A FOOD PRODUCT AND METHODS OF PACKAGING RAW WET PROTEIN FOR RETAIL

Abstract

According to the present disclosure, there is provided a container to food product (20) having a self-standing flexible pouch (22); a raw wet protein portion (14) disposed within the pouch (22); and a closure (34) sealing the pouch (22). There may also be provided a method of packaging a raw wet protein portion (14) for retail, the method comprising: opening an empty self-standing flexible pouch (22); filling the empty pouch (22) with a raw wet protein portion (14); and sealing the pouch (20).

Description

FIELD

The present invention describes a food product and a method of packaging a raw wet protein product for retail. In particular, a food product packaging comprising a self-standing flexible pouch and raw wet protein portions is described.

BACKGROUND

The sale of raw wet protein products, in particular poultry, typically involves packaging made out of 3 components. A tray, such as a rigid plastic or polystyrene tray or container on which the meat is placed, a plastic film and a conventional wrap label are all required. The space beneath the plastic film can contain gases to prevent the food from deteriorating/to stop its appearance degrading with time. Such packages are sometimes called tray lidded CAP (controlled atmosphere packaging) packs. Such packages are typically sold in the chiller cabinets of supermarkets as a fresh product. Such packages are ubiquitous primarily because they are easily stackable and present the product to the consumer.

A problem with tray lidded CAP packs are that they only allow for a limited number of display options, due to the pack layout. Additionally, the rigid materials used tend to occupy more space in consumer bins and landfill.

Focusing on the disadvantages of conventional packaging (such as tray lidded CAP packs) of raw wet protein products for producers, during the filling process, the empty trays, film and conventional wrap label all need to be transported to the filling factory. For example, the storage requirements for 50,000 trays and the associated film and conventional wrap are approximately 7 pallets vs. 1 pallet for 50,000 flexible pouches. Based on 7½ million trays per annum, this equals approximately 709 pallets or 27 full load lorries.

A problem with transporting traditional polystyrene trays is that they take up a lot of space for their weight. The delivery lorry still uses fuel, and wears itself out, driving with a very light load of plastic trays. The plastic trays take up a lot of space in the packaging factory whilst they are waiting to be used.

A further problem for conventional packaging is that the trays require manual handling during filling to ensure that the product is orientated the correct way in the packaging. This is labour intensive. Once packed, the plastic trays are weighed and allowed to proceed along a conveyor belt to a sealing station, where the plastic film is sealed to the tray, covering the raw wet protein inside the tray. Manual handling can cause cross contamination including transfer of uncooked meat juices or products to the outside of the tray, lid, conventional wrap, staff and all ancillary equipment. Different tray sizes, used for different products, also require an associated downtime and changeover of tools, with the associated additional time and cost involved.

One final important issue is that the machines used to apply the raw wet protein portions to the tray require gas flushing of the complete tool chamber in order to ensure that the atmosphere (also called premix air) sealed within the tray by the lid is of the required constituents. The trays are then driven by lorry to a supermarket and put into typically waist-high refrigerated cabinets for display to be purchased by customers.

The meat packing industry is very conservative when it comes to safety. There are on-going concerns about bacterial contamination of raw wet protein. The manufacturing factories are very reluctant to change anything for fear of causing contamination problems.

For retailers, conventional trays offer only a limited number of chiller cabinet display options. This is a particular issue for these products because the graphics are typically restricted to the front lid only or the conventional wrap label. Both the front lid and the conventional wrap label are generally aligned away from the consumer, making the product packaging less appealing. Again, based on 7½ million trays, approximately 44,000 kg of packaging is used, which retailers are required to declare. Additionally, as noted above, there is a risk of cross contamination due to transfer from the packer in the production and filling factory to the store and on to the consumers shopping trolley, which may contain other products including baby food, fresh fruit and salads.

Additional considerations are the current disadvantages of the present tray lidded CAP packs for the consumer. In addition to the cross contamination issues during purchase of the tray, there is further risk of cross contamination within shopping bags and fridges. The lids of the CAP trays are typically weld sealed and require the use of a sharp implement to open the packs. Once opened, of raw wet protein generally has to be handled before being transferred into a cooking vessel, which is unpleasant for some people. Any unused or accidentally opened raw product has to be used at once or stored in a separate leakproof container. If the product is to be frozen, the trays due to their bulky and rigid nature occupy significantly greater space in the freezer than the raw wet protein product. Once used, the recyclable trays are rigid, bulky and occupy a lot of bin space.

It is known to make plastic pouches for cereals that are self-standing. However, dry foodstuffs, such as cereals, are often packaged in a completely different factories than raw wet protein products (such as raw meat). Dry foodstuffs are quite a different industry. For example, such pouches may not have special atmospheres inside them involving Vac/gas flush cycle. It is also known to make non-self-standing sachets of cooked protein—for example catfood. However, such pouches do not self-stand, require refrigeration and are not “pure” unalloyed, meat—it is meat in a sauce, or meat in a jelly, and has often been cooked. It is not uncooked, natural, “raw”, meat for human consumption. Accordingly, the processes for such retort cooking products are by necessity different to the requirements for a chilled raw product.

This invention provides an alternative packaging solution for raw wet protein products that at least partially addresses or alleviates the above disadvantages of conventional packaging.

In summary, for at least the reasons outlined above, an improved raw wet protein product and method for packaging a raw wet protein product for retail is desired.

SUMMARY

These and other aspects of the invention will be apparent from, and elucidated with reference to, the embodiments described hereinafter.

According to a first aspect of the present invention, there is provided a food product comprising: a self-standing flexible pouch; a raw wet protein portion within the pouch; and a closure sealing the pouch.

By providing a food product with raw wet protein portions in such pouches or packaging the waste of packaging is significantly reduced. This reduces the packaging for the producer, retailer and particularly the consumer therefore increasing the green, ecologically sound, nature of the packaging when compared to traditional raw meat packaging.

By self-standing, it is intended that the product is able to stand upright on a substantially flat surface such as a refrigerated display shelf without support. Such self-standing pouches are sometimes called self-supporting pouches or upstanding pouches. Typically, such self-standing pouches are taller than they are wide—this creates a pleasing appearance on display shelving (the appearance that they are standing upright).

For example, a packaging factory typically orders one pallet of plastic pouches or even a roll of plastic film if the pouches are made from the film on-site. The empty plastic pouches (if they are pre-formed/made elsewhere), or the roll of film, takes up far less space in the delivery lorry. The plastic pouches are typically lighter than a polystyrene tray. However a further advantage is that it is a more efficient use of the delivery logistics, and storage logistics, at the packaging factory to have plastic pouches. The pouches are normally formed from a single sheet of plastic folding, and sealed to itself.

Once purchased, the consumer can take the packaging home and open it—for example by cutting open the top. In some embodiments the opening of the closure allows the raw wet protein portion to be dispensed by upturning and squeezing the pouch. The consumer may then pour or squeeze the wet protein foodstuff out of the packet/pouch. This can avoid the user touching the chicken—some consumers do not like to touch wet raw wet protein portions.

In other examples, the closure is integral with the pouch and is optionally a tearable portion of the pouch. Alternatively, the closure is a zipper for sealing the pouch. In such embodiments, the zipper allows the pouch to be resealed after opening.

In embodiments the pouch can have an antibacterial coating. This coating is typically on the external surface of the pouch.

It can be appreciated that the raw wet protein portion may consist mainly of raw wet protein in addition to associated products such as water. Sauces and/or marinades may also be added to the pouch to form part of the intended raw wet protein portion for consumption. The raw wet protein portion may be a poultry meat portion. For example, diced chicken, strips of chicken, or small chicken fillets. Other wet small piece raw protein foodstuff/solid foodstuffs may also be used, for example pork, lamb, venison, rabbit, minced meat, fish, shellfish, etc.

One advantage of using a pouch is that label information may be used that is printed directly onto the pouch. The label information on the pouches can be displayed vertically—as opposed to the traditional way of displaying flat trays of chicken—which is horizontally—and where customers have to look down at the label to see it—and so there is a limit in the height at which packaged chicken can be displayed in a supermarket. By having the label information/graphical information on the pouch on the pouch displayed vertically, the pouches can be displayed to users at higher heights, including above waist height, for example at chest height, eye level, etc.

Due to the nature of the raw wet protein portions within the pouch, the packaging typically requires refrigeration.

The pouch of the food product will in many embodiments be transparent, or at least partially transparent such as having a transparent window—so that the customer can see the raw wet protein portion, and can see that it looks fresh. This can be an important buying criterion. An attraction of raw wet protein in a transparent pouch is that you can see the meat, and decide that you like the look of it prior to purchase.

The pouch may have an altered internal atmosphere. The composition of the altered internal atmosphere can be tailored to keep the wet protein portion in the best condition to prevent the wet protein from soiling in taste and/or appearance.

When the raw wet protein portion is removed from the pouch, the packaging is typically able to be flattened. For example, when the end user opens the plastic pouch and dispenses the raw wet protein portion they are left with a flat, thin, flexible, plastic pouch that takes up very little space. They can put this into their domestic rubbish bin and it takes up far less space than a conventional polystyrene tray, which has a depth, due to side walls, and is quite rigid—some people break the polystyrene tray into two to reduce the space it takes up. The volume of landfill is therefore reduced by using the present invention.

The pouches do not have to be substantially rectangular, they may be shaped to provide aesthetic benefits, such as to reflect the contents and/or origin of the raw wet protein contained therein.

According to a second aspect of the present invention there is provided a method of packaging a raw wet protein portion for retail, the method comprising: opening an empty self-standing flexible pouch; filling the empty pouch with a raw wet protein portion; and closing and sealing the pouch. By empty, it is appreciated that this means generally empty of existing products. Indeed, typically, such self-standing flexible pouches are normally provided flat. Accordingly, the step of opening the pouch may require some inflation of the pouch. Alternatively, or additionally, the pouch may be pinched open or it may be opened in another conventional way.

The machine for filling the packets/pouches can also weigh them after filling, and instead of having 10 people pick up strips of raw wet protein portions such as chicken and pieces of chicken and placing them in polystyrene trays on a moving conveyor belt, and a human weighing the filled tray, there will be no one at all filling the container—a filling machine will have raw wet protein portions fed into it, and the machine will have a weighing station for ensuring a consistent weight of raw wet protein portions, a filling station for filling the pouches, an atmosphere modification station for injecting an altered atmosphere into the pouches, and a sealing station for sealing closed the pouches. All of these stations might be located at the same place—all the stations might be the same station. Typically, it can be a rotary or carousel arrangement with different functions at different places.

After filling the pouch the method can further comprising the steps of: evacuating air from within the unsealed filled pouch; and injecting a pre-mixed gas into the evacuated pouch. The pre-mixed gas may be a composition for preserving the raw wet protein portions as outlined in the first aspect. Air may be evacuated from the unsealed filled pouch by insertion of a snorkel into the pouch. The pre-mixed gas may also be injected into the evacuated pouch using the snorkel or an additional snorkel. This step may be performed prior to closing the pouch or prior to sealing the pouch after closing the pouch—in the latter case, the snorkel may be inserted into the closed pouch or the pouch may be closed around the snorkel, which is then removed.

Then the package is sealed with the “altered” atmosphere inside it. The sealing is performed quick enough to ensure that the altered special atmosphere remains within the package. This is not the same thing as filling the packet in a general chamber of special atmosphere; advantageously the entire room does not need to be in the special atmosphere.

Opening the pouch may further comprise the step of confirming that the pouch is fully open. A sensor can be used in the machine to detect if the pouches are open. If the sensor detects that the pouch is not open, a signal is sent to pause the production line and to not drop the wet protein portions until the next bag arrives. This ensures that the raw wet protein portions are correctly inserted into the pouches.

Sealing the pouch can further comprise the step of applying heat and/or pressure to a portion of the pouch. This acts to seal the pouch, typically along a predefined portion of the pouch aligned with a tear notch or zipper. After sealing, the sealed pouch can be cooled to ensure the seal is fully cured.

Once filled and sealed, the sealed pouch is discharged for further processing. This may include weighing or labelling or metal detector stations.

The pouches may have an antibacterial coating. The coating may be applied to the outside surface of the pouch and optionally also to the inside surface of the pouch. Application to the outside of the pouch aids prevention of cross-contamination. The pouches may be either provided to the machine for filling the pouches with the antibacterial coating pre-applied (i.e. before filling of the pouches), or the coating may be applied to the filled pouches (for example by spraying or printing).

According to another aspect of the present invention there is defined a raw wet protein portion packaged according to the second aspect.

According to a third aspect, there is provided a self-standing flexible pouch for packaging wet protein portions, said pouch comprising: a closure for sealing the pouch; wherein the pouch has an antibacterial coating, optionally or preferably on the external surface of the pouch. It can be appreciated that features described as relevant to the first aspect (and second aspect) can be applied to the third aspect.

According to another aspect, there is provided a refrigerated display unit having a shelf, wherein the packaging according to any embodiment of the first aspect is provided on the shelf such that the pouch is presented vertically. The pouch may be presented at approximately above waist height of an average consumer.

According to another aspect of the present invention, there is provided a method of decanting raw wet protein portions from packaging, comprising the steps of: providing a food product packaging according to any embodiment of the first aspect; opening the closure to allow access to the raw wet protein portion; inverting the packaging; and/or squeezing the packaging.

According to another aspect of the present invention there is provided a method of reducing packaging waste of packaged raw wet protein, the method comprising providing a packaged raw wet protein portion in a food product packaging according to any embodiment of the first aspect.

According to another aspect of the present invention there is defined the use of a self-standing plastic pouch in the packaging and display of packaged raw wet protein portions to reduce the volume of domestic waste associated with the packaging once the raw wet protein has been used by a consumer.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments will be described, by way of example only, with reference to the drawings, in which

FIG. 1 illustrates a known sealed food product packaging;

FIG. 2 illustrates an empty opened pouch according to aspects of the present invention;

FIG. 3 a food product according to aspects of the present invention, including the pouch of FIG. 2;

FIG. 4a is a side view of a known production line for producing food products as shown in FIG. 1;

FIG. 4b is a top view of the production line of FIG. 4a;

FIG. 5a is a side view of a production line for producing food products as shown in FIG. 3;

FIG. 5b is a top view of the production line of FIG. 5a;

FIG. 6 is an enlarged section of part of the production line shown in FIG. 5b;

FIG. 7a is a side view of part of the production line shown in FIG. 6;

FIG. 7b is a top view of the part shown in FIG. 7a; and

FIG. 8 is a schematic of a valve system shown in FIGS. 7a and 7b.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 shows a known food product 10 for the packaging and display of raw wet protein portions, such as portions of poultry or other raw wet protein products, including fish, shellfish, pork, beef, etc. Such food product packaging is sometimes called tray lidded CAP pack. FIG. 1 shows a tray 12 into which portions 14 of raw wet meat protein are typically placed. The trade 12 may be transparent, translucent or any other colour chosen typically to enhance the appeal of the finished food product on the supermarket shelf. The tray is typically made from polystyrene or other such rigid plastic material The tray 12 defines a space into which the portions 14 are placed. The tray may be sealed by a, typically transparent, plastics film 16 and may be adorned with a label (not shown).

FIG. 2 shows a food product 20 according to aspects of the present invention. The product 20 has a pouch 22 with an opening 24. The opening 24 allows access to the interior of the pouch 22 into which portions of raw wet protein portions 14 may be placed. The product 20 also has a transparent window or portion 26 through which the portions 14 can be viewed by a consumer. It can be appreciated that the size, transparency and presence of the transparent portion may be tailored for different food products. The product 20 also features a tear strip 28 that allows for removal of a top portion 30 of the pouch 22 after the pouch has been sealed, allowing access to the contents of the pouch 22.

The pouch 22 of the food product 20 is provided with a base portion 32 that is at least as wide as the opening 24. This allows the food product 20 to be self-supporting or upstanding so that it can be placed onto a shelf vertically, displaying the contents or labelling of the pouch 22 to a consumer. As shown, the pouch 22 is generally taller than its width and depth to create the illusion that the pouch 22 is standing whilst on display. The pouch 22 may be tapered, that is the opening 24 may be smaller than the base portion 32, but generally the opening 24 and base portion 32 are the same size.

The opening 24 is shown as running along the upper length of the pouch 22, however it can be appreciated that the opening may be smaller in size and only allow access across a portion of the upper surface 30 of the pouch 22. Additionally or alternatively, the opening 24 may be provided at least partially on the side wall of the pouch 22 to create a side or corner opening.

The pouch 22 is typically made from a laminate structure comprising several layers such as polypropylene contacting the raw wet protein portions and polyester as an outer layer to provide strength to the pouch and a printable surface. Barrier layers such as aluminium foil and abrasion resistance layers such as nylon may also be provided. This construction allows the pouch 22 to be flexible whilst self-standing or self-supporting. It also allows the pouch 22 to be flattened when empty.

FIG. 3 shows the food product 20 of FIG. 2 after the mouth or opening 24 of the pouch 22 has been sealed. In the example shown, the top portion 30 of the pouch 22 above the tear strip 28 has been heat sealed to bond the opening 24 closed. Accordingly, the closure 34 is integral with the pouch 22. It can be appreciated that other closures may be used including a zipper. Use of a zipper allows for resealing of the pouch 22 after opening.

The pouch 22 is provided with an antibacterial coating (not shown) provided on the external surface of the pouch 22. Label information and graphical information can be printed directly onto the external surface of the pouch providing a cleaner and neater finished look to the product 20. Such information is provided vertically to allow consumers to view the information easily when the product is stacked vertically and self-standing on a shelf.

FIGS. 4a and 4b show a production line 100 for providing the food products 10 shown in FIG. 1. The production line has workers 102, in the example shown 14 workers 102, at different stages of the production line. In the example shown, 12 workers are at a weigh and fill station 104 where trays 106 are filled with raw wet protein portions and weighed. The trays 106 are then placed onto a conveyor and into a tray lidding machine 108 where the transparent film 16 is added. Once sealed, the trays 106 are re-weighed at a weighing station 110 and a label applied at station 112. Finally, the labelled, sealed trays are collected at station 114.

FIGS. 5a and 5b show a production line 200 according to the present disclosure. Only two workers 102 are required for this production line, increasing labour efficiency.

In use, raw wet protein pieces 14 are provided to conveyor 210. Conveyor 210 provides the portions to a hopper 220 that weighs and sorts the wet protein into portions 14.

A separate machine 230 provides empty pouches 22 to a carousel 240. The empty pouches 22 may be provided with an antibacterial coating already applied to the external surface of the pouches 22. Once loaded, the pouches 22 are opened using a gripper device (not shown). A sensor is used to confirm that the pouch has been opened. Conditional on the sensor indicating that the pouch is open, a signal is sent to the hopper 220 to provide the portions 14 into the pouch 22. Once filled, the pouches 22 are treated and sealed (see FIGS. 6 and 7) before being provided to another conveyor 270 where they are reweighed and pass through a metal detector 280 before being collected at station 290.

FIG. 6 shows an enlarged portion of the carousel 240 showing a vacuum gas station 250 and a heat seal station 260. FIGS. 7a and 7b show the detail of the vacuum gas station 250. In use, a filled pouch 22 is provided to the station with the opening 24 open. Once the machine comes to a standstill, snorkels 252 drop into the pouch 22 through opening 24. Gripper arms (not shown) move apart to stretch the pouch opening 24. The opening is then closed to provide an air tight seal using rubber coated jaws. Via a valve system 254, air is removed from the pouch 22 and protective gas is injected. Once this procedure is complete, the snorkels 252 withdraw from the pouch 22 and the pouch is provided to the sealing station 260. As the pouch moves between stations, the top of the pouch 22 is held closed by biased guides, such as spring loaded guides. The pouch 22 is then heat sealed to achieve a hermitic seal and to form a closure 34. An antibacterial coating may then be applied to the external surface of the pouch 22 (if not already present), for example by spraying.

Details of the valve system 254 are shown in FIG. 8. Snorkels 252 are provided with gas from a reservoir 254a via a regulator 254b. Gas valves 254c regulate the supply of the protective gas from the reservoir 254a. In addition, vacuum may be provided by a vacuum pump 254d supplied by opening vacuum valves 254e. A sediment 254f and filter 254g are provided to protect the pump 254d. The system may be flushed and cleaned with water via water valve 254h regulating supply of water connection 254i.

It should be noted that the Figures are diagrammatic and not drawn to scale. Relative dimensions and proportions of parts of these Figures have been shown exaggerated or reduced in size, for the sake of clarity and convenience in the drawings. The same reference signs are generally used to refer to corresponding or similar feature in modified and different embodiments.

From reading the present disclosure, other variations and modifications will be apparent to the skilled person. Such variations and modifications may involve equivalent and other features which are already known in the art of vacuum switching, and which may be used instead of, or in addition to, features already described herein.

Although the appended claims are directed to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention.

Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. The applicant hereby gives notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.

For the sake of completeness it is also stated that the term “comprising” does not exclude other elements or steps, the term “a” or “an” does not exclude a plurality, and reference signs in the claims shall not be construed as limiting the scope of the claims.

Claims

1. A food product comprising:

a self-standing flexible pouch;

a raw wet protein portion within the pouch; and

a closure sealing the pouch.

2. The product of claim 1, wherein opening of the closure allows the raw wet protein portion to be dispensed by upturning and/or squeezing the pouch, wherein when the raw wet protein portion is removed from the pouch, the pouch is able to be flattened.

3. The product of claim 1, wherein the closure is integral with the pouch and is a tearable portion of the pouch.

4. The product of claim 1, wherein the closure is a zipper for sealing the pouch, wherein the zipper allows the pouch to be resealed after opening.

5. (canceled)

6. The product of claim 1, wherein the pouch has an antibacterial coating on the external surface of the pouch.

7. The product of claim 1, further comprising a sauce or marinade disposed within the pouch.

8. The product of claim 1, wherein the pouch comprises label information printed directly onto the pouch.

9. (canceled)

10. The product of claim 1, wherein the pouch is at least partially transparent.

11. The product of claim 1, wherein the pouch has an altered internal atmosphere.

12. (canceled)

13. A method of packaging a raw wet protein portion for retail, the method comprising:

opening an empty self-standing flexible pouch;

filling the empty pouch with a raw wet protein portion; and

closing and sealing the pouch.

14. The method of claim 13, wherein after filling the empty pouch the method further comprising the steps of:

evacuating air from within the unsealed filled pouch; and

injecting a pre-mixed gas into the evacuated pouch.

15. The method of claim 14, wherein the step of evacuating air from the unsealed filled pouch includes the step of inserting a snorkel into the pouch.

16. The method of claim 14, further comprising the step of injecting pre-mixed gas into the evacuated pouch using the or a snorkel.

17. The method of claim 13, wherein opening the pouch further comprises the step of confirming that the pouch is fully open.

18. The method of claim 17, wherein a sensor is used to confirm that the pouch is fully open, said sensor providing a signal to a weighing device to fill the pouch with the weighed raw wet protein portion.

19. The method of claim 13, wherein sealing the pouch further comprises the step of applying heat and/or pressure to a portion of the pouch.

20. The method of claim 19, wherein the sealed pouch is cooled to ensure the seal is fully cured.

21. (canceled)

22. (canceled)

23. The method of claim 13, further comprising the step of applying an antibacterial coating to an external surface of the pouch.

24. The method of claim 13, further comprising the step of providing the empty self-standing flexible pouch with an antibacterial coating prior to opening of the pouch.

25. A raw wet protein portion packaged according to the method of claim 13.

26. A self-standing flexible pouch for packaging wet protein portions, said pouch comprising:

a closure for sealing the pouch;

wherein the pouch has an antibacterial coating on the external surface of the pouch.

27. A pouch according to claim 26, wherein the closure is integral with the pouch and is a tearable portion of the pouch.