PACKAGED PRODUCT, PACKAGING APPARATUS AND PROCESS FOR MAKING SUCH A PACKAGED PRODUCT

A package comprising includes a base film, at least one closing film, and at least one product interposed between the base film and the closing film. The closing film is hermetically fixed to the base film at a sealing band with the product housed in a packaging seat defined between the closing film and the base film. Also described is a process for making the package described above.

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Description
FIELD OF THE INVENTION

The present invention relates to a packaged product capable of exhibiting a pleasing appearance, due to the appropriate combination of paper material and plastic material. The invention also relates to a packaging apparatus and process for making such a packaged product. The process and the apparatus object of the present invention are adapted for the packaging of articles, in particular food products, having a substantially regular geometric structure such as, for example, slices of solid food products (cheese, fish, meat).

PRIOR ART

Among the packaging processes, processes are known that make vacuum packages, processes that make packages in a controlled atmosphere and processes that simply serve for closing the product inside a package. Known packaging processes, in particular the vacuum packaging and controlled atmosphere processes, can be used for packaging food or perishable products such as meat, fish, cheese, ready meals, etc.

Vacuum packaging processes make packages by using plastic films: vacuum packages can be made with the sole use of one or more plastic films suitably arranged around the product to be packaged or by coupling one or more plastic films to a supporting structure (such as a tray) intended to support the product to be packaged. The vacuum packaging process is essentially a thermoforming process that involves the preparation of a product inside or above a rigid or semi-rigid support, for example defined by a tray, a cup or other support. The support and the related product are placed inside a vacuum chamber. Inside the chamber, a thermoplastic film is sealed to an upper edge of the support; thereafter, the air present in the package is extracted in such a way that the thermoplastic film can adhere to the product placed inside the support.

The controlled atmosphere packaging processes involve the preparation of a product inside or above a rigid or semi-rigid support, for example defined by a tray, a cup or other support. The support and the relative product are arranged inside a chamber where a controlled atmosphere is created (i.e. having a different composition compared to the normal atmospheric composition) and where a plastic film is sealed to an upper edge of the support, thereby hermetically closing the product.

The known packaging processes described above allow a product to be housed inside an enclosure made entirely of plastic material which, although suitable for ensuring the tightness of the package, does not often ensure a pleasant appearance. In order to overcome this drawback, the tendency (for example in the food sector) to wrap the previously vacuum-packed product slice with paper has become widespread. This paper wrapping operation is however carried out manually, with a consequent negative impact in terms of operating costs for making each package and the quality of the final package. Furthermore, the described solution entails in practice a first plastic package and then a second outer paper packaging, with consequent waste of material and negative impact in terms of cost of the material necessary for each package.

OBJECT OF THE INVENTION

The object of the present invention therefore is to substantially solve the drawbacks and/or limitations of the known solutions described above.

A first object of the invention is to provide a new package that allows ensuring an adequate hermetic sealing of the product, while substantially improving the aesthetic appeal of the package.

Another object of the invention is to provide a package which, with respect to the known solution described above, can ensure a considerable saving in terms of the overall amount of material used to package the same product. Another object of the invention is to provide a package that can be produced automatically or semi-automatically. In addition, it is an object of the invention to provide a packaging apparatus and process capable of making a package according to the invention. In particular, it is an object of the invention to provide a packaging apparatus and process capable of minimizing the use of plastic and/or paper material, reducing material waste to a minimum. Another auxiliary object is to provide a packaging apparatus and process capable of operating safely and in particular capable of achieving the object of removing air or generating a controlled atmosphere without compromising the aesthetic of the final packaged product.

These and yet other objects, which will become more apparent from the following description, are substantially achieved by a package and a packaging apparatus and process according to what is expressed in one or more of the accompanying claims and/or the following aspects, taken alone or in any combination with each other or in combination with any one of the appended claims and/or in combination with any of the other aspects or features described below.

SUMMARY

Aspects of the invention are described hereinafter. In a 1st aspect, a package (100) is provided, optionally for food, comprising:

  • at least one base film (1),
  • at least one closing film (10),
  • at least one product (P), optionally food, interposed between the base film (1) and the closing film (10),

wherein said product (P) is disposed on an abutment area (5) of the base film (1), the closing film (10) being tightly fixed to the base film at a sealing band (4) extending as a closed-loop around the abutment area (5),

and wherein the product (P) is housed in a packaging seat (6) defined between the closing film (10) and the base film (1) and delimited, at the base film (1), by said sealing band (4).

In a 2nd aspect according to the first aspect, the sealing band (4) is contained inside a perimetral edge (7) of the base film (1).

In a 3rd aspect according to any one of the preceding aspects, the sealing band (4) delimits an external area (9) on the base film (1) arranged radially outside the sealing band (4) and not covered by the closing film (10).

In a 4th aspect according to any one of the preceding aspects, the sealing band (4) delimits an internal area (8) extending radially towards the inside of the sealing band (4), in contact with the product (P), optionally the sealing band (4) is radially interposed between the external area and the internal area.

In a 5th aspect according to any one of the preceding aspects, the base film (1) has an upper surface (1a) having a larger overall area with respect to an internal area of the surface portion delimited on the base film (1) itself by an external perimeter edge (4a) of the sealing band (4).

In a 6th aspect according to the 4th or 5th aspect, the base film (1) has an upper surface (1a) having a greater overall area with respect to the internal area (8), in particular greater than the overall area defined by the sum of the internal area (8) and an area of the sealing band (4).

In a 7th aspect according to any one of the preceding aspects, the base film (1) comprises an upper surface (1a) having an overall area greater than 150%, optionally greater than 200%, with respect to an internal area of the surface portion delimited on the base film (1) itself by the external perimetral edge (4a) of the sealing band (4).

In an 8th aspect according to any one of the aspects 5th to 7th, the sealing band (4) and the packaging seat (6) are disposed at a substantially central area of the upper surface (1a) of the base film (1).

In a 9th aspect according to any one of the preceding aspects, the base film (1) comprises at least one paper layer (2) and at least one plastic layer (3) overlapped on and coupled to the paper layer (2), optionally the base film (1) is only made of a paper layer (2) and at least one plastic layer.

In a 10th aspect according to the preceding aspect, the abutment area (5) of the product (P) is defined on the plastic layer (3).

In an 11th aspect according to the 9th or 10th aspect, the packaging seat (6) is defined between the closing film (10) and the plastic layer (3) of the base film (1).

In a 12th aspect according to any one of the aspects 9th to 11th, the closing film (10) is hermetically fixed to the plastic layer (3) of the base film at the sealing band (4).

In a 13th aspect according to any one of the preceding aspects, the base film (1) can be configured in at least a first operative configuration, in which the base film (1) is disposed in a plane, and in at least a second operative configuration, in which the base film (1) has a main sheet layer (11) placed below said at least one product (P), and a plurality of auxiliary sheet layers (12) extending from said main sheet layer (11) and folded around said product (P).

In a 14th aspect according to the preceding aspect, the sheet layers (12) of the base film (1), in the second operative configuration, overlap the closing film (10).

In a 15th aspect according to the 13th or 14th aspect, the base film (1), in the second operative configuration, visually hides at least part of the closing film (10), optionally the base film (1), in the second operative configuration, completely hides the closing film (10),

even more optionally, the base film (1), in the second operative configuration, is folded all around the product (P), visually hiding it.

In a 16th aspect according to any one of the aspects 13th to 15th, in the second operative configuration, the paper layer (2) of the base film (1) faces towards the outside of the package (100) oppositely to the packaging seat (6) for visually hiding both the plastic layer (3) of the base film (1) and the closing film (10).

In a 17th aspect according to any one of the aspects 13th to 16th, in the second operative configuration, the auxiliary sheet layers (12) of the base film (1) exhibit end edges (13) reciprocally overlapped on and constrained to each other so as to block the package (100) in said second operative configuration.

In an 18th aspect according to the preceding aspect, the mutually overlapping end edges (13) are constrained to each other by:

  • one or more adhesive zones interposed between overlapping end edges (13), or
  • one or more adhesive labels (14) extending astride overlapping end edges (13).

In a 19th aspect according to any one of the aspects 13th to 16th, the closing film (10) is applied so as to form a vacuum package (100) in which inside the packaging seat (6) a pressure substantially lower than the atmospheric pressure is present (T=20° C. above the sea level), the closing film (10) forming a plastic skin at least partly in contact with the product (P) and the base film (1).

In a 20th aspect according to any one of the preceding aspects, the base film (1) has a predetermined number of through holes (15), optionally said through holes (15) pass through the thickness of the paper layer (2) and the plastic layer (3) of the base film (1).

In a 21st aspect according to the preceding aspect, the through holes (15) are disposed at the sealing band (4) and are closed by the closing film (10).

In a 22nd aspect according to the 20th or 21st aspect, the through holes (15) are configured for allowing:

  • the extraction of gas present between the closing film (10) and the respective base film (1) so that a vacuum sealing of the closing film (10) is achieved at the respective base film (1), where the closing film (10) is configured for intimately adhering to the surface of the product (P) to be packaged and to at least a portion of the base film (1), and/or
  • the introduction of a gas between said closing film (10) and the respective base film (1) to define a modified atmosphere package.

In a 23rd aspect according to any one of aspects 9th to 22nd, wherein:

  • the paper layer (2) of the base film (1) exhibits at least 50% by weight, preferably at least 70% by weight, of organic material comprising one or more of cellulose, hemicellulose, lignin, lignin derivatives,
  • the plastic layer (3) is overlapped on and coextensive to the paper layer (2) and is coupled to the paper layer (2) itself,
  • the closing film (10) comprises at least one weldable layer (10a) facing the plastic layer (3) of the base film (1), the weldable layer (10a) being of a plastic material heat-sealable to the plastic material with which the plastic layer (3) of the base film (1) is made;

and wherein the closing film (10) is tightly fixed to the plastic layer (3) by heat-sealing at said closed sealing band (4).

In a 24th aspect according to anyone of the aspects 9th to 23rd, the base film (1) is only made by means of at least one paper layer (2) and a plastic layer (3) adapted to cover, in whole or in part, the paper layer (2).

In a 25th aspect according to any one of the aspects 9th to 24th, the base film (1) is made of sheet material, the plastic layer (3) covers, in whole or in part, only one side of the paper layer or covers, in whole or in part, the paper layer on both sides so that the paper layer is interposed between at least two opposing plastic layers.

In a 26th aspect according to any one of aspects 9th to 25th, the base film (1) is made entirely of plastic material, in particular of a single-layer or multilayer thermoplastic material.

In a 27th aspect, a packaging process is provided for making a package (100) according to any one of the preceding claims, comprising the following steps:

  • moving at least one base film (1) from a supplying station (201) towards a packaging station (202), each base film (1) being defined by a respective portion of a base continuous support (301) or being defined by a respective discrete element,
  • positioning at least one product (P) at each base film (1),
  • moving at least one closing film (10) from a respective supplying station (203) towards the packaging station (202), each closing film (10) being defined by a respective portion of a closing continuous support (302) or being defined by a respective discrete element,
  • aligning each closing film (10) with the respective base film (1) so that the product (P) is disposed between the base film (1) and the closing film (10),
  • fixing the closing film (10) tightly to the respective base film (1) for defining the sealing band (4) and the packaging seat (6) wherein the product (P) is housed,
  • extracting the package (100) from the packaging station (202).

In a 28th aspect according to the preceding aspect, the step of fixing the closing film (10) comprises fixing it to the plastic layer (3) of the base film (1).

In a 29th aspect according to the 27th or 28th aspect, when each base film (1) is defined by a portion of a base continuous support (301) supplied by the respective supplying station (201), once the step of fixing the closing film (10) is performed, the base continuous support (301) is transversally cut for separating each base film (1) from the rest of the base continuous support (301) and for defining a plurality of packages (100) disconnected from each other.

In a 30th aspect according to any one of aspects 27th to 29th, once the step of moving the closing film (10) into the packaging station (202) is performed, the closing continuous support (302) is transversally cut for separating each closing film (10) from the rest of the closing continuous support (302) and for defining a plurality of packages (100) disconnected from each other.

In a 31st aspect according to any one of aspects 27th to 30th, the process further comprises, at the packaging station (202):

  • a step of heating the closing film (10) at least before and optionally also during the step of fixing said closing film (10), and
  • a step of extracting a gas present between the closing film (10) and the respective base film (1) for vacuum fixing the closing film (10) to the respective base film (1) wherein the closing film (10) intimately adheres to the surface of the product to be packaged (P) and to at least a portion of the base film (1), optionally a portion of the upper surface of the plastic layer (3) of the base film (1).

In a 32nd aspect according to any one of aspects 27th to 31st, each base film (1) exhibits a predetermined number of through holes (15), said through holes being:

  • preformed when the base film (1) is a preformed discrete element, or
  • in-line made by a drilling tool (204) active on each base film (1) before the base film (1) reaches the packaging station (202), or
  • in-line made by a drilling tool (204) active on each base film (1) inside the packaging station (202).

In a 33rd aspect according to any one of aspects 27th to 32nd, at least one between the base continuous support (301) and each base film (1) is moved by a conveyor (205) having an operative tract extending at the packaging station (202), and wherein the conveyor (205) is configured for enabling a gas to flow through the thickness of the conveyor (205) itself between an upper side and lower side of the operative tract, and wherein the step of extracting the gas comprises at least suctioning the gas through the through holes (15) present in the base film (1) and through the thickness of the conveyor (205).

In a 34th aspect according to any one of aspects 27th to 33rd, once the package (100) has been extracted from the packaging station (202), the base film (1) is disposed at least in a first operative configuration, wherein the base film (1) is disposed flat, and then in at least one second operative configuration, wherein the base film (1) exhibits at least one main sheet layer (11) disposed below said at least one product (P), and auxiliary sheet layers (12) extending from said main sheet layer (11) and folded around said food product (P) so that the auxiliary sheet layers (12) of the base film (1) cover the closing film (10) and the product (P), and optionally so that the paper material (2) of the base film (1) faces towards the outside of the package (100) oppositely to the packaging seat (6) for visually hiding both the plastic layer (3) of the base film (1) and the closing film (10).

In a 35th aspect according to the preceding aspect, each base film (1) is defined by a respective discrete element, and wherein before the base film (1) enters the packaging station (202), the main sheet layer (11) and the plurality of auxiliary sheet layers (12) are defined in each base film (1) by one or more folding steps, wherein:

  • the main sheet layer (11) exhibits an upper surface (1 b) having an area sufficient to house the product (P) and for defining with the closing film (10) said sealing band (4), particularly wherein the sealing band (4) extends along a perimetral side of the main sheet layer (11),
  • the auxiliary sheet layers (12), at least during the steps of fixing the closing film (10) and optionally of suctioning the gas, are disposed in a rest configuration, folded below the main sheet layer (11) oppositely to the product (P).

In a 36th aspect according to the preceding aspect, the process further comprises at least the following steps:

  • positioning the base film (1) in the packaging station in the configuration in which it has the auxiliary sheet layers folded underneath the main sheet layer, the product is positioned on the main sheet layer of the base film (1)
  • hermetically fixing the closing film (10), optionally by heat-sealing, only to the main sheet layer (10) so that the product is hermetically closed between the base film (1) and the closing film (10),
  • thereafter, positioning the base film (1), the product (P) and the closing film (10) out of the packaging station,
  • thereafter, placing the base film (1) in the second operative configuration with the auxiliary sheet layers (12) folded around said product (P).

In a 37th aspect according to the 34th or 35th or 36th aspect, the process comprises a step of blocking the base film (1) at said operative configuration with the auxiliary sheet layers (12) of the base film (1) which exhibit end edges (13) reciprocally overlapped on and constrained to each other, optionally wherein said end edges (13) are reciprocally overlapped being constrained to each other for example by applying one or more adhesive areas interposed between overlapped end edges (13) or by applying one or more adhesive labels (14) extending astride of overlapped end edges (13).

In a 38th aspect according to any one of aspects 27th to 37th, once the step of fixing the closing film (10) to the base film (1) is performed and the base film (1) is placed in said first operative configuration, the base film (1) exhibits an upper surface (1a) having an overall area greater than the area of the surface portion delimited on the base film (1) itself by an external perimetral edge of the sealing band (4).

In a 39th aspect according to the preceding aspect, the product (P) is positioned in a substantially central area of the upper surface (1a) of the base film (1), and at the first operative condition the base film (1) exhibits an upper surface (1a) having an overall area greater than the area of the lower surface (10b) of the closing film (10) and more precisely greater than 150%, optionally greater than 200%, than the area of the surface portion delimited on the base film (1) itself by an external perimetral edge (4a) of the sealing band (4).

In a 40th aspect according to any one of the preceding aspects, the product (P) is a food product.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments and some aspects of the invention are described hereinafter with reference to the accompanying drawings, provided only for illustrative and, therefore, non-limiting purposes, in which:

FIG. 1 is a perspective view of a preferred embodiment of a package according to the present invention;

FIG. 1A is a sectional view according to line IA-IA, of the package in FIG. 1;

FIG. 1B is a detailed view of FIG. 1A;

FIG. 2 is a sectional view of a further embodiment of a package according to the present invention;

FIG. 2A is a sectional view according to line IIA-IIA, of the package in FIG. 2;

FIG. 2B is a detailed view of FIG. 2A;

FIG. 3 is a perspective view of a package arranged according to a wrapped configuration;

FIG. 4 is a schematic sectional view according to line IV-IV, of the package in FIG. 3;

FIG. 5 is a schematic sectional view of a further embodiment of the package, for example obtainable by wrapping the package in FIG. 2;

FIGS. 6-9 are schematic representations of different packaging apparatus for making a package according to the present invention;

FIGS. 10A to 11D schematically show process steps—before and subsequent to a packaging step of one or more products—for obtaining a package according to the present invention.

 CONVENTIONS

It should be noted that in the present detailed description, corresponding parts illustrated in the various figures are indicated by the same reference numerals. The figures may illustrate the object of the invention by representations that are not in scale; therefore, parts and components illustrated in the figures relating to the object of the invention may relate solely to schematic representations.

The terms upstream and downstream refer to a direction of advancement of a package—or of a base film for making said package—along a predetermined path starting from a starting or forming station of a base film for said package, through a packaging station and then up to a package unloading station.

Definitions Product

The term product P means an article or a composite of articles of any kind. For example, the product may be of a foodstuff type and be in solid, liquid or gel form, i.e. in the form of two or more of the aforementioned aggregation states. In the food sector, the product may comprise: meat, fish, cheese, treated meats, prepared and frozen meals of various kinds.

Control Unit

The packaging apparatus 200 described and claimed herein includes at least one control unit 210 designed to control the operations performed by the apparatus. The control unit can clearly be only one or be formed by a plurality of different control units according to the design choices and the operational needs.

The term control unit means an electronic component which can include at least one of: a digital processor (CPU), a memory (or memories), an analog circuit, or a combination of one or more digital processing units with one or more analog circuits. The control unit can be “configured” or “programmed” to perform some steps: this can be done in practice by any means that allows configuring or programming the control unit. For example, in the case of a control unit comprising one or more CPUs and one or more memories, one or more programs can be stored in appropriate memory banks connected to the CPU or to the CPUs; the program or programs contain instructions which, when executed by the CPU or the CPUs, program or configure the control unit to perform the operations described in relation to the control unit. Alternatively, if the control unit is or includes analog circuitry, then the control unit circuit may be designed to include circuitry configured, in use, for processing electrical signals so as to perform the steps related to control unit. The control unit may comprise one or more digital units, for example of the microprocessor type, or one or more analog units, or a suitable combination of digital and analog units; the control unit can be configured for coordinating all the actions necessary for executing an instruction and instruction sets.

Actuator

The term actuator means any device capable of causing movement on a body, for example on a command of the control unit (reception by the actuator of a command sent by the control unit). The actuator can be of an electric, pneumatic, mechanical (for example with a spring) type, or of another type.

Base Film 1

The term base film 1 means a support of sheet material having an upper surface on which the product P can be placed. The base film 1 can be of any shape, for example rectangular, rhomboidal, circular or elliptical. The base film 1 can be formed by means of a specific manufacturing process distinct from the packaging process or can be implemented in line with the packaging process.

The base film 1 comprises at least one paper layer 2 of paper material. In particular, the paper layer of the base film exhibits at least 50% by weight, preferably at least 70% by weight, of organic material comprising one or more of cellulose, hemicellulose, lignin, lignin derivatives. The subject paper layer extends between two prevailing development surfaces whose distance defines the thickness of said paper layer.

The base film 1 further comprises at least one plastic layer 3 overlapped and coupled to the paper layer 2; the plastic layer 3 covers at least a part of at least one of the two prevailing development surfaces of the paper layer. The plastic layer can, for example, comprise a film for food use. In particular, the plastic layer completely covers the paper layer and is configured for defining an inner surface of the package. The plastic layer can also be used to define a sort of barrier to water and/or humidity useful for preventing the weakening and loss of structurality of the base film with consequent uncontrolled deformation of the paper layer. The plastic layer can be applied to the paper layer in the form of a so-called coating or lacquer of a thickness generally between 20 and 400 μm, in particular between 30 and 200 μm, more particularly between 30 and 80 μm. Advantageously, but not limitedly, the plastic layer may comprise a poly-coating of the paper layer with thickness values which can for example range between 20 and 400 μm, in particular between 30 and 200 μm, even more particularly between 30 and 80 μm, of coating material. The plastic layer may, by way of example, comprise at least one selected from the group of the following materials: PP, PE (HDPE, LDPE, MDPE, LLDPE), EVA, polyesters (including PET and PETg), PVdC.

The base film 1 may comprise in addition to or in place of the paper and plastic layer, one or more additional layers at least partly of plastic material, in particular of mono-layer and multilayer thermoplastic material. Preferably, the base film 1 is provided with gas barrier properties. As used herein, this term refers to a film or sheet of material that has an oxygen transmission rate of less than 200 cm3/(m2*day*bar), less than 150 cm3/(m2*day*bar), less than 100 cm3/(m2*day*bar) when measured in accordance with ASTM D-3985 at 23° C. and 0% relative humidity. Gas barrier materials suitable for single-layer thermoplastic containers are e.g. polyesters, polyamides, ethylene vinyl alcohol (EVOH), PVdC and the like. The gas barrier polymers that can be used for the gas barrier layer are PVDC, EVOH, polyamides, polyesters and mixtures thereof. Generally, a PVDC barrier layer will contain plasticizers and/or stabilizers as known in the art. The thickness of the gas barrier layer will preferably be set in order to provide the material of which the base film is composed with an oxygen transmission rate at 23° C. and 0% relative humidity of less than 50, preferably less than 10 cm3/(m2*day*atm), when measured in accordance with ASTM D-3985.

The base film 1 can comprise at least one heat-sealable layer to allow sealing of a sealing film (coating film) to the base film. In general, the heat-sealable layer will be selected from polyolefins, such as ethylene homo- or copolymers, propylene homo- or copolymers, ethylene/vinylacetate copolymers, ionomers and homo- or co-polyesters, e.g. PETG, a glycol-modified polyethylene terephthalate.

Additional layers, such as adhesive layers, for example to make the gas barrier layer better adhere to the adjacent layers, may preferably be present in the material of which the base layer 1 is made and are selected based on the specific resins used for the gas barrier layer.

A frangible layer, that is easy to open, can be positioned adjacent to the thermo-weldable layer to facilitate the opening of the final packaging. Blends of low-cohesion polymers which can be used as a frangible layer are for example those described in WO99/54398. The overall thickness of the base film 1 will be typically, but not limited to, up to 5 mm, preferably comprised between 0.01 and 3.00 mm and more preferably between 0.05 and 1.50 mm, even more preferably between 0.15 and 1.00 mm).

The base film 1 may further comprise a hot-weldable layer of a low melting material on the film. This hot-weldable layer can be co-extruded with a PET based layer (as described in patent applications No. EP-A-1,529,797 and WO2007/093495) or it can be deposited on the base film by solvent deposition or by extrusion coating (for example described in US documents 2,762,720 and EP-A-1,252,008).

Closing Film 10

A closing film 10 made of plastic material, in particular polymeric material, is applied to the base film 1 so as to create a fluid-tight package housing the product.

In order to make a vacuum package, the film applied to the base film 1 is typically a flexible multi-layer material comprising:

  • at least one thermo-weldable layer capable of welding to the base film 1, in particular to an inner surface of the base film;
  • at least one heat-resistant layer;
  • optionally a gas barrier layer.

For use in a skin-pack or VSP packaging process, plastic materials, especially polymers, should be easily formed as the film needs to be stretched and softened by contact with the heating plate before it is laid on the product and the base film. The film must rest on the product conforming to its shape and possibly to the internal shape of the base film 1.

The thermo-weldable outer layer can comprise any polymer capable of welding to the inner surface of the base film. Suitable polymers for the thermo-weldable layer can be ethylene and ethylene copolymers, such as LDPE, ethylene/alpha-olefin copolymers, ethylene/acrylic acid copolymers, ethylene/vinyl acetate copolymers or ethylene/vinyl acetate copolymers, ionomers, co-polyesters, for example PETG. Preferred materials for the thermo-weldable layer are LDPE, ethylene/alpha-olefin copolymers, e.g. LLDPE, ionomers, ethylene/vinyl acetate copolymers and mixtures thereof.

Depending on the product to be packaged, the closing film 10 may comprise a gas barrier layer. The gas barrier layer typically comprises oxygen-impermeable resins such as PVDC, EVOH, polyamides and mixtures of EVOH and polyamides. Typically, the thickness of the gas barrier layer is set to provide the closing film 10 with an oxygen transmission rate of 23° C. and 0% relative humidity of less than 100 cm3/m2*m2*atm, preferably less than 50 cm3/(m2*day*atm), when measured in accordance with ASTM D-3985. Common polymers for the heat-resistant outer layer are, for example, ethylene homo- or copolymers, in particular HDPE, ethylene copolymers and cyclic olefins, such as ethylene/norbornene copolymers, propylene homo- or copolymers, ionomers, polyesters, polyamides. The closing film 10 may further comprise other layers such as adhesive layers, filling layers and the like to provide the thickness necessary for the closing film 10 and improve its mechanical properties, such as puncture resistance, abuse resistance, formability and the like. The closing film 10 is obtainable by any suitable co-extrusion process, through a flat or circular extrusion head, preferably by co-extrusion or by hot blow molding.

Again for use in a skin-pack or VSP packaging process, the closing film 10 is substantially non-oriented. Typically, the closing film 10, or only one or more of its layers, is crosslinked to improve, for example, the strength of the closing film 10 and/or heat resistance when the closing film 10 is brought into contact with the heating plate during the vacuum skin packaging process. Crosslinking can be achieved by using chemical additives or by subjecting the layers of the closing film 10 to an energy-radiation treatment, such as high-energy electron beam treatment, to induce crosslinking between molecules of the irradiated material. Films suitable for this application preferably have a thickness in the range between 50 and 200 μm, between 70 and 150 μm.

Peculiar compositions based on polyester are those used for the films of the so-called ready-meals. For these films, the polyester resins of the film may constitute at least 50%, 60%, 70%, 80% and 90% by weight of the film.

The closing film 10 can be single-layer. The typical composition of the single-layer films comprises the polyesters as defined herein and mixtures thereof or the polyolefins as defined herein and mixtures thereof.

In all the layers of the closing film 10 described herein, the polymeric components may contain suitable amounts of additives normally included in such compositions.

Some of these additives are normally included in the outer layers or in one of the outer layers, while others are normally added to the inner layers. These additives include slipping or anti-blocking agents such as talc, waxes, silica and the like, or antioxidant agents, stabilizers, plasticizers, fillers, pigments and dyes, cross-linking inhibitors, cross-linking agents, UV absorbers, odor absorbers, oxygen scavengers, antistatic agents, antifog agents or compositions and similar additives known to the man skilled in the art of packaging.

The closing film 10—optionally one or more of the layers of films constituting said closing film 10—may be provided with one or more holes adapted to allow the fluid communication between the inner volume of the package and the external environment, or, in the case of a food product, allow the packaged food to exchange gas with the outside; the perforation of the closing film 10 can, for example, be performed by means of a laser beam or mechanical means, such as rollers provided with needles. The number of perforations applied and the size of the holes influence the permeability to the gases of the film itself.

Micro-perforated films are usually characterized by OTR values (evaluated at 23° C. and 0% RH in accordance with ASTM D-3985) of 2500 cm3/(m2*day*atm) up to 1000000 cm3/(m2*day*atm). Macro-perforated films are usually characterized by OTR values (evaluated at 23° C. and 0% RH in accordance with ASTM D-3985) higher than 1000000 cm3/(m2*day*atm).

Furthermore, the films described herein relating to the closing film 10 can be formulated to provide strong welds with the base film 1 or peelable from said base film 1. A method of measuring the strength of a weld, herein referred to as a “welding force, is described in ASTM F-88-00. Acceptable welding force values to have a peelable weld are between 100 g/25 mm and 850 g/25 mm, 150 g/25 mm to 800 g/25 mm, 200 g/25 mm to 700 g/25 mm.

Material Specifications

The term paper material means paper; in particular, the sheet material that can be used to make the paper layer can have a weight of between 10 and 600 g/m2, in particular between 40 and 500 g/m2, even more particularly between 50 and 250 g/m2.

PVDC is any vinylidene chloride copolymer in which a prevalent amount of the copolymer comprises vinylidene chloride and a lower amount of the copolymer comprises one or more unsaturated monomers copolymerizable therewith, typically vinyl chloride and alkyl acrylates or methacrylates (for example methyl acrylate or methacrylate) and mixtures thereof in different proportions.

The term EVOH includes saponified or hydrolyzed ethylene-vinyl acetate copolymers and refers to ethylene/vinyl alcohol copolymers having an ethylene co-monomer content preferably composed of a percentage of from about 28 to about 48 mole %, more preferably from about 32 and about 44 mole % of ethylene and even more preferably, and a saponification degree of at least 85%, preferably at least 90%.

The term polyamides is meant to indicate homo- and co- or ter-polymers. This term specifically includes aliphatic polyamides or co-polyamides, e.g. polyamide 6, polyamide 11, polyamide 12, polyamide 66, polyamide 69, polyamide 610, polyamide 612, copolyamide 6/9, copolyamide 6/10, copolyamide 6/12, copolyamide 6/66, copolyamide 6/69, aromatic and partly aromatic polyamides or copolyamides, such as polyamide 61, polyamide 6I/6T, polyamide MXD6, polyamide MXD6/MXDI, and mixtures thereof.

The term polyesters refers to polymers obtained from the polycondensation reaction of dicarboxylic acids with dihydroxylic alcohols. Suitable dicarboxylic acids are, for example, terephthalic acid, isophthalic acid, 2,6-naphthalene dicarboxylic acid and the like. Suitable dihydroxylic alcohols are for example ethylene glycol, diethylene glycol, 1,4-butanediol, 1,4-cyclohexanodimethanol and the like. Examples of useful polyesters include poly(ethylene terephthalate) and copolyesters obtained by reaction of one or more carboxylic acids with one or more dihydroxylic alcohols.

The term copolymer means a polymer derived from two or more types of monomers and includes terpolymers. Ethylene homo-polymers include high density polyethylene (HDPE) and low density polyethylene (LDPE). Ethylene copolymers include ethylene/alpha-olefin copolymers and unsaturated ethylene/ester copolymers. The ethylene/alpha-olefin copolymers generally include copolymers of ethylene and one or more co-monomers selected from alpha-olefins having between 3 and 20 carbon atoms, such as 1-butene, 1-pentene, 1-hexene, 1-octene, 4-methyl-1-pentene and the like.

Ethylene/alpha-olefin copolymers generally have a density in the range of from about 0.86 to about 0.94 g/cm3. It is generally understood that the term linear low density polyethylene (LLDPE) includes that group of ethylene/alpha-olefin copolymers which fall in the density range of between about 0.915 and about 0.94 g/cm3 and in particular between about 0.915 and about 0.925 g/cm3. Sometimes, linear polyethylene in the density range between about 0.926 and about 0.94 g/cm3 is referred to as linear medium density polyethylene (LMDPE). Lower density ethylene/alpha-olefin copolymers may be referred to as very low density polyethylene (VLDPE) and ultra-low density polyethylene (ULDPE). Ethylene/alpha-olefin copolymers can be obtained with heterogeneous or homogeneous polymerization processes. Another useful ethylene copolymer is an unsaturated ethylene/ester copolymer, which is the ethylene copolymer and one or more unsaturated ester monomers. Useful unsaturated esters include vinyl esters of aliphatic carboxylic acids, in which esters have between 4 and 12 carbon atoms, such as vinyl acetate, and alkyl esters of acrylic or methacrylic acid, in which esters have between 4 and 12 carbon atoms. Ionomers are copolymers of an ethylene and an unsaturated mono-carboxylic acid having the carboxylic acid neutralized by a metal ion, such as zinc or, preferably, sodium. Useful propylene copolymers include propylene/ethylene copolymers, which are copolymers of propylene and ethylene having a percentage by weight content mostly of propylene and propylene/ethylene/butene ter-polymers, which are copolymers of propylene, ethylene and 1-butene.

Detailed Description Product

Reference numeral 100 indicates as a whole a package for containing at least one product P, for example of a food type and having a substantially regular geometric structure, such as slices of solid food products (cheese, fish, meat).

The package 100 comprises at least one base film 1, adapted to support the product P. In a preferred but not limiting embodiment of the invention, the base film 1 comprises at least one paper layer 2 and at least one plastic layer 3 overlapped and coupled to the paper layer 2; the paper layer 2 and the plastic layer 3 are firmly adhered to each other. In greater detail, the plastic layer 3 is overlapped and coextensive with respect to the paper layer 2. In greater detail, the paper layer 2 and the plastic layer 3 are integrally coupled to each other to essentially define a single multilayer sheet; the coupling between the plastic layer and the paper layer can, for example, be made by calendering. In the accompanying figures, a non-limiting embodiment of the base film 1 having a single paper layer 2 and a single plastic layer 3 is shown; the possibility of implementing an embodiment of the package 100 having one or more paper layers and one or more plastic layers is not excluded. Preferably, the plastic layer 3 completely covers the paper layer 2 such that the base film 1 is delimited on one side by a development surface of the paper layer and on the opposite side by a development surface of the plastic layer 3.

In greater detail and as visible in the accompanying figures, the plastic layer 3 directly receives the product P in contact therewith; in particular, as for example visible in the detailed FIGS. 1B and 2B, the base film 1—optionally the plastic layer 3—defines an upper surface 1a suitable for receiving the product P directly. The section of the package 100 shown in FIGS. 1A and 1B schematically show the layered composition of the base film 1.

The base film 1 is configured for hermetically engaging with a closing film 10 to define the packaging of the product P, in particular the closing film 10 is engaged to the plastic layer 3 of the base film 1 at a sealing band 4. The closing film 10 will be further described in greater detail.

The base film 1 externally has a perimetral edge 7, inside which the sealing band 4 is contained, which delimits, on the plastic layer 3 of the base film 1, an internal area 8 extending radially inwards of the sealing band 4 and in contact with the product P. In particular, the area 8 of the plastic layer 3 is arranged between the paper layer 2 and the closing film 10 (see FIGS. 1A and 2A).

The base film 1 further comprises a predetermined number of through holes 15, in particular arranged at the sealing band 4, as shown in FIGS. 1 and 2, and in particular in the relevant sections in FIG. 1A, 1B and 2A, 2B. The through holes 15 affect both the plastic layer 3 and the paper layer 2 of the base film 1, so as to put the upper surface 1a in communication with a lower surface of the base film 1. The through holes 15 are made in such a way as to allow, during the manufacturing steps of the package 100, the removal of air present inside the packaging seat 6 in order to define a vacuum package or, alternatively, the introduction of a predetermined type of gas. In a preferred embodiment, the through holes 15 have a circular shape, in particular the through holes 15 have a diameter between 0.5 mm and 30 mm, more particularly between 1 mm and 20 mm. Both the removal of air present inside the packaging seat 6 and the introduction of a predetermined type of gas aim to improve the state of preservation of the product P. The interaction between through holes 15 and closing film 10 is described hereinafter.

The base film 1 can be configured in at least one first operative configuration, in which the base film 1 is arranged flat (see FIGS. 1 and 2). In this first operative configuration, but not limitedly, the upper surface 1 a of the base film 1 has a greater overall area than the inner area 8, more precisely the upper surface 1a of the base film 1 has a total area greater than 150% with respect to the area 8. Even more precisely, the upper surface 1a of the base film 1 has a total area greater than 200% with respect to the area 8.

The base film 1 can also be configured in at least one second operative configuration shown in FIG. 3 and in the corresponding sections in FIGS. 4 and 5, in which the base film 1 has a main sheet layer 11 located below the product P, and a plurality of auxiliary sheet layers 12 extending from the main sheet layer 11 and folded around the product P, so as to define a package wrapped by the base film 1 itself. The main sheet layer 11 has an upper surface 1b of area sufficient to house the product P.

In this second operative configuration, the auxiliary sheet layers 12 of the base film 1 overlap the closing film 10, and the paper layer 2 of the base film 1 faces outwardly of the package 100 oppositely to the packaging seat 6. During the second operative configuration, both the plastic layer 3 of the base film 1 and the closing film 10 are visually hidden; in the second operative configuration, the product P is completely wrapped in the base film 1 which visually conceals the product P. In other words, during the second operative configuration, only the layer of base film 1, optionally outside the first area 8, is visible.

In the second operative configuration, the auxiliary sheet layer 12 of the base film 1 have end edges 13 reciprocally overlapped on and constrained to each other in order to block the package 100. In the same operative configuration, the end edges 13 are mutually constrained to each other by, for example, applying one or more adhesive areas interposed between overlapping end edges 13 or by applying one or more adhesive labels 14 positioned astride the end edges 13. Optionally, the overlapped end edges 13 are mutually constrained to each other by the use of staples, in particular metal staples. In a further embodiment, the auxiliary sheet layers 12 are only folded and the overlapping end edges 13 are not mutually constrained.

The closing film 10 is configured for ensuring the closing of the product P, which is interposed between the base film 1 and the closing film 10, precisely arranged on an abutment area 5 of the plastic layer 3 of the base film 1. The closing film 10, advantageously but not limitingly transparent, is hermetically fixed to the plastic layer 3 of the base film 1 at the sealing band 4 extending in a closed loop around the abutment area 5. In a preferred embodiment, the closing film 10 is hermetically fixed to the plastic layer 3 of the base film 1 by a heat-sealing process at the sealing band 4. In particular, the closing film 10 comprises at least one weldable layer 10a facing the plastic layer 3 of the base film 1, consisting of a plastic material heat-sealable to the plastic material with which the plastic layer 3 of the base film 1 is made.

The section of the package 100 shown in FIGS. 1A and 1B schematically shows the closing film 10, according to a preferred embodiment.

The product P is housed in a packaging seat 6 defined between the closing film 10 and the plastic layer 3 of the base film 1. The packaging seat 6 is delimited, at the base film 1, by the sealing band 4 (see FIGS. 1 and 2).

In a preferred embodiment, the closing film 10 is applied so as to form a vacuum package 100 in which, inside the packaging seat 6, there is a pressure substantially lower than the atmospheric pressure (T=20° C., above sea level). The closing film 10 therefore forms a plastic skin in contact with the product P and with the plastic layer 3 of the base film 1, as shown in FIGS. 1 and 2.

In an optional embodiment, the closing film 10 is applied in such a way as to form a package 100 in which a predetermined type and quantity of gas is present inside the packaging seat 6 to improve the state of preservation of the food product P placed inside the 100 package itself.

During the process steps related to the manufacturing of the package 100, the extraction of the air present inside the packaging seat 6 in order to obtain a vacuum package 100 or, according to the optional embodiment, the introduction of a predetermined the type of gas used to store the product P inside the packaging site 6, takes place through the use of the through holes 15. As shown in FIGS. 1 and 2, the consequent adhesion of the closing film 10 at the sealing band 4 seals the through holes 15, interrupting the passage of fluid between the packaging seat 6 and the external environment and ensuring correct maintenance of vacuum or preservation gas. The steps of extracting the air or introducing the storage gas through the through holes 15 are described in detail below.

In a preferred embodiment shown in FIG. 1, the sealing band 4 further delimits on the base film 1, in particular on the plastic layer, an external area 9 disposed radially outside the sealing band 4 and not covered by the closing film 10. In this configuration, the upper surface 1 a of the base film 1 has an overall area greater than 150%, optionally greater than 200%, with respect to the area of the surface portion delimited on the same base film 1 by an external perimetral edge 4a of the sealing band 4. In other words, in the latter embodiment, the closing film 10 covers only a portion of the upper surface 1a of the base film 1, in particular in which the closing film 10 is positioned in a central area of the upper surface 1a of the base film 1 (see FIG. 1). In particular, in the latter embodiment, the length of the external perimetral edge 4a of the sealing band 4 is smaller than the length of the perimetral edge 7 of the base film 1.

In a further embodiment shown in FIG. 2, the sealing band 4 extends up to the perimetral edge 7 of the base film 1. In this embodiment, the closing film 10 covers the upper surface 1a of the base film 1 up to the perimetral edge 7.

The embodiment described above comprises a base film 1 comprising at least one paper layer and at least one plastic layer; in an alternative embodiment, the base film 1 can be entirely made of plastic material, in particular of a single-layer or multilayer thermoplastic material. In this configuration, the closing film 10 is constrained by heat-welding to the plastic base film 1: the product P is then housed between two films (films 1 and 10) made of plastic material. In one embodiment, the base film may have a printed layer such that in the second operative configuration of the package 100, the base film 1 can visually hide at least part of the closing film, in particular the whole closing film P and the product P.

Packaging Procedure

Another object of the present invention is a process for making the package 100, according to any one of the appended claims and/or according to the description given above. The process described below preferably uses the apparatus 200 described below. It should also be noted that, according to a further aspect of the invention, the various process steps described below can be carried out under the control of a control unit 210 which acts on suitable actuators and/or motors and/or pumps and/or valves in order to carry out the various steps described and on the one hand to determine the movements of the various moving parts and on the other to control the suction and/or injection of gas into a packaging chamber within which the package 100 is formed at least in part.

The process involves moving at least one base film 1 from a supplying station 201 to a packaging station 202 along an advancement path A; as seen for example in FIGS. 6 and 7, each base film 1 can be defined by a respective preformed discrete element. In this configuration, each base film 1 (discrete element) may have holes 15 preformed on the discrete element or such holes may be made in-line during the process. However, in the accompanying figures only the configuration in which the holes 15 are preformed on the base film 1 or on each discrete element has been illustrated in a non-limiting manner. The possibility of drilling the base film 1 (discrete element) before the same reaches a packaging station 202 of the product P or directly inside said packaging station 202 is not excluded.

In the configuration in which the base film 1 is defined by a discrete element, the supplying station 201 can for example comprise one or more storage compartments of a plurality of discrete elements such as illustrated in FIGS. 6 and 7.

Alternatively, the base film 1 can be defined by a respective portion of a base continuous support 301 as illustrated for example in FIG. 8. In this configuration, the supplying station may comprise a reel configured to unwind the continuous support 301 preferably in a tape configuration. In the continuous support configuration 301, the method may provide in-line formation of the holes 15 on said support 301 by means of a drilling tool 204 active on each base film 1 before the base film 1 reaches the packaging station 202. As for the discrete element embodiment, the base continuous support 301 can be drilled inside the packaging station 202 in such a way that the holes 15 are defined immediately before the packaging step of the product, which will be better detailed hereinafter.

The movement of the base film 1 or continuous support 301 can be carried out by means of a conveyor 205 having an operative tract extending at the packaging station 202. In a non-limiting embodiment of the invention, the conveyor 205 comprises a conveyor belt; alternatively the conveyor 205 may comprise at least one selected from the group of: one or more drive chains, one or more drive belts, rollers or transport drums. Preferably but not limitedly, the conveyor 205 is configured for allowing the passage of gas through the thickness of the conveyor 205 itself between an upper side and a lower side of the operative tract. In the accompanying figures, an embodiment of the conveyor 205 is shown which has a series of through holes 205a which are configured for communicating directly with the holes 15 of the base film 1 or of the continuous support 301. In fact, the holes 15 are aligned with the through holes 205a of the conveyor 205 so as to allow the passage of gas by continuous flow through the conveyor and the base film 1 or continuous support 301. In order to align the through holes 205a of the conveyor 205 with the through holes 15, the method can provide an initial synchronization step (alignment) with the machine stationary between the continuous support 301, the conveyor 205 and the drilling tool 204; the control unit 210 is then configured for maintaining the speed of movement of the conveyor 205 synchronized with the feeding speed of the continuous support 301 from the supplying station 201 so as to keep the holes 205a aligned with the holes 15.

In the case of base film 1 defined by preformed discrete elements, the control unit 210 is configured for controlling the supplying station 201 for releasing the base films 1 onto the conveyor so that the holes 15 of the latter are aligned with the through holes 205a of the conveyor 205.

In the case of drilling of the base film 1 (discrete element or continuous support 1) inside the packaging station, the control unit 210 is configured for monitoring the entry of said base film 1 into the station 202 and controlling in a sequence the drilling of the film 1 and then the packaging of the product P.

The process also provides for a step of positioning at least one product P at each base film 1, for example by means of a supplying station 212 (see, for example, FIGS. 6-8). The product P is placed on the base film 1 before it is introduced into the packaging station 202; for example, the positioning of the product can take place between the supplying station 201 and the packaging station and in particular following the drilling of the continuous support 301. In greater detail, the product P is positioned in a substantially central zone of the upper surface 1 a of the base film 1; as specified above, at the first operative condition, the base film 1 has an upper surface 1a having a greater overall area with respect to the area of the abutment area 5, in particular greater than the first area 8.

The process further comprises a step of moving at least one closing film 10 from a respective supplying station 203 towards the packaging station 202: each closing film 10 is defined by a respective portion of a closing continuous support 302—as for example schematized in a non-limiting way in FIG. 7—or is defined by a respective discrete element, as for example schematized in FIG. 6.

The closing film 10 is then aligned with the respective base film 1 so that the product P is disposed between the base film 1 and the closing film 10 (FIG. 6-9). Following the alignment step, the process comprises the hermetic fixing of the closing film 10 to the base film 1, in particular to the plastic layer 3 of the respective base film 1, so as to define the sealing band 4 and the packaging seat 6 in which the product P is housed. At least the step of hermetic sealing of the closing film 10 to the base film 1 is carried out in the packaging station 202 inside which at least one step of heating the closing film 10 is carried out at least before and optionally also during the step of fixing said closing film 10.

As shown schematically in FIGS. 6-8, the packaging station 202 is configured for engaging a closing film 10 whose size ensures the entire covering of the product P and the entire covering of the base film 1 to define a package 100 as for example shown in FIG. 2. The packaging station may however be configured so as to provide a closing film 10 whose size (overall dimensions) is less than the size of the base film (see, for example, FIG. 6) to allow the formation of a package 100 as illustrated in FIG. 1. In the latter configuration, the base film 1 has an upper surface 1 a whose overall area is greater than the area of a lower surface 10b of the closing film 10 and more precisely greater than 150%, optionally greater than 200%, with respect to the area of the surface portion delimited on the same base film 1 by an external perimetral edge of the sealing band 4.

The process may further comprise a step of extracting a gas present between the closing film 10 and the respective base film 1 for vacuum fixing the closing film 10 to the respective base film 1 wherein the closing film 10 intimately adheres to the surface of the product to be packaged P and to at least one portion of the upper surface of the plastic layer 3 of the base film 1. Alternatively, the process may comprise a step of extracting air between the closing film 10 and the respective base film 1 and a simultaneous introduction of a gas between said closing film 10 and the respective base film 1 to define a modified atmosphere package.

The gas extraction step—in one embodiment of the process—provides for the suction of gas through the through holes 15 present in the base film 1 and through the thickness of the conveyor 205. As mentioned above, the holes 15 can be made on the base film 1 (discrete element or continuous support 301) before the latter is introduced into the packaging station or directly into the packaging station; in the case of drilling in the packaging station 202, this step may be performed before the sealing film 10 is constrained to the same base film 1 or later, but in any case before proceeding with the possible step of gas extraction from the seat 6.

The process then provides for the extraction of the package 100 from the packaging station 202; when each base film 1 is defined by a portion of a base continuous support 301 supplied by the respective supplying station 201, once the step of fixing the closing film 10 is performed, the base continuous support 301 is transversally cut for separating each base film 1 from the rest of the base continuous support 301 and for defining a plurality of packages 100 disconnected from each other. As can be seen, for example, in FIG. 8, the cutting step is performed by means of a cutting station 211 located downstream of the packaging station 202. The cutting station 211 also allows the transverse cutting of the closing continuous support 302 so as to separate each closing film 10 from the rest of the closing continuous support 302 and define a plurality of packages 100 disjointed from each other (FIG. 8).

FIG. 8 shows a non-limiting process that provides for cutting the closing continuous support 302 and the continuous support 301. It is however possible to provide for the fixing of a closing film 10 as a discrete element to a continuous support 301; in this case, the cutting step provides for the separation only of the base film 1 from the support 301. In this configuration, the cutting of the continuous support 301 can be carried out flush with the closing film 10 to obtain a package 100 as illustrated in FIG. 2, or it can be carried out remotely from the closing film 10 as schematically illustrated in FIG. 8 in order to obtain a package 100 as schematically illustrated in FIG. 1.

Once the package 100 has been extracted from the packaging station 202, the base film 1 is disposed at least in a first operative configuration, wherein the base film 1 is disposed flat, and then in at least one second operative configuration, wherein the base film 1 exhibits at least one main sheet layer 11 disposed below said at least one product P, and auxiliary sheet layers 12 extending from said main sheet layer 11 and folded around said food product P so that the auxiliary sheet layers 12 of the base film 1 cover the closing film 10 and the product P; in the second configuration, the base film 1 is configured for visually hiding at least part of the closing film 10 and in particular the product. In more detail, in the second operative configuration the paper layer 2 of the base film 1 faces towards the outside of the package 100 oppositely to the packaging seat 6 for visually hiding both the plastic layer 3 of the base film 1 and the closing film 10. As described above for the package 100, the first operative configuration of the package is schematically illustrated in FIGS. 1 and 2 while the second operative configuration of the package is schematically illustrated in FIG. 3. The passage from the first to the second operative configuration essentially consists in wrapping at least part of the base film 1 around the product P. This wrapping step can be performed by a wrapping station 208 located downstream of the packaging station 202 and in particular, if present, downstream of the cutting station 211. Following the wrapping of the base film 1, the method may further comprise a step of blocking the base film 1 in at said second operative configuration; in the second operative configuration, the auxiliary sheet layers 12 of the base film 1 have end edges 13 mutually overlapped and constrained to each other. For the blocking of said auxiliary sheet layers, the method may provide for the connection of the end edges 13 mutually overlapping, for example by applying one or more adhesive zones interposed between overlapping end edges 13 or by applying one or more adhesive labels 14 extending across overlapping end edges 13.

If the base film 1 is entirely made of plastic material or if the paper layer 2 is coated with a plastic material on the side opposite the plastic layer 3, the package blocking in the second operative configuration can be performed by mutually heat-sealing the auxiliary sheet layers 12 on the main sheet layer.

In an embodiment of the manufacturing process of the package 100 shown in FIGS. 9-11D, the use of base films 1 defined by discrete elements is provided; said discrete elements, before being introduced into the packaging station, are defined in each base film 1 by one or more folding operations, the main sheet layer 11 and the plurality of auxiliary sheet layers 12. In particular, prior to the introduction of the base film in the packaging station, the method provides for folding of the same base film 1 such that:

  • the main sheet layer 11 exhibits an upper surface 1b having an area sufficient to house the product P and for defining with the closing film 10 said sealing band 4, particularly wherein the sealing band 4 extends along a perimetral side of the main sheet layer 11,
  • the auxiliary sheet layers 12, at least during the steps of fixing the closing film 10 and optionally of suctioning the gas, are disposed in a rest configuration, folded below the main sheet layer 11 oppositely to the product P.

In greater detail, downstream of the packaging station 202, at least one folding station 213 is provided which has one or more auxiliary sheet layers below the main sheet layer 11 (see for example FIGS. 9 and 10A).

The folding steps of the base film are also schematically illustrated in FIGS. 10B and 10C. In the packaging station 202, the closing film is essentially fixed only on the main sheet layer 11 available or not covered by the product P.

Once the closing film 10 has been tightly sealed on the main sheet layer 11, the method provides for the extraction of the package from station 202; subsequently, the step of wrapping the auxiliary sheet layers 12 around the product is performed as shown schematically in FIG. 11D.

Packaging Apparatus

Another object of the present invention is a packaging apparatus 200 for making a package 100 according to one or more of the appended claims and/or according to the detailed description given above.

The apparatus 200 as for example schematically illustrated in FIGS. 6-9, comprises a plurality of operating stations arranged sequentially to define a production line, each of said operating stations configured for performing a predetermined operation on a semi-finished product so as to obtain the package 100 at the output of the line.

The various operating stations of the apparatus 200 are described below, following an order, preferably but not in a limiting manner, of sequence of the processing steps.

The apparatus 200 comprises a supplying station 201 configured for providing the base film 1 in the form of discrete or continuous support elements 301 and arrange it along the production line. The supplying station 201 may provide the continuous support 301 wound on a reel movable by rotation, in particular said reel can be: a) moved by an electric motor, b) braked, c) free in rotation. Alternatively, the supplying station 201 of the base film may comprise a station for storing and dispensing a plurality of discrete base films.

The movement of the base film 1 or continuous support 301 along a predetermined advancement path A is ensured by the presence of the conveyor 205 which, as specified above, preferably but not limitedly comprises a conveyor belt driven by one or more electric motors and configured for supporting the base film 1 or support 301. In a further embodiment, said conveyor 205 comprises a system for laterally hooking the film 1 or support 301 by means of clamps, so as to impose its movement through the use of one or more electric motors.

Downstream or upstream of the supplying station 201, the apparatus 200 may comprise a drilling tool 204 configured for making the holes 15 on the base film 1, preferably on the continuous support 301. Advantageously but not limitedly, the drilling tool and the conveyor are connected to the control unit 210 configured for synchronizing the movement of said tool 210 with the movement of the conveyor 205 and in particular with the movement speed of the continuous support 301. As described above, the conveyor 205 may comprise a plurality of through holes 205a: the holes 15 of the base film 1 or of the continuous support are configured for facing in such a way as to allow air to pass through the conveyor and the film 1 or continuous support 301.

The apparatus 200 comprises a supplying station 212 of products P which is configured for positioning one or more products P above the base film 1 or the continuous support 301. In particular, the supplying station is also connected to and controlled by the control unit 210 configured for positioning at least one product P on the abutment area 5 of the base film 1. In fact, the supplying station 212 is configured for supplying at least one product P according to the position of the base film 1 or of the continuous support 301.

Subsequent to the supplying station 212 with respect to the advancement path A, the apparatus 200 comprises a respective supplying station 203 of the closing film 10 or of a closing continuous support 302. The supplying station 203 is configured for providing the closing film 201 and disposing it at the base film or at the continuous support 301. FIG. 6 shows a non-limiting embodiment of the configuration of the supplying station 203, which provides for unwinding the closing continuous support 302 from a reel movable by rotation, in particular said reel can be: a) moved by an electric motor, b) braked, c) free in rotation.

Downstream of the supplying station 203 with respect to the advancement path A, the apparatus 200 comprises a packaging station 202, shown schematically in FIGS. 6-9, 11A, configured for receiving the base film 1 or continuous support 301 on which one or more products P and at least the closing film 10 or a portion of the closing continuous support 302 are housed. The packaging station 202 is configured for fluidly engaging the closing film 10 (or a portion of the closing support 302) to the base film or continuous support 301. In order to ensure the fluid-tight engagement, the packaging station 202 comprises an upper tool 202a having a heater of the closing film 10, or portion of the closing support 3020, and a lower tool 202b configured for receiving the base film 1 or continuous support 301. The upper tool 202a having the heater is configured for performing a heat-sealing of the closing film 10 (or portion of the support 302) on the base film 1 (or continuous support 301), so as to define the seat 6 for the product P.

The upper and lower tool 202a, 202b are movable with respect to one another between at least one spaced condition, at which the lower tool and the upper tool 202a, 202b allow the introduction of the films 1 and 10—or portions of supports 301 and 302—in the packaging station 202, and at least one approached closed condition, at which the lower and upper tool 202a, 202b define a fluid-tight chamber.

The packaging station 202 can be provided in a non-limiting manner with a suction system 209 configured for removing air from the inside of the packaging station 202 itself so as to define a pressure lower than atmospheric pressure. In particular, the packaging station 202 is configured for removing air from the seat 6 when the closing film 10 (or portion of the closing continuous support 302) is fluid-tightly engaged with the base film (or continuous support 301) through channels 209a defined on the lower tool: these channels are configured for arranging the holes 15 in fluid communication—optionally through the holes 205a of the conveyor 205—with the suction system 209 (see, for example, FIGS. 6-9).

Optionally, the packaging station 202 can be provided, in a non-limiting manner, with a blowing system configured for injecting gas into the packaging station 202 in order to obtain a modified atmosphere environment.

As specified above, the holes 15 of the base film 1 (discrete element or continuous support 301) can be made by the drilling tool placed upstream of the packaging station 202; in a variant embodiment, the drilling tool can be integrated into the packaging station 202: the holes can then be made inside the packaging station 202 before or after the closing film 10 is fixed to the base film 1.

The packaging station 202 optionally comprises a heater of the closing film 10 so as to facilitate the correct distribution of said film 10 (or portion of the closing continuous support 302) around the product P.

As for example visible in FIGS. 6-9, the packaging station may further comprise a suction system 207 associated with the upper tool; said suction system 207 is configured for acting on the closing film 10 (or on the portion of the closing continuous support) to retain it and in particular place it in contact with an inner surface of said upper tool.

Downstream of the packaging station, the apparatus 200 comprises a wrapping station configured for wrapping at least the base film around the product to define the package, as schematically illustrated in FIG. 3.

If the closing film 10 or closing continuous support 302 is engaged to the continuous support 301, the apparatus 200 further comprises a cutting station 211 configured for defining the discrete packages 100 as illustrated for example in FIGS. 1 and 2.

In the case of discrete base films 1, the apparatus can provide a folding station 213 arranged upstream of the packaging station 202 and configured for folding the auxiliary sheet layers 12 below the main sheet layer 11. In this configuration, as illustrated for example in FIGS. 9 and 11A, the closing film 10 or portion of the support 302 is constrained to the available portion of the main sheet layer 11 not covered by the product P. On leaving the packaging station 202, the package 100 is fed into the winding station 208 to fold the auxiliary sheet layers 212 above the product P to define the package as shown in FIGS. 3-5.

Claims

1. A package for foodstuff, comprising:

at least one base film;
at least one closing film; and
at least one food product interposed between the base film and closing film;
wherein the food product is disposed on an abutment area of the base film, the closing film being tightly fixed to the base film at a sealing band extending as a closed-loop around the abutment area;
wherein the food product is housed in a packaging seat defined between the closing film and the base film and delimited, at the base film, by said sealing band;
wherein the base film is configurable in: at least one first operative configuration, in which the base film is disposed flat, and at least a second operative configuration, in which the base film has a main sheet layer disposed below the food product and a plurality of auxiliary sheet layers extending from said main sheet layer and folded around said food product; and
wherein the base film comprises at least one paper layer and at least one plastic layer overlapped and coupled to the paper layer, wherein the abutment area of the food product is defined on the plastic layer, wherein the closing film is hermetically fixed to the plastic layer of the base film at the sealing band.

2. The package of claim 1, wherein in the second operative configuration, the auxiliary sheet layers of the base film overlap the closing film.

3. The package of claim 1, wherein the base film—in the second operative configuration—fully visually hides the closing film.

4. The package of claim 1, wherein in the second operative configuration, the auxiliary sheet layers of the base film exhibit end edges reciprocally overlapped on and constrained to each other so as to block the package in said second operative configuration.

5. (canceled)

6. The package of claim 1, wherein—in the second operative configuration—the paper layer of the base film faces towards the outside of the package oppositely to the packaging seat for visually hiding both the plastic layer of the base film and the closing film.

7. The package of claim 1, wherein the sealing band is contained inside a perimetral edge of the base film, the sealing band delimiting on the base film:

an internal area extending radially towards the inside of the sealing band, in contact with the food product (P),
an external area disposed radially outside the sealing band and not covered by the closing film.

8. The package of claim 1, wherein the sealing band is contained inside a perimetral edge of the base film, the sealing band delimiting on the base film an external area disposed radially outside the sealing band and not covered by the closing film.

9. The package of claim 8, wherein the sealing band delimits an inner area of the base film, extending radially inwardly of the sealing band, in contact with the food product, the sealing band being radially interposed between the external area and the internal area.

10. (canceled)

11. The package of claim 1, wherein the base film has a number of through holes that are disposed at the sealing band and are closed by the closing film,

said through holes being configured to allow: extraction of gas present between the closing film and the respective base film so that a vacuum sealing of the closing film is achieved at the respective base film, where the closing film is configured for intimately adhering to the surface of the food product to be packaged and to at least a portion of the base film, and/or introduction of a gas between said closing film and the respective base film to define a modified atmosphere package.

12. The package of claim 1, wherein the closing film is applied so as to form a vacuum package in which inside the packaging seat a pressure substantially lower than the atmospheric pressure is present (T=20° C. above the sea level), the closing film forming a plastic skin at least partly in contact with the food product and the base film.

13. The package of claim 1, wherein:

the paper layer of the base film exhibits at least 50% by weight, of organic material comprising one or more of cellulose, hemicellulose, lignin, lignin derivatives,
the plastic layer is overlapped on and coextensive to the paper layer and is coupled to the paper layer itself,
the closing film comprises at least one weldable layer facing the plastic layer of the base film, the weldable layer being of a plastic material heat-sealable to the plastic material with which the plastic layer of the base film is made;
wherein the closing film is tightly fixed to the plastic layer by heat-sealing at said closed sealing band.

14. A packaging process for making the package of claim 1, the method comprising:

moving at least one base film from a supplying station towards a packaging station, each base film being defined by a respective portion of a base continuous support or being defined by a respective discrete element;
positioning at least one food product at each base film;
moving at least one closing film from a respective supplying station towards the packaging station, each closing film being defined by a respective portion of a closing continuous support or being defined by a respective discrete element;
aligning each closing film with the respective base film so that the food product is disposed between the base film and the closing film;
fixing the closing film tightly to the respective base film for defining the sealing band and the packaging seat wherein the food product is housed; and
extracting the package from the packaging station.

15. The process of claim 14, wherein when each base film is defined by a portion of a base continuous support supplied by the respective supplying station, once after the step of fixing the closing film is performed, the base continuous support is transversally cut for separating each base film from the rest of the base continuous support and for defining a plurality of packages disconnected from each other.

16. The process of claim 14, wherein after the step of moving the closing film into the packaging station is performed, the closing continuous support is transversally cut for separating each closing film from the rest of the closing continuous support and for defining a plurality of packages disconnected from each other.

17. The process of claim 14, further comprising, at the packaging station:

a step of heating the closing film at least before and optionally also and/or during the step of fixing said closing film, and
a step of extracting a gas present between the closing film and the respective base film for vacuum fixing the closing film to the respective base film wherein the closing film intimately adheres to the surface of the food product to be packaged and to at least one portion of the upper surface of the plastic layer of the base film.

18. The process of claim 14, wherein each base film exhibits a predetermined number of through holes, said through holes being:

preformed when the base film is a preformed discrete element;
in-line made by a drilling tool active on each base film before the base film reaches the packaging station,
in-line made by a drilling tool active on each base film inside the packaging station.

19. The process of claim 18, wherein at least one between the base continuous support and each base film is moved by a conveyor having an operative tract extending at the packaging station, and wherein the conveyor is configured for enabling a gas to flow through the thickness of the conveyor itself between an upper side and lower side of the operative tract, and wherein the step of extracting the gas comprises at least suctioning the gas through the through holes present in the base film and through the thickness of the conveyor.

20. The process of claim 14, wherein after the package has been extracted from the packaging station, the base film is disposed at least in a first operative configuration, wherein the base film is disposed flat, and then in at least one second operative configuration, wherein the base film exhibits at least one main sheet layer disposed below said at least one product, and auxiliary sheet layers extending from said main sheet layer and folded around said food product so that the auxiliary sheet layers of the base film cover the closing film and the food product, and so that the paper material of the base film faces towards the outside of the package oppositely to the packaging seat for visually hiding both the plastic layer of the base film and the closing film.

21. The process of claim 20, wherein each base film is defined by a respective discrete element, and wherein before the base film enters the packaging station, the main sheet layer and the plurality of auxiliary sheet layers are defined in each base film by one or more folding steps, wherein:

the main sheet layer exhibits an upper surface having an area sufficient to house the food product and for defining with the closing film said sealing band, particularly wherein the sealing band extends along a perimetral side of the main sheet layer,
the auxiliary sheet layers, at least during the steps of fixing the closing film, are disposed in a rest configuration, folded below the main sheet layer oppositely to the food product.

22. The process of claim 21, wherein

the base film is positioned in the packaging station in the configuration in which it has the auxiliary sheet layers folded underneath the main sheet layer, the food product is positioned on the main sheet layer of the base film
the closing film is hermetically fixed, optionally heat sealed only to the main sheet layer so that the food product is hermetically closed between the base film and the closing film
thereafter, the base film, the food product and the closing film are brought out of the packaging station,
thereafter, the base film is placed in the second operative configuration with the auxiliary sheet layers folded around said food product.

23. The process of claim 20 comprising a step of blocking the base film at said operative configuration with the auxiliary sheet layers of the base film which exhibit end edges reciprocally overlapped on and constrained to each other.

24. The process of claim 14, wherein after the step of fixing the closing film to the base film is performed and the base film is placed in said first operative configuration, the base film exhibits an upper surface having an overall area greater than an internal area of the surface portion delimited on the base film itself by an external perimetral edge of the sealing band.

25. (canceled)

Patent History
Publication number: 20200180833
Type: Application
Filed: May 16, 2018
Publication Date: Jun 11, 2020
Inventors: Stefano Capitani (Como), Riccardo Palumbo (Arona (NO)), Giampiero Medea (Cinto Euganeo (PD))
Application Number: 16/613,174
Classifications
International Classification: B65D 75/32 (20060101); B65B 31/02 (20060101); B65D 81/20 (20060101); B65B 11/48 (20060101); B65B 11/52 (20060101); B65B 25/06 (20060101); B65B 41/02 (20060101); B65B 51/05 (20060101); B65B 51/10 (20060101); B65B 61/00 (20060101);