal space, and
thereby
shape by molding to the profilE therein, any suitably cut meat primal, that
has been
separated by cutting devices from an animal carcass immediately after
slaughter of
the animal and prior to rigor mortis of the animal carcass and primal cuts.
The
apparatus may be arranged in any suitable manner including the arrangement
shown
in FTGLTRE 212 which is constructed from four components, including a "trough"
shaped member 2832, a_ mating closure 2834 and two identical plugs 2836.
Plugs 2830 are profiled to act as "pistons" in a conduit that is arranged by
assembly
of the components 2832 and 2834. The conduit includes member 2832 with mating
member 2834 which, when in a closed and operating position, has an irregular
cross-
section profile and the "piston" like plugs, 2836 are arranged to sealingly
fit, closely
within the conduit. The conduit has parallel horizontally disposed walls that
provide
the conduit along which the "piston" like plugs can be positioned at any
desired
location within the conduit and thereby providing a space, between plugs 2836,
into
which item 2838 can be locate3. The apparatus is arranged to be stackable and
the
lower, outer surface of member 2832 is profiled to mate with the upper
external
surface of member 2834 by "nesting" therewith when stacked in a vertically
arranged
column.
A suitable (pre-rigor mortis) primal cut of meat, 2838 such as a New York
Strip primal, can be placed in trough 2832, with plugs 2836 positioned, one at
each
end of primal, to provide a defined space with primal located therein. Member
2832
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can be mated with member 2832 and closed so as to contact plugs 2836.
Members 2832 and 2834 can be fixed in position relative to each other and
plugs 2836 can be moved, by mechanical powered devices and under pressure
toward
each other so as to compress item 2838 to the extent required that will cause
item 2838 to adopt a profile identical to the internal profile of the space
defined by
members 2832 and 2834 and plugs 2836. Assembly including members 2832, 2834
and plugs 2836 with item 2838 contained therein can be fixed by any suitable
method
to a finished configuration and stacked with other similar assemblies such as
on any
suitable pallet. Pallet with assemblies stacked thereon, can then be re-
located into a
temperature controlled chamber. Temperature controlled chamber can be set at
any
suitable temperature that may be elevated up to not more than about 140
degrees F
for a selected period of time after which the temperature may be gradually
reduced to
about 29.5 degrees F. Item 2838 will therefore cool and rigor mortis will
cause
"setting" of the profile of item 2838. Item 2838 can then be removed from
molding
assembly and sliced. Slicing can be conducted automatically while located
inside an
oxygen free chamber and with carbon dioxide or any other suitable gas or blend
of
gases provided at any suitable pressure, present therein.
In another preferred embodiment smaller portions of pre-rigor boneless meat
such as beef can be placed into the container assembly and processed therein
in such
a manner that will result in smaller pieces of pre-rigor boneless meat
adhering
together to form a single piece that can then be sliced into consumer
desirable slices.
Pre-rigor boneless beef may include portions of fat and muscle tissue that can
be
placed into the container, prior to processing, in any desired arrangement
such that
after processing, the single piece of meat will have a similar appearance to a
primal
such as a New York strip. In this way, less valuable smaller pieces of
boneless beef
can be used to produced larger and more valuable primal cuts of beef.
Containers and Plugs for Shaping Meat Primals
FIGURE 215 shows a container and plug 3802, which may be manufactured
by injection molding and from a plastics material such as nylon or
alternatively a gas
permeable and porous material such as a chemically foamed polypropylene or
polyester plastics materials may be manufactured from a stainless steel mesh.
Preferably, a plurality of profiles of the containers and plugs that
facilitate an
adjustable volume feature will be required in order to provide for all primal
shapes
and sizes. For example about 80 different containers and plugs would be
required to
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accommodate all of the various shapes of primal meat portions that are
typically
produced in the dis-assembly of a single beef cow.
The container may typically include a rectangular, round or oval plan profile
with a flat bottom and substantially vertical walls extending upwardly from
the base.
The base and walls are continuously attached at a suitably radiused
confluence. One,
two or more lugs 3804 can be conveniently located, one or more on each
opposing
side of the container to locate the container onto rails 3800 so as to retain
and hold
the container in a desired position at a desired height from the floor. The
rails may
be arranged with an electrically or pneumatically powered driver to move or
slide the
.10 container along the rails,. to another position for further processing
such as placing
the plug 3802 in position by automatic or mechanical apparatus, after loading
the
primal into space 3808. The consistency of the material from which the
container is
manufactured can be such that it will deform slightly when subjected to
pressure but
will return to its original shape when the pressure is released. A beve13810
is
provided as shown so as to facilitate an easy penetration by the plug 3802 or
3812,
into the opening in the container.
The plug may be provided in various profiles. An alternative plug 3812 is
shown in FIGURE 216 with additional details shown in enlarged cross-sectional
view of FIGURES 218-219. The plug includes a "rigidly" flexible, relatively
shallow
(shallower than the container 3800), "cup" shaped plug, with a flat or
suitably
profiled face 3814, and upwardly extending, flexible walls 3816 with tapering
thickness, flaring outwardly and terminating at a rim 3818. The flexible walls
can be
provided at an angle of about 5 degrees from vertical relative to horizontal
face 3814.
The upwardly extending walls are joined to the plug face 3814 with a suitable
radius
therebetween as shown. The upper rim 3818 of the plug wall is tapered to
provide a
thin cross-section at the outer edge of the lip and is flexible. An additional
rim 3820
located on the opposite side of recess 3822 as shown, that follows a path
around the
perimeter of face 3814 thereby providing a recess. Slots 3824 are provided
through
rim to a depth equal to the height of the rim such that the base of each slot
is on the
same plane and level with face. Slots allow liquids such as liquid purge and
blood to
escape therethrough and then between the flexible walls of the plug and the
inner
surface of the container 3800. A controlled and pre-determined pressure P can
be
applied to the plug 4101 as shown in FIGURE 221 so as to cause the liquid
purge to
be expelled from space 4107 through sides 4105. The pressure P is equal to the
weight W of red meat pri_nal contained therein multiplied by a constant x.
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Constant x is determined by the type of meat being processed and could be
equal to
W, or several times W and is determined by customer quality requirements.
The profile and dimensions of the plug are arranged so as to provide an easy
penetration into the matching opening of the corresponding container, however,
as
the plug penetrates the container opening, the tapered disposition of the
walls
provides for intimate contact and sealing between the rim 3818 and the inner
surface
of the container vertical walls. The container and plug, when assembled
together as
shown in FIGURE 216 provide an enclosed space 3808 that is substantially
sealed
and isolated from external atmosphere. The space 3808 has a volume that can be
varied within the limitations of the container, by moving the plug position,
relative to
the container. Preferably, however, the intimate contact between the rim 3818
and
the inside surface of the container walls is maintained in a substantially
"airtight"
fashion.
More specifically, according to this present invention, the pre-rigor mortis
primal meat portion, having been dc-boned, is sprayed, washed or dipped in a
solution including one or more of the following: carbonic acid, acetic acid,
ascorbic
acid, citric acid and any other suitable substance that can be used to inhibit
or
eliminate bacterial growth on the primal meat portion. The primal meat portion
is
then placed into the container of correspondingly suitable dimensions and the
plug is
inserted into the open end of the container. The assembled container, primal
meat
portion and plug can be located with the lugs engaged onto the rails and
positioned
directly and in alignment above the press base. The press base is elevated so
as to
closely retain the container as shown. The wall 3830 is lowered so as to
engage with
the outer surface of the upper portion of the container walls as shown in
FIGURE 215. Clamp 3832 is then lowered and penetrates opening of the container
with radius 3834 engaging with bevel 3810 and stretching the container opening
outwardly thereby clamping it against the inner surface of wall 3830 and
providing
an airtight seal therebetween. Wall 3830 can be attached to an upper plate
(not
shown) forming a chamber that is isolated from external air. A vacuum source
is
attached and air is evacuated from between clamping assembly and plug.
Progressively, 3836 is lowered so as to compress the plug against prima13838,
followed by clamp 3840 and finally clamp 3842 is lowered. Clamps 3842, 3840,
3836 are then in contact with the upper surface of the plug and all applying
suitable
pressure. The vacuum source is then disconnected, allowing atmospheric air to
apply
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CA 02387349 2002-04-03
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pressure to the outer surface of the plug. In this manner, substantially all
air can be
removed from within the container assembly.
The container assembly is opened as follows: A port 3$44 is shown in the
container base. The port is provided to allow connection to a source of
compressed
clean gas or clean air. The compressed gas can then be injected through the
port and
assist in the removal of the prir.~al when desired or after the primal has
been stored in
the container for a desired period of time.
The assembled container and plug with the primal contained therein may be
immersed into clean water, brine or other suitably treated, bacteria free,
temperature
controlled medium that is temperature controlled by refrigeration.. Following
the
desired reduction or elevation of the primal temperature the container
assembly can
be relocated within an ultra high pressure (UHP) chamber and exposed to an
ultra
high pressure on the order of about 30,000 psi to about 100,000 psi or more.
This
procedure can tenderize the primal and also kill bacteria that may be present.
UHP
equipment used may be similar to such equipment manufactured by Flow
International, Incorporated of Kent, Washington, USA.
Alternatively, sequentially or simultaneously, the container assembly can be
attached to an electrical source so as to pass a high voltage current through
the primal
and thereby treat by way. of "Ohmic" heating. Preferably, any bacteria that
may be
present with the primal can be substantially eliminated or killed.
The container and, plug assembly can then be removed from the pressure
chamber and again immersed in a cooling medium when the temperature of the
primal can be reduced to a desired and optimum temperature prior to removal
from
the container and followed by automatic slicing. In this manner rigor mortis
occurs
so that the shape of the primal meat portion after cooling within the
container is
similar to the inner profile of the container, providing a more efficient
shape for
slicing with automatic slicing equipment.
In another preferred embodiment the container may be arranged and used to
process several, smaller, (thinner) fresh primals simultaneously. This can be
achieved with the use of partitions or separating plates. The separating
plates can be
interposed between the smaller fresh primal portions in an arrangement that
can
include placing a first primal into the container followed by a separating
plate,
followed by a second primal, followed by a second separating plate, followed
by a
third primal, followed by a plug. Any quantity of fresh primal portions, that
can fit
within the container, can be processed in this manner.
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Containers and Plugs for Shaving-Multiple Meat Primals
In another preferred embodiment, the container may be arranged and used to
process several primals simultaneously. FIGURE 217 shows an assembly
constructed according to the present invention that includes container 3900, a
first 3902, second 3904 and third 3906 primal with first 3908 and second 3910
separating plates therebetween. The plug is shown in position after insertion
and all
air has been removed from the space between the container base and the plug
3812.
The assembly can then be immersed in cooling medium for further processing and
chilling.
In yet another preferred container embodiment, the container may be arranged
and used to process several primals simultaneously without the use of
separating
plates. FIGURE 220 shows detail of a cross-section through an assembly
constructed
according to the present invention that includes a container 4000 with a first
4002
and second 4004 tenderloin contained therein. The plug 4006 is shown in
position
after insertion and substantially all air has been removed from the space
between the
container base and the plug. The assembly can then be immersed in a cooling .
medium for further processing and chilling. This process can provide an
apparatus of
attaching two tenderloins together to produce a single tenderloin of uniform
profile
and cross-sectional shape. The tenderloin can then be removed and sliced into
slices
of equal profile size and weight.
In yet a further preferred embodiment, the primal meat portions can be
removed from the container 4100, after chilling and rigor mortis, and sliced
automatically and without separation of slices. Preferably, after slicing and
while
still generally held together in a single item, the sliced primal meat portion
can be
placed into a preformed gas barner bag and sealed therein or alternatively
placed into
a gas barner packaging tray that has been automatically thermoformed, in-line
on a
machine such as a Multivac 8530 (Manufactured by Multivac Sepp Haggenmuller
GmbH & Co. The gas barrier packaging tray can be profiled and shaped so as to
be
similar and/or identical in internal profile to the container 4100. The gas
barrier
packaging tray can then be located into a vacuum chamber and a substantially
gas
barrier lid, that may be a skin vacuum package (otherwise known by those
skilled in
the arts, as SVP), and conveniently heat sealed therein at flanges around the
cavity of
the gas barner packaging tray. Preferably, a hermetically sealed primal meat
portion
package can be produced that contains the primal meat portion that has been
conveniently sliced according to a customer specification and requirement. The
1~9: AMENDED SHEET

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vacuum or SVP packaging process, that can be automatically performed with the
use
of 8530 can rapidly and automatically produce a plurality of the hermetically
sealed
primal meat portion packages can be stored in temperature controlled storage
conditions. Preferably, a hermetically sealed primal meat portion package can
be
further processed by UHP apparatus prior to sale and delivery to customers.
Plant Layout
Referring now to FIGURE 222, a preferred equipment layout according to the
present invention includes three rectangular components being identified by
the
reference numera13350. Preferably, the equipment includes three similar
components. Each component . is arranged to form a horizontally displaced,
rectangular or square tube with doors at each end. The tube is conveniently
position
so that access to the doors at each end of the tube can be accessed for
loading of
packaging materials into the tube. When the doors are shut, the tube is sealed
to
provide a fully enclosed container or enclosure in which the EPS or FP trays
can be
stored. Conveniently located ports are provided into the walls of the tube
such that
suitable gasses can be introduced as required within the tube thereby
displacing
substantially all atmospheric air and most particularly atmospheric oxygen
there
from.
The tube is loaded with quantities of EPS and/or FP trays and the doors are
closed to provide a sealed container. Most preferably nitrogen, other inert
and/or any
other suitable gasses are provided into the tube so as to displace
substantially all air
from the interior of the tube and thereby providing a condition where the gas
is in
contact with the surface of the EPS and/or FP trays. Preferably, an ozone
generator
may be installed and chlorine gas may be provided within the enclosure. Any
gasses
and most particularly oxygen, that may be present within the cells of the
trays can
therefore freely diffuse and exchange with the gas in contact with the tray
surfaces.
With the passage of time, gas contained within the cell structure of the tray
walls
will therefore be displaced with gas in contact with the outer surface of the
trays.
Preferably, oxygen gas will be substantially removed from the cell structure.
Oxygen
will gradually accumulate and the level of "free" residual oxygen remaining in
the
tube can be monitored by automatic gas analysis and maintained at a minimum
and
desired level. This is achieved by extracting gasses from within the tube at a
point
near an end of the tube while providing an equal quantity of additional oxygen
free
gas into the tube at a point near to the opposite end of the tube from the
extraction
point at the other end of the tube.
'180 AMENDED SHEET ~' ~~~~j°
E

CA 02387349 2002-04-03
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Equipment 3302 is a tray sealing apparatus which is arranged to produce
packages, including tray, web and perishable goods contents shown as ground
meat.
The perishable goods may be portions of beef, pork or any other suitable
perishable
goods.
Referring now to equipment 3318, a representation of an apparatus is shown
for producing substantially gas barrier "master containers" from a roll of
suitable
material 3316. Equipment 3318 may be a Multivac R 530 that has been adapted to
suit the production system of the present invention. Equipment 3320 shown at
can be
provided for (optionally) locating an oxygen absorber into each master
container with
the retail packages before sealing a barrier lid to the master container.
'f'he barrier lid
material 3322 includes a roll of the barrier plastics lid material.
Apparatus 3334 shown in FIGURE 222 represents a typical carousel style
vacuum packing machine, such as an "Old Rivers" equipment that has 8 vacuum
chambers fitted thereto. The carousel style vacuum packing machine, 3332, is
shown
fitted with 8 vacuum chamber assemblies similar to that as shown in FIGURE 223
and described herein. Referring now to FIGURE 223, a closed vacuum
chamber 2700 including upper vacuum chamber 2702 and lower vacuum plate 2704
is shown. A rack 2706 with 2708 trays containing perishable goods 2705, red
meat,
are shown inside closed vacuum chamber 2700. An evacuation port 2710 in direct
communication with a source of vacuum is provided. A switch is attached to the
vacuum source so as to provide on/off control. Two continuous and concentric
'O'
rings 2712 are located between the edges of 2702 and 2704 and spaced apart
providing a space 2714 ther~between. The distance between 'O' rings is
arranged
such that when multiplied b~ the length of space 2714 the total projected area
between the concentric 'O' rings can be calculated. Total projected area shall
therefore be equal to PI x 'L1'. When a vacuum is applied to port 2710, the
closing
force created between 2702 and 2704 can be determined. Assuming that vacuum
can
be represented in terms of 8C% of atmospheric air pressure, at approximately
14 psi,
then the chamber total closing force, in pounds, would be equal to DI x LI x
.8 x 14.
A gas or blend of desired gasses can be provided within the closed vacuum
chamber
at a pressure above atmospheric pressure which will provide a chamber opening
force. However, in this arrar:gement, the closing force can be arranged to
exceed the
opening force thereby providing a method of maintaining a pressure with the
closed
chamber at a level above that of the prevailing atmospheric air pressure while
the
closed vacuum chamber remains closed due to the closing force provided. A
further
,:181,.: AMENDED SHEET

CA 02387349 2002-04-03
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evacuation port 2716 is provided in 2702 and a gassing port 2718 is provided
also.
The upper vacuum chamber 2702 is arranged so that it can be lifted vertically
upward
and away from 2704 allowing removal of the rack with trays and another rack
with
trays can be placed therein such that a continuous production process can be
undertaken. The upper vacuum chamber 2702 and the lower vacuum plate 2704 may
be arranged with clamping and structural supports so as to allow an increase
of gas
pressure to gas provided therein to any desired pressure such as 500 psi or
more.
Perishable goods are located in an EPS (foamed polystyrene) tray with
inherent or enhanced gas permeability. A gas permeable web is positioned above
the
EPS tray. The web has adhesive applied to the region of the web that will come
into
contact with flanges of the tray so as to provide a seal between web and tray.
The
web is then sealed to the flanges of the tray. The flange of the tray may be
compressed as shown to provide improved structural integrity and strength.
The EPS tray with intzerent or enhanced gas permeability can quickly
transfer, remove and exchange substantially all oxygen gas from foam cells
during
"carousel evacuation and gassing process".
The web may be printed on one or both sides with panels that can be seen
from the upper side after sealing to the tray. A bar code can be applied to
label on
the underside of the package. The bar code can include code information such
as the
specific weight of tray contents, date packaged and type of content goods.
Information can be read by- a scanner at any time after packaging and
converted to
consumer readable information that can be printed by, for example, ink jet
printers
onto the panel prior to retail display.
A device to cause oscillation of gas pressure within the chamber at a
frequency that will cause improved and more rapid exchange of air and oxygen
contained within cells of EPS tray with desired gas provided in chamber, can
be
provided. Furthermore, the oscillation of gas pressure within the chamber, can
cause
the permeable web to raise and lower and provide a space between the web and
upper
surface of the goods thereby allowing the gas provided in the chamber to
directly
contact the tray contents beneath the web. Oscillation can also provide
improved
contact with the goods an ~ enhanced absorption of the gasses by the goods.
The
oscillation may be set at a range of gas pressures that are above or below
prevailing
atmospheric pressure. The gas may include other substances in vapor, atomized
or
powder form and the composition may be selected and include the most suitable
blend of one or more of the following: nitrogen, oxygen, argon, carbon
dioxide,
182'. AMENDED SHEET

CA 02387349 2002-04-03
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hydrogen, krypton, neon, helium, xenon, 03, F2, H2, 02, KMnO4, HCIO, C102, Br2
and I2.
A desirable blend of gasses such as carbon dioxide and ozone can be provided
within the closed chambers 2702 and 2704 with the rack with trays contained
therein.
Refernng now to FIGURE 222, racks with trays can be automatically loaded
into open vacuum chambers 3332 which are then closed. A vacuum source is then
applied to port 2710 and a desired gas provided into closed vacuum chambers
after
removal of atmospheric air there from. The carousel is rotated,
intermittently, in the
counterclockwise direction shown in FIGURE 222 and stopped such that after
each
vacuum chamber assembly 3332 has fully traveled around the perimeter of the
carousel the rack with trays can be automatically removed from each vacuum
chamber and replaced with another. Therefore a continuous and automatic
process of
treating trays containing perishable goods with desired gasses can be
provided.
Refernng now to equipment 3326, a diagrammatic representation of an
automatic carton erecting, filling and sealing equipment is shown. A supply of
cartons is also shown as 3324.
Referring now to equipment 3328, a representation of ,an automatic-carton
palletizer, such as model FL 100 manufactured by Columbia Machine, Inc.,
Vancouver Washington, is shown. The palletizer is arranged to automatically
palletize finished cartons of packaged perishable goods with a supply of empty
pallets 3330. Finished cartons can be automatically transferred from equipment
3326
to the palletizer 3328.
Equipment 3304 is a representation of equipment configured to locate tray
flange covers prior to loading of the perishable goods into the tray. The
flange
covers are described in Australian patent application PM8415. Equipment 3308
is a
representation of a section of the packaging equipment that is exposed as
require to
facilitate efficient loading of the perishable goods into the trays. Equipment
3310 is
a representation of equipment configured to remove tray flange covers and as
generally described in Australian patent application PM8415. Equipment 3306 is
a
representation of the direction of flow of an alternative perishable goods to
be
optionally loaded into the trays.
Equipment 3336 is a representation of equipment configured to receive,
grind, condition and process meat and other similar perishable goods like the
one
shown in FIGURE 186. Equipment 3340 is a meat grinder. Equipment 3342 is a
pressure vessel. Equipment 3344 is a secondary meat grinder. Equipment 3346 is
a
'183: AMENDED SHEET ~~

CA 02387349 2002-04-03
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pressure vessel. Equipment 3338 represents the perishable food item, such as
portions of meat, that is to be processed and packaged. Equipment 3304 is a
diagrammatic representation of equipment configured to locate tray flange
covering
members prior to loading of the perishable goods into the tray. Equipment 3308
is a
diagrammatic representation of a section of the packaging equipment that is
exposed
as require to facilitate efficient loading of the perishable goods into the
trays.
Equipment 3312 is a representation of a roll of plastics lid material intended
for
sealing to flanges of the trays after perishable goods have been placed
therein.
Equipment 3314 is a representation of an optional feature and equipment for
locating
labels onto the underside or, after adjustment, upper side of the retail
packages after
sealing of lid material to flanges of the trays. Equipment 3318 is a
representation of
an apparatus for producing substantially gas barrier "master containers" from
a roll of
suitable material 3316, locating an optional oxygen absorbing material into
each
master container with the retail packages and sealing a lid to the master
container that
is unwound from a roll of plastics lid material shown as 3322. Equipment 3334
is a
representation of a typical carousel type vacuum packaging machine that has
been
modified according to the description provided herein, and located adjacent to
both
packaging equipment items 2 and 3, so as to facilitate easy transfer of
finished
' packages therebetween. Equipment 3332 is one of 8 vacuum chambers mounted to
the carousel and as shown in FIGURE 223. Equipment 3326 is a representation of
an
automatic carton erecting, filling and sealing equipment with a supply of
cartons 3324. Equipment 3328 is a representation of an automatic palletizer.
Equipment 3300 is a representation of equipment configured to exchange air
and more particularly, atmospheric oxygen, contained within the cell structure
of
foamed polystyrene trays (EPS trays) and foamed polyester trays (FP trays).
FIGURE 240 shows a cross-sectional side view of half of the arrangement and
FIGURE 241 shows a cross-section across the full width of the arrangement,
through
parts of a preferred apparatus and packaging.
Equipment 3350 is a diagrammatic representation of an alternative
equipment configured to exchange air and atmospheric oxygen, contained within
the
cell structure of foamed polystyrene trays (EPS trays) and foamed polyester
trays (FP
trays).
Thermoforming Apparatus
AMENDED SHEET'

CA 02387349 2002-04-03
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Referring now to FIGURE 224, a plan view of equipment layout according to
the present invention is shown that can be used to produce trays constructed
according to this invention.
The equipment layout is shown in a convenient arrangement for the efficient
production of the trays. Primary extruder 4600 is arranged adjacent to
secondary
extruder 4602 in a normal condition for production of expanded polystyrene
foam
sheet. Direction of flow is shown traveling toward wind-up mechanism 4604 with
spool 4606 attached thereto. A roll of EPS sheet material 4608, is shown
adjacent to
tube 4610. Tube 4610 follows a path that is conveniently arranged parallel
with
IO tube 4612. A cross-section through tube 4610 is shown in FIGURE 225. Tube
4b10
extends to a point of termination adjacent to thermoforming machine shown as
4614.
A second EPS foam extrusion system with primary extruder 4616 and secondary
extruder 4618 is located adjacent to the first EPS foam sheet extrusion system
4600
and 4602. Second extrusion system extrudes sheet in direction of flow as shown
and
I5 toward winder 4620, spool 4622 and roll 4624 adjacent to the entry end of
tube 4612.
The construction of tube 4612 can be identical to tube 4610. Tube 4610 and
tube 4612 are parallel to each other and follow a concentric path such that
4612
terminates at an end in close proximity to thermoforming machine 4626. Tubes
4610
and 4612 follow parallel and concentric paths that spiral upwardly thereby
providing
20 an extended length of tubes 4610 and 4612 and contained within a convenient
area.
Refernng now to, FIGURE 225, a section through tube 4612 is detailed.
Spool 4606 can be seen inside tube 4612 resting on belt 4628 and belt 4630.
Belt 4628 and belt 4630 are held taught and arranged to engage with drive
sprockets
conveniently located so as to engage the belts. Belts can, thereby, carry
spool 4606.
25 Carrying members extend throughout the full length of tubes 4610 and 4612
thereby
carrying spools 4606 through tube 4612 and 4610. A dish 4632 is mounted to a
pneumatic cylinder 4634 such that when extended the dish can elevate the spool
4606
upwardly so as to lift the spool away from driving belts 4628 and 4630. Tube
4612
is shown mounted directly onto a floor, however the tube can be elevated above
the
30 floor by suitable frame members. Gas 4636 is provided in tube 4612, gas may
be
nitrogen gas. A three dimensional sketch of spoo14606 is shown with roll of
material 4638 wound thereon. Spools 4606 can be loaded into the entry end of
tubes 4612 and 4610 which are conveniently located adjacent to the winding
members attached to foam extrusion equipment. Spools can be carried through
35 tubes 4610 and 4612 on bel~a 4628 and 4630 that may be operating
continuously.
AMENDED SHEET

CA 02387349 2002-04-03
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Dish 4632 is located conveniently between belt 4628 and belt 4630. Dish 4632
and
spool 4606 can thereby be elevated, by activating pneumatic cylinder, upwardly
and
away from contacting belts 4628 and 4630. Pneumatic cylinder 4634 with dish
attached thereto may be provided in sections that extend throughout the full
length of
tubes 4610 and 4612. By operating belts 4628 and 4630 with forward driving
motion
and pneumatic cylinder 4634 and dish, spools 4606 can be carried through
tubes 4610 and 4612 according to demand.
Preferably, tubes 4610 and 4612 can be flooded with a suitable gas such as
nitrogen or a blend of gasses including argon, carbon dioxide, nitrogen and a
quantity
of oxygen that does not exceed about 5% and is not less than about 1000 PPM of
blend of gasses, through ports 4640 and 4642. Spools with rolls of EPS foam
material can be stored in tubes 4610 and 4612 for a period of time as may be
required
in the normal aging of EPS foam material. This period of time may be in the
order of
twelve hours and accordingly the length of tubes 4610 and 4612 will be
arranged so
as to accommodate sufficient spools of material required for production of
trays and
also allowing for the twelve hour residence time as required. After storing
the
. , spools 4606 in tubes 4610 and 4612 quantities of spools can be removed
from the
exit end of the tubes adjacent to the thermoforming machines. Spools can be
loaded
onto the thermoforming machines and thermoformed trays with flaps can be
manufactured, as required.
Referring now to F1GURE 227, a cross-section through a thermoforming
machine oven is shown. The oven includes a substantially sealed and enclosed
rectangular tube with heaters 4633, 4635 arranged above and below EPS sheet
4631
that can be carried therethrough. The EPS sheet can be fed into the oven
through a
slot that is slightly larger than a cross-section through the EPS sheet. Tube
4646 is
attached to the under section of the oven and tube 4644 is attached to the
upper
section of the oven. Gas can be provided at a pressure above the ambient
atmospheric pressure, from a "nitrogen generator" directly into tube 4646. Gas
can
be extracted from tube 4644 that follows a path along path 4648 and through
cooler 4650. Tube 4644 aelivers the gas and an additional quantity of air
along
tube 4644 and into the nitrogen generator. The nitrogen generator generates
nitrogen
gas by way of separating oxygen from air and allowing only nitrogen to pass
into and
through tube 4646. Gas may be provided into tube 4646 directly from tube 4644
if
required.
1$G AMENDED SHEET

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Referring again to FIGURE 224, a plan view of tubes 4660, 4662, 4664, 4666
are shown passing through a wall. The tubes may be filled with a suitable gas.
Fully
formed trays with flaps can be loaded into the tubes for direct transfer and
use on
packing machines.
Preferably, the thermoforming apparatus herein described can be incorporated
into the plant layout schematic of FIGURE 222. Referring now to FIGURE 228, a
slight modification to a previous equipment plan is shown for producing trays
according to the present invention. Equipment includes four tubes 4700, 4702,
4704,
and 4706. Each item is arranged to form a horizontally displaced, rectangular
or
square tube with doors at each end. Each tube is conveniently positioned so
that
access to doors at each end of tube can be accessed for loading of packaging
materials into tube. When the doors are shut, the tube is sealed to provide a
fully
enclosed container or enclos~zre in which the EPS or FP trays can be stored.
Conveniently located ports are provided into the walls of the tube such that
suitable
gasses can be introduced as required within the tube thereby displacing
substantially
all atmospheric air and most particularly atmospheric oxygen there from.
. Each tube is loaded with quantities of EPS and/or FP trays and doors are
closed to provide a sealed container. Most preferably nitrogen, other inert
and/or any
other suitable gasses are provided into the tube so as to displace
substantially all air
from the interior of the tube and thereby providing a condition where gas is
in contact
with the surface of EPS andlor FP trays. Additionally, an ozone generator may
be
installed and chlorine gas may be provided within the enclosure. Any gasses
and
most particularly oxygen, that may be present within the cells of the trays
can
therefore freely diffuse and exchange with the gas in contact with the tray
surfaces.
With the passage of time, gas contained within the cell structure of the tray
walls
will therefore be displaced with gas in contact with the outer surface of the
trays.
Most importantly oxygen gas will be substantially removed from the cell
structure.
Oxygen will gradually accurmlate and the level of "free" residual oxygen
remaining
in the tube can be monitored by automatic gas analysis and maintained at a
minimum
and desired level. This is achieved by extracting gasses from within the tube
at a
point near an end of the tube while providing an equal quantity of additional
oxygen
free gas into the tube at a point near to the opposite end of the tube from
the
extraction point at the other end of the tube.
Ouen and Closed Cell Structures
'1'$?- AMENDED SHEET

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Referring now to FIGURES 229-237, cross-sectional and enlarged views of
expanded polystyrene (EPS) foam sheet are shown, wherein FIGURE 229 shows a
cross-section through a portion of co-extruded EPS foam including three layers
4500,
4502 and 4504. FIGURE 230 shows a cross-section through a portion of extruded
EPS foam sheet including three layers 450b, 4508 and 4510 and wherein layers
4506
and 4510 include skin similar to the section shown in FIGURE 233.
Referring to FIGURE 229, outer layers 4500 and 4504 sandwich an inner
layer 4502. Outer layers 4500 and 4504 include closed cell EPS foam as shown
in
FIGURE 232. "Closed cell" EPS foam describes a physical condition where the
cells
or bubbles, that are filled with gas, generally include enclosed spherical
spaces where. . .
the cell, bubble or sphere is not fractured and therefore any gas contained
therein can
enter or exit the spheres by diffusion through the spherical wall only and not
through
fractures or openings in the sphere wall. FIGURE 232 shows a grouping of cells
or
bubbles that contain a gas which may be air. Layer 4502 includes a layer of
open
celled EPS foam as shown in FIGURE 235. "Open cell" EPS foam is a physical
condition where most cells or bubbles are fractured and allow gas and other
matter to
invade the internal space of the open cells readily. Production of open cell
EPS foam
can be effected by introducing contaminants into the polystyrene melt prior to
foaming. The contaminants may include a surfactant to enhance liquid absorbing
properties, can cause fractures in the cell walls to appear. Closed cell EPS
foam is
produced by ensuring that there are no contaminants in the polystyrene melt
prior to
foaming. Closed cell foam generally provides a more mechanically stable and
rigid
structure than does open cell foam. Therefore in order to produce a more
mechanically stable and rigid packaging tray, closed cell polystyrene is a
preferred
construction material. However closed cell EPS foam resists absorbing liquids
such
as blood, water and purge. In order to produce a superior EPS foam packaging
material that has both liquid absorbing and structurally sound properties use
of a
combination of both types of open and closed cell foam is preferable. A
preferred
material would include three layers of co-extruded multi-layer foam sheet
where
layers 4500 and 4504 include closed cell EPS foam and layer 4502 includes open
cell
EPS foam.
Referring now to FIGURE 230 a cross-section through a preferred material is
shown where a three layer material includes two outer layers 4506 and 4510 and
a
center layer 4508. Layers 4506 and 4510 are similar and include a skin that
can be
3S induced by exposing a mono extruded layer of EPS foam, before the foam has
cooled
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and solidified, to relatively cool air applied thereto under regulated
pressure. By
applying the regulated compressed air in this way a skin can be formed by
deflating
the open or closed cell structure at one or both surfaces of the EPS sheet.
The
layer 4508 includes a layer of open cell EPS foam.
Refernng now to FIGURE 231, the closed cells are shown schematically, as
being exposed to gas pressure that is higher than gas pressure inside the
closed cells.
Enlarged view of closed cell FIGURE 237 shows a ratio of a pressure
differential
where P equals the external gas pressure and P1 the closed cell internal gas
pressure.
FIGURE 234 shows a grouping of closed cell EPS foam cells where the internal
pressure P1 is greater than the external gas pressure P.
The present invention to provides a method to substantially remove oxygen
gas that may be retained within the cell structure of the EPS foam packaging
materials and to also reduce the amount of oxygen and/or slow the rate at
which
oxygen may re-enter the cell structure after removal from storage and
processing in a
suitable gas. The following steps disclose a method that can be used to
achieve this
condition. Any or all of the following steps may be effected in the sequence
shown
or any other sequence that enhances the most efficient and rapid removal of
undesirable gasses, including oxygen, from the structure of the packaging
materials:
Place a quantity of EPS foam packaging materials, such as trays with flaps, in
a gas tight and sealed pressure chamber, with evacuation and gassing ports
therein
and valves attached so as to allow evacuation and gassing, with suitable gas,
of the
pressure chamber as desired.
Provide a vacuum inside the pressure chamber, by lowering gas pressure
therein, and maintain for a period of time so as to enhance the removal of
oxygen
from the structure of the packaging materials in a desired manner.
Introduce a suitable gus into the pressure chamber at an initial selected and
suitable pressure that may be below ambient atmospheric pressure.
Maintain the selected and suitable pressure for a period of time that enhances
the removal of oxygen from the structure of the packaging materials in a
desired or
optimised manner.
Progressively increase the pressure of the suitable gas in the pressure
chamber, in a continuous or intermittent manner, over time, until the gas
pressure is
above atmospheric pressure.
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Maintain the gas pressure for a period of time that enhances the removal of
oxygen from the structure of the packaging materials in a desired or optimized
manner.
By heating and/or cooling apparatus, maintain the temperature of the
packaging materials and the suitable gas in the pressure chamber, at a
temperature
that enhances the removal of oxygen from the structure of the packaging
materials in
a desired or optimized manner.
During the process, described above, exchange the suitable gas, while
maintaining the suitable gas pressure in the pressure chamber as required,
which can
continuously occur during the process, at a suitable rate of exchange to
ensure that
any undesirable gas, including oxygen, that may become present in the suitable
gas,
is substantially removed from within the pressure chamber.
Remove the packaging materials from the pressure chamber and allow the
packaging materials to physically expand as can occur due to a higher relative
gas
pressure that may exist in the closed cell structure of the EPS packaging
materials.
Maintain the packaging materials at a suitable temperature for a suitable
period of time, after removal from the pressure chamber.
The steps disclosed above may be repeated, sequentially or otherwise and in a
manner that provides an efficient process to remove undesirable gasses from
the
structure of the packaging materials and to enhance the expansion of the
packaging
materials in a desired manner.
In this way oxygen gas can be removed, from within the open and closed cell
structure of EPS foam material, and replaced with the suitable gas at a
pressure above
atmospheric pressure. The packaging materials can then be used for packaging.
The
higher pressure within the closed cell structure can gradually equilibrate
with that of
the prevailing ambient atmospheric air pressure, however during this
equilibration
period the rate of re-entry of atmospheric oxygen into the structure of the
packaging
materials can thereby be reduced.
In another preferred embodiment, adhesives such as any suitable bonding
medium may be applied to surfaces of the flaps of tray and the tray walls and
base by
any suitable "ink jet" apparatus. Furthermore, colored graphic printing and
any
desired information can be printed and/or applied to any desired surfaces
of'the tray
and flaps by any suitable "ink jet" apparatus. The "ink jet" equipment is
manufactured by several companies such as Hewlett Packard, Xerox, SciTex,
Marconi/Video Jet and others. The equipment can be arranged to apply inks,
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lacquers and adhesive materials as required by, for example, arranging the ink
jet
equipment adjacent to a conveyor that can transport the trays with flaps at a
suitable
speed and in such a manner Zs to allow application of the inks and other
materials to
the trays and flaps, as required. The conveyor may be arranged adjacent to and
S integrated with thermoforming machinery such that immediately after
producing
trays with flaps, the trays can be automatically transferred onto the
conveyor. The
conveyor can be arranged to carry trays with flaps at a controlled speed and
as
required to allow application of inks and any suitable materials thereto by
ink jet
printer.
Tray Treatment Method and Apparatus for the Removal of Oxy"gen ..
Referring now to FIGURE 238, details of an apparatus for storing foam (EPS
or polyester foam) trays, for exchanging gas in cells with a preferred gas is
shown.
This apparatus provides a method to substantially remove any residual oxygen
that
may be retained in the cell structure of EPS packaging materials intended for
use in
packaging fresh red meats in a "low oxygen" master container, case ready
packaging
system. The method disclosed herein can provide a process to remove and
replace
the residual oxygen, with a desired gas, more rapidly than occurs when the EPS
packaging materials are stored in a chamber containing desired gas in a static
condition at ambient atmospheric pressure. The apparatus includes a
rectangular or
suitably profiled tube 4200 . The tube 4200 is arranged to have two open ends
4202
and 4204, one at each end of the tube 4200. The tube is provided with
evacuation
port 4206 and gas entry port 4208. The tube can be filled with precut foam
(EPS)
trays with flaps, or sheets of foam 4210. The tube can be arranged to have a
suitable
length and be configured in such manner as to allow automatic loading from the
trim
press of a suitably modified thermoforming and tray trimming apparatus. The
tube
can further be arranged so as to allow automatic removal of one tray with
flaps at a
time for subsequent automatic processing of the tray with flaps to form a
finished
tray with bonded and sealed flaps.
Open ends 4202 and 4204 can be arranged to mate with covering caps (not
shown) in such a manner as to completely enclose the tube and provide airtight
seals
at both open ends. The completely enclosed tube 4200 can thereby provide a
vacuum
chamber containing the trays with flaps such that when a vacuum source is
connected
to evacuation port 4206 substantially all air contained therein can be
removed. After
evacuation of the air from the tube, the vacuum within the tube can be
maintained for
a period of time, the period of time being sufficient to allow removal of
substantially
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all retained air and oxygen from the cell structure of the trays with flaps.
After
removal of substantially alI air and oxygen from within the cell structure, a
suitable
gas such as nitrogen or carbon dioxide can be provided into the tube via gas
entry
port 4208. The gas can be retained within the enclosed and sealed tube 4200
for a
period of time sufficient to allow the cell structure to become filled with
the suitable
gas. Alternatively, evacuation of air from within the tube can be adjusted to
provide
a remaining gas or air pressure therein at any pressure between zero and
ambient
atmospheric air pressure and suitable gases can be provided in the tube so as
to blend
with any remaining air contained therein after evacuation to a desired
pressure. Such
process of evacuation and gassing can be repeated in accordance with an
optimized
process that will result in the most rapid exchange of retained oxygen in the
cell
structure with a desired gas.
In another preferred embodiment, the evacuation port 4206 may be provided
in the sealing cover over open end 4204 and the gas entry port 4208 may be
provided
in the sealing cover over the open end 4204. The preferred embodiment can
thereby
provide an arrangement where a vacuum source can be attached to the evacuation
port and a gas source can be attached to gas entry port and provide a
continuous flow
of gas through the tube from one end to the other so as to contact the surface
of the
trays with flaps contained 'herein. The pressure of the gas flowing through
the tube
can be arranged at a level most suitable to achieve the most rapid removal of
air and
oxygen that may be contained within the cell structure of the trays with flaps
and
thereby exchange the oxygen with the desired gas.
Referring now to diagram FIGURE 238, details are shown of an apparatus for
storing foam (EPS or polyester foam) trays, for exchanging gas such as oxygen
that
may be contained in the cell structure of the trays, with a preferred gas. The
apparatus removes any residual oxygen that may be retained in the cell
structure of
the EPS trays that are intended for use in packaging fresh red meats in a "low
oxygen" master container, case ready packaging system. The apparatus and
method
disclosed herein can provide a process to remove and replace the residual
oxygen,
with a desired gas, more rapidly than occurs when the EPS packaging materials
are
stored in a chamber containing desired gas in a static condition at ambient
atmospheric pressure.
The apparatus includes a rectangular or suitably profiled tube 4200. The tube
is arranged to have two open ends 4202 and 4204, one at each end of the tube.
The
tube is provided with evacuation port 4206 and gas entry port 4208. The tube
can be
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filled with precut foam (EPS) trays with flaps, or sheets of foam 4210. The
tube can
be arranged to have a suitable length and be configured in such manner as to
allow
automatic loading from the trim press of a suitably modified thermoforming and
tray
trimming apparatus. The tube can further be arranged so as to allow automatic
removal of one tray with flaps at a time for subsequent automatic processing
of the
tray with flaps to form a finished tray with bonded and sealed flaps as
described
above.
The open ends 4202 and 4204 can be arranged to mate with covering caps
(not shown) in such a manner as to completely enclose the tube and provide
airtight
seals . at both the open ends. The completely enclosed tube can thereby
include a
vacuum chamber containing the trays with flaps such that when a vacuum source
is
connected to evacuation port 4206 substantially all air contained therein can
be
removed. After evacuation of the air from the tube, the vacuum within the tube
can
be maintained for a period of time, the period of time being sufficient to
allow
removal of substantially all retained air and oxygen from the cell structure
of the
trays with flaps. After removal of substantially all air and oxygen from
within the
cell structure, a suitable gas such as nitrogen or carbon dioxide can be
provided into
the tube via gas entry port 4208. The gas can be retained within the enclosed
and
sealed tube for a period of time, which may be 1 to 2 hours, sufficient to
allow the
cell structure to become filled with the suitable gas. In a preferred
procedure, the air
will be substantially evacuated through the evacuation port 420b and then a
gas such
as nitrogen will be introduce~:l Through port 4208 at a suitable low pressure.
The gas
will be held at the suitable low pressure for a period of dme and then, the
low
pressure of the gas will be gradually increased, over a period of time, and
until the
gas pressure is increased to a maximum gas pressure above ambient atmospheric
pressure. The maximum gas pressure may be 60 psi or more.
Alternatively, a partial evacuation of air from within the tube 4200, to a
level
that does not completely evacuate the tube but lowers the air pressure therein
to a
pressure above zero and belovf ambient atmospheric air pressure. A suitable,
oxygen
free, gas such as nitrogen can be provided into the tube, through the port
4208, so as
to blend with the remaining air contained therein. This process of partial
evacuation
followed by gassing can be repeated, sequentially until the oxygen gas
contained in
the EPS cell structure is removed and in an optimized process that will result
in the
rapid exchange of the retained oxygen in the cell structure with a desired
gas.
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In another preferred embodiment the evacuation port 4206 may be provided
in the sealing cover over the open end 4204 and the gas entry port 4208 may be
provided in the sealing cover over the open end 4202. A vacuum source can be
attached to the evacuation port 4206 and a suitable gas source, such as
nitrogen or a
blend of gasses including argon, carbon dioxide, nitrogen and a quantity of
oxygen
that does not exceed 5% a:~d is not less than 1000 PPM, can be attached to the
gas
entry port 4208 and thereby providing a continuous flow of gas through the
tube
from port 4208 to evacuation port 4206 so that the suitable gas contacts the
surface of
the trays with flaps contained herein. The pressure of the gas flowing through
the
tube can be arranged at a level most suitable to achieve the most rapid
removal of air
and oxygen that may be contained within the cell structure of the trays with
flaps.
In yet another preferred embodiment, a plurality of the rectangular tube 4200,
may be conveniently stacked together and located inside a suitably sized
vacuum
chamber. Substantially all air may be evacuated from within the vacuum chamber
and held with the vacuum source attached thereto for a period of time
sufficient to
allow removal of substantially all gas from within the expanded polystyrene
foam
cell structure. A suitable gas, such as nitrogen can then be provided into the
vacuum
chamber, at a pressure equal or greater than ambient atmospheric pressure so
as to
completely fill the vacuum chamber and contact all surfaces of foam trays in
the
tubes. After a period of time the plurality of tubes can be removed from the
vacuum
chamber.
Referring now to FIGURE 239, another embodiment of a rectangular tube
having top bottom open ends is shown. Preferably, the rectangular tube may be
manufactured from any suitable material such as stainless steel or other
plastics
material and may be arranged to have any convenient length. Preferably, the
rectangular tube can be manufactured with longitudinally parallel sides and a
cross-
section that corresponds with the cut size of the trays that are shown
therein. More
specifically the rectangular tube will have a cross-sectional opening that is
sized so as
to be slightly larger that the cut size of the trays contained therein. For
example, if
the plan, cut size dimensions of the trays is 5 inches long by 4 inches wide
the
opening in the rectangular tube will be about 5.125 inches long by about 4.125
inches
wide.
A gas entry port 8102 is shown located in the wall of the rectangular tube at
about equal distance from each end of the rectangular tube. A plurality of
additional
gas entry ports may be provided at any suitable location in the wall of the
rectangular
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tube. Most preferably, a suitable gas or blend of gasses, such as nitrogen,
may be
provided inside the rectangular tube through the entry port 8102. The gas may
be
provided by an injector into the rectangular tube through one or more of gas
entry
ports at a set pressure and volume. Gas may be provided at a pressure that is
varied
by normal methods or alternatively by way of a set pitch sound that may also
be
varied in a manner to enhance gas exchange. Preferably, length of rectangular
tube 8100 can be arranged such that when trays are passed through the
rectangular
tube, the residence time of trays within the rectangular tube will be
sufficient to allow
gas exchange to occur between suitable gas provided through the entry port and
into
. the rectangular tube and gasses such as oxygen that may be contained within
the cell
structure of the trays. Trays may be loaded through an opening at the open
tope of
rectangular tube and unloaded through the open bottom.
Preferably, rectangular tube is vertically disposed such that gravity will
provide sufficient force to cause the trays to pass through the opening
through the
rectangular tube, when trays are removed from the bottom of rectangular tube.
Alternatively, the rectangular tube may be horizontally disposed and a driver
such as
an auger (not shown) may be provided to transfer the trays through the
rectangular
tube. Preferably, the rectangular tube may be arranged so as to connect with
an
automatic tray dispenser so that trays can be automatically removed, one or
more at a
time, and subsequently be positioned onto a packaging machine in readiness for
loading of perishable goods such as fresh red meat therein. A plurality of
rectangular
tubes may be arranged together in a grouping so as to process a plurality of
trays
simultaneously.
The rectangular tube can be manufactured to suit trays of any size.
Tray Forming_Apparatus
Referring now to FIGURES 240-241 where a cross-section of the tray
forming apparatus 2200 is illustrated. The apparatus is intended for used in a
method
for removing oxygen gas from the structure of expanded polystyrene packaging
materials that are intended for use in packaging perishable goods that could
be
deleteriously affected by the presence of oxygen in quantities that exceed 500
PPM.
The method includes but is not limited to the use of any suitable gas at any
suitable
pressure arranged to pass through the packaging materials by providing the
suitable
gas to one side of the packaging materials at a pressure above what is the gas
pressure of any gas that is present on the opposing side of the packaging
materials.
The suitable gas will thereby be caused to pass through the packaging
materials and
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furthermore cause a reduction in oxygen contained in the structure of the
packaging
material s.
The apparatus includes two parts. The first part shown in FIGURE 240 is a
side view cross-section with the apparatus in a closed position and a tray
clamped
between an upper chamber 2252 and a lower chamber 2254. FIGURE 240 shows
half of the apparatus with a center line marked through what would be the
center of
the apparatus. The other half of the apparatus is a mirror image of the part
that is
shown. FIGURE 241 shows a cross-section across the entire width of the upper
and
lower chambers 2252 and 2254.
The apparatus 2200 includes an upper and lower chamber which are arranged
so as to be moveable toward and away relative to each other, thereby allowing
trays
to be processed in a continuous mode.
A porous mold 2256, that is profiled to follow the contours of the tray and to
neatly fit within the confinement of the chambers 2252 and 2254, is provided
and can
be fixed to the upper chamber. A gassing port 2258 is provided in the lower
chamber 2254 and an evacuation port 2260 is provided in the upper chamber
2252.
The porous mold 2256 can he manufactured from a suitable porous material and
may
have grooves and slots machined across the surface of the profiled face 2262
that are
all connected to evacuation. port 2260, thereby allowing gasses to be
evacuated
therethrough and through port 2260. The apparatus can be configured to
accommodate one or more trays, however, for ease of explanation the apparatus
shown in FIGURES 240-241 preferably accommodates one tray. A blade 2264 is
provided within chamber 2254 which is attached to a moving member. The
blade 2264 can be arranged in a continuous length to provide a knife edge that
follows the perimeter of what will become the processed and cut tray. Space is
provided between the surface of the profiled mold 2256, as shown, providing a
space
into which a suitable pressurized gas can be provided.
A tray 2268, having extended flanges, 2270, is located on the porous
mold 2256 and the chambers 2252 and 2254 are closed so as to clamp the
flange 2270 around the full perimeter of the tray. The tray 2268 may be
thermoformed from expanded polystyrene and therefore has a porosity and can
therefore allow pressurized has to pass therethrough. Pressurized nitrogen gas
can
then be provided into the space through port 2258 at a suitable pressure. A
vacuum
source can be attached to port 2260. The gas thereby passes through the porous
tray
walls and can displace oxygen gas that may be present therein. The pressurized
gas
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can be provided into the space and passed through the tray porous walls far
sufficient
time to displace substantially all oxygen gas that may have formerly been
present
therein. The blade 2264 with knife edge can be activated and moved by the
moving
member 2266 so as to cut through the tray flange 2270. Chambers 2252 and 2254
S are opened allowing the tray 2268 to be removed in readiness for additional
trays to
be processed in a similar fashion as described above. Trays 2268 can be
removed
and replaced on the porous mold 2256 in a continuous, intermittent and
automatic
procedure. The porous mold 2256 can be interchanged with other molds having
different profiles to suit other trays of different size and profile.
Flange 2270 and any other part of the tray 2270 and the flap 2272 may be
compressed, as desired, to substantially remove gas from the foam cells
thereby
forming a substantially solid section in the tray, flap 2272 and flange 2270
as
required. In this way the solid section can be arranged to provide a
continuous solid
section around the perimeter of the tray such that a web of material such as
pPVC
can be sealed to the solid section along a strip like path around what will
become a
perimeter of a finished package: The solid section may be located at the
connection
between the flap 2272 and the tray 2268 such that the flap 2272 and the tray
2268 can
be hinged and folded so as to allow contact of tray flange 2270 with the tray
2268.
The apparatus is similar to a standard expanded polystyrene thermoforming
machine, where two parallel platens are arranged in close relative proximity
and with
a powered device for moving the platens toward and away from each other.
Matched
tools including two parts, are typically mounted onto the platens such that a
heated
sheet of expanded polystyrene or other suitable sheet, can be located between
the
platens and separated matched tool parts. The platens can be moved toward each
other to a position that clamps the heated sheet between the two parts of the
matched
tool, thereby imparting a three dimensional profile that corresponds to the
profile of
the matched tool, into the sheet. After the sheet cools, the platens and the
matched
tool open and the profiled sheet can be removed automatically to allow the
positioning of another sheet of EPS sheet therebetween. The EPS sheet is
typically
arranged in a continuous web.
As disclosed in the aforementioned description, trays can be processed in an
automatic and continuous mode, such that any oxygen gas that may be retained
in the
EPS cell structure can be substantially removed and replaced with a desired
gas such
as nitrogen. The method and apparatus described herein, can also be
incorporated
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into standard thermoforming machinery used for production of thermoformed EPS
trays.
In a preferred embodiment, the trays with flaps can be produced on an
automatic apparatus that heats a web of EPS sheet in an oven that
substantially
excludes oxygen so as to ensure that during any expansion of the EPS sheet
during
heating, immediately prior to thermoforming of the EPS sheet, oxygen gas will
be
substantially prevented from entering into the cell structure of the EPS
sheet. This
can be achieved by providing a suitable gas such as nitrogen in the oven
during the
heating of the EPS sheet, the nitrogen gas being in direct contact with the
surfaces of
the EPS sheet. The EPS sheet can then be transferred directly into a forming
station
that is arranged to substantially exclude oxygen gas therefrom and
furthermore, apply
pressurized nitrogen gas to one side of the tray with flaps during the forming
process
and causing the nitrogen gas to pass into and through the tray and flaps
during the
forming process. Adhesive or solvent can then be applied to selected areas of
the
flaps and the tray, either before or after trimming the tray with flaps from
the sheet of
EPS material. Then automatically fold the flaps and mechanically apply
sufficient
pressure to the flaps to hold against the walls of tray and cause bonding
between the
flap and the tray at desired regions therebetween.
A preferred embodiment includes, but is not limited to automatically or
manually performing the following steps:
1. Providing .a tray that may be thermoformed from expanded
polystyrene (EPS) with flaps as shown in diagram. The tray having dimensions
that
will provide for the efficient use of the internal capacity of typical,
refrigerated
transport vehicles.
2. Exposing the tray to a gas that excludes oxygen and allowing the gas
to exchange with any gasses contained within the cells of the EPS thereby
substantially displacing any atmospheric oxygen from the cells.
3. Providing perishable goods onto the base of the tray. The perishable
goods having been treated arid processed to substantially eliminate any
bacteria
thereon.
4. Sealing a gas permeable material such as pPVC to the flanges of the
tray.
5. Folding and then sealing the flaps to flanges of the tray.
6. Placing the tray or a plurality of similar trays into a gas barrier master
container.
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7. Displacing substantially all atmospheric gas, and particularly
atmospheric oxygen, within the master container, with a desired single or
blend of
desired gasses.
8. Sealing a lid over the opening in the master container to form a
hermetically sealed package containing the trays with perishable goods and
desired
gas.
9. Placing the master container inside a carton such as can be
manufactured from corrugated cardboard and enclosing the master container.
10. Locating a plurality of the closed cartons onto a standard (GMA
. specified) pallet (Dimensions of 40" x 48") so as to maximize the efficient
use of the
area provided by the pallet.
Tra~Materials of Construction
A mufti-layer, co-extruded plastics sheet product extruded through an annular
die is disclosed, including substantially amorphous polyester polymers, with
additives, sinular, but not exclusively, to the structures shown in FIGURES
242-250
where at least one of the layers is a foamed polyester and where at least one
or more
other layers includes at least about 30% regrind material derived from the
skeletal
scrap remaining after prod~.~ction of thermoformed trays from the sheet, with
the
balance of the regrind layer including a chosen virgin amorphous polyester
polymer.
FIGURE 242 shows a multilayer coextruded plastic sheet constructed
according to the present- invention including five layers. Beginning from the
uppermost layer 2900, the c~~-extruded first layer 2900 includes a mix of
blended
components about 50% Eastman 6763 and about 50% Eastman 19411. The first
layer 2900 is about 0.001 inches thick. The second co-extruded layer 2902
includes
Eastman 9921 and is about 0.0025" thick. The third co-extruded layer 2904
includes
a blended mix of foamed Eastman 9663 and Eastmann additive G4ZZZ-3AZZ, and is
about 0.012" thick. The fourth co-extruded layer 2906 includes Eastman 9921
and is
about 0.0015" thick. The filth layer 2908 includes regrind material recovered
from
tray thermoforming processes, and is about 0.002" thick. The overall thickness
of the
sheet material shown in FIGURE 242 is about 0.018" thick.
FIGURE 243 shows a multilayer coextruded plastic sheet constructed
according to the present invention. The sheet material includes four layers.
Starting
from the uppermost layer, the first co-extruded layer 2909 includes a blended
mix of
about 60% Eastman 9921 and about 40% Eastman 6763. The first layer 2909 is
about 0.002" thick. The second co-extruded layer 2910 includes a blended mix
of
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foamed Eastman 9663 and Eastman additive G4ZZZ-3AZZ, and is about 0.011"
thick. The third co-extruded layer 2912 includes regrind material derived from
skeletal scrap recovered from the tray thermoforming process, and is about
0.0015"
thick. The fourth co-extruded layer 2914 includes a blended mix of about 60%
Eastman 9921 and about 40% Eastman 6763 and is about 0.002" thick. The overall
thickness of the material shown in FIGURE 243 is about 0.0165" thick.
FIGURE 244 shows a multilayer, coextruded plastic sheet including three
layers. Beginning with the uppermost layer, the first co-extruded layer 2916
includes
a blended mix of about 20% Eastman 6763, 50% Eastman 9921, and about 30% of
regrind material. The first layer 2916 is about 0.0025" thick. The second co-
extruded layer 2918 includes a mix of blended and foamed Eastman 9663 and
Eastman additive G4ZZZ-3AZZ. The second layer 2918 is about 0.011" thick. The
third co-extruded layer 2920 includes a mix of about 20% Eastman 6763, about
50%
Eastman 9921, and about 30% regrind material. The third layer 2920 is about
0.0025" thick. The overall thickness of the sheet material of FIGURE 244 is
about
0.016" thick.
FIGURE 245 shows a multilayer, coextruded plastic material constructed
according to the present invention. The sheet material includes five layers.
Beginning with the upp:,rmost layer, the first co-extruded layer 2922 includes
a
blended mix of about 50% Eastman 19411 and about 50% Eastman 6763. The first
layer 2922 is about 0.001" thick. The second co-extruded layer 2924 includes a
blended mix of about 90% Eastman 9921 and about IO% of regrind material
derived
from skeletal scrap recovered from the tray thermoforming process. The second
layer 2924 is about 0.006" thick. The third co-extruded layer 2926 includes a
blended mix of about 90% of regrind material derived from skeletal scrap from
the
tray thermoforming process and about 10% of Eastman 9921. The third layer 2926
is
about 0.003 inches thick. The fourth co-extruded layer 2928 includes a mix of
blended and foamed Eastman 9663 and Eastman additive G4ZZZ-34ZZ. The fourth
layer 2928 is about 0.019 inches thick. The fifth co-extruded layer 2930
includes a
mix of about 90% Eastman 9921 and about 10% of regrind material. The fifth
layer 2930 is about 0.0005" thick. The overall thickness of the sheet material
of
FIGURE 245 is about 0.03" thick.
FIGURE 246 shows a multilayer, coextruded plastic sheet material
constructed according to the present invention. The sheet material includes
five
layers. Beginning with the uppermost layer 2932, the layer 2932 includes about
50%
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CA 02387349 2002-04-03
-220-
blended Eastman 6763 and about 50% Eastman 19411. The first co-extruded
layer 2932 is about 0.0015" thick. The second co-extruded layer 2934 includes
about 10% blended Eastman 9921 and about 90% regrind materials derived from
skeletal scrap recovered from tray thermoforming process. The second layer
2934 is
S about 0.0015" thick. The third co-extruded layer 2936 includes blended and
foamed
Eastman 9663 and Eastman additive G4ZZZ-3AZZ. The third layer 2936 is about
0.010" to about 0.019 thick. The fourth co-extruded layer 2938 includes about
10%
blended Eastman and about 90% regrind materials derived from skeletal scrap
recovered from tray thermoforming process. The fourth layer 2938 is about
0.0015"
- 10 thick. The fifth co-extruded layer 2940 includes about 5U% blended
Eastman 6763
and about 50% Eastman 19411. The fifth layer 2940 is about 0.0015" thick. The
overall thickness of the sheet material of FIGURE 246 is about 0.016" thick.
T_ray Materials of Construction
. Refernng now to FIGURE 247, a cross-sectional view through a portion of
15 material constructed according to the present invention is shown. Polyester
sheet
material is co-extruded in a three layer construction having two outer layers
2000 and
2002 of Eastman APET 9921 (about 0.002" thick, each) and an inner layer 2004
of
foamed Eastman 9663 with an Eastman recommended quantity of Eastman melt
strength enhancer G4ZZZ-3AZZ. Inner layer 2004 is about .015" thick. Inner
20 layer 2004 is foamed with a suitable quantity of nitrogen gas,
substantially excluding
air from foam cells. The total thickness of co-extruded sheet is approximately
.019"
thick. The gas barner properties of the outer layers of Eastman 9921 are such
that air
will be substantially prevented from permeating into the inner layer of foamed
polyester. Sections of the material have been compressed so as to solidify the
inner
25 layer of foamed Eastman Polyester 9663 with the melt strength enhancer.
Both
edges of co-extruded sheet are sealed together, by any suitable sealer,
preferably
immediately after co-extrusion and prior to winding onto a roll. Sealing edges
substantially prevents air from permeating into inner layer 2004 of foamed
polyester.
Material is wound onto a roll and is then stored, most preferably in a
temperature
30 controlled storage area and at a temperature below 10°C. Following
storage, the roll
of co-extruded polyester material is substantially converted into trays of a
desired
profile and size by a thermoforming apparatus such as shown in FIGURE 248
where
a cross-section through such a tray is shown. Thermoforming apparatus includes
a
typical method of pre-heating the sheet, clamping convenient rectangular
sections of
35 the heated sheet and vacuum (or pressure) forming the sheet onto a suitable
tray
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CA 02387349 2002-04-03
-221-
forming mould, however, at the moment of thermoforming and prior to cooling of
the
sheet, a suitably shaped tool, that may also be heated to a desired
temperature, can be
pressed against the flange regions, or edge of the flange regions, of the
trays during
the forming process and thereby compress the flanges. Most desirably the
compression of the flanges will cause substantially all gas to be expelled
from the
inner layer of foamed polyester in the flange regions only. Said trays are
severed, by
a cutting member, from the sheet of material such that the edges of the flange
are
substantially sealed together. Such a process can provide a tray with gas
barrier outer
layers of polyester and an inner foamed layer of polyester such that the inner
layer is
substantially prevented from direct contact with ambient air. In this way
ambient air
will be substantially prevented from permeating into the inner layer and also
providing a gas barrier to substantially prevent nitrogen gas within the foam
cells
from escaping and exchanging with air.
FIGURE 249 shows a cross-section of the material showing an upper 2000,
an inner 2004, and a lower 2002 layer. The upper layer 2000 is about 0.002"
thick,
the inner layer 2004 of foam polyester is about 0.15 thick and the lower layer
2002 is
. about 0.002" thick. FIGURE 250 shows the material of FIGURE 249 when the
material is compressed according to the present invention. Outer layers 2000
and
2004 remain substantially about 0.002" thick, but inner layer 2004 has been
compressed to about 0.001" thick.
Tray Rib Forming_Apparatus
Referring now to FIGURE 251 a tray with ribs formed in accordance with
this invention is shown. The inventor has previously invented a system whereby
a
low oxygen modified wing system including a "master container" (container)
with
trays therein, is evacuated. During evacuation, all contents of the container
are
exposed to a very high level of vacuum, furthermore, the pressure of nitrogen
gas,
contained within the inner layer foam cells which is approximately equal to
the
prevailing ambient atmospheric pressure, will exert an "exploding" pressure
against
the inner surfaces of the outer layers. Pressure can cause distortion
resulting in, at
least, partial separation of in.~er layer from outer layers. Furthermore, in
extreme
cases tray walls could rupture and burst open. Clearly, such an event is
undesirable
and this present invention provides a method, equipment and production of a
tray
(product), that can minimize this undesirable event. By including regions of
dense
material, the inventor has discovered that trays can withstand the low
pressure
atmosphere used in the above application.
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CA 02387349 2002-04-03
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FIGURE 251 shows a three dimensional section of a tray that has been
thermoformed from sheets of material similar to those described in the
structures
shown in FIGURES 242-246. FIGURE 253 is a view of a section through a wall of
the tray with ribs 2100 provided therein. Referring now to FIGURE 254, an
apparatus that can be used to provide ribs 2100 is shown. Ribs can be provided
by
closing heat bank 2118 onto wall of tray 2114 when tray 2114 is supported by
pad 2116. Heat bank 2118 can thereby weldlheat seal a portion of the inner
surface
of the outer layers 2108, 2112 to each other after compression of inner layer
2110
foam cells such that the outer layers become welded/ heat sealed to each other
at the
point of contact. Radius 2106 of ribs 2100 as shown in FIGURE 253 ran be
adjusted
and also the distance of pitch from radius to radius can also be adjusted by
production of equipment providing the desired adjustments. Adjustments can be
made in order to provide for optimized configuration of radius 2106 and pitch
such
that the exploding effect of exposure to high vacuum that could otherwise
result in
the rupturing of the tray, as described above can be minimized.
In a preferred embodiment, an apparatus for compressing a web of
. material 2124 to provide ribs therein is detailed in FIGURE 255. Heat banks
2120
and 2124 are arranged, as required, in a mechanism so as to enable compressing
of
material therebetween and thereby bond outer layer 2126 and inner layer 2130
together with compressed foamed polyester layer 2128 therebetween. A cross-
sectional view through a portion of compressed material 2124 with an aperture
punched therethrough is shown in FIGURE 256. Additionally a mechanism for
providing perforations in an outer layer of a tray wall thermoformed from the
material shown in FIGURE 247, is also detailed in FIGURE 257. Perforations
2136
can be provided to allow communication and transfer of gasses from the foamed
polyester layer 2128 and through perforations 2136.
Rib Fornling Apparatus
Referring now to FIGURE 258, a cross-section through a tooling assembly of
tool parts 2200 and 2202, with a section of material 2124 (after
processing/forming),
is shown. Tooling part 2200 is temperature controlled by passing liquid 2206
through conveniently located passageways shown as ports 2204. Liquid is
preconditioned to a specified and desired temperature and is passed through
ports 2204 at a rate sufficient to control the temperature of tooling part
2200.
Similarly part 2002 can be temperature controlled in a similar manner (not
shown).
Evacuation holes 2208 are located in part 2200 and evacuation ports 2210 are
also
203 AMENDED SHEET

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